CASE 821E Service Manual

SERVICE MANUAL

WHEEL LOADER 821E TIER 3

84299244 (Replaces 87364100)

Revised December 2009 Issued September 2006

SECTION INDEX

GENERAL Section Title

Section Number

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

CASE, LLC. 700 State Street Racine, WI 53404 U.S.A.

Bur 5-3090

Copyright © 2006 CNH Ameica LLC. All rights reserved. Printed in U.S.A. Issued August, 2006

1001 Section 1001 GENERAL TORQUE SPECIFICATIONS


Bur 8-71603

Copyright © 2004 CNH America LLC. All rights reserved. Printed in U.S.A. Issued April, 2003 Revised July, 2005

1001-2

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

Bur 8-71603

Revised 7-05

3 4 5 6

Printed in U.S.A.

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

Newton metres

3/4 inch

380 to 456

515 to 618

Size

PoundFeet

7/8 inch

600 to 720

814 to 976

7/16 inch

54 to 64

73 to 87

1.0 inch

900 to 1080

1220 to 1465

1/2 inch

80 to 96

109 to 130

1-1/8 inch

1280 to 1440

1736 to 1953

9/16 inch

110 to 132

149 to 179

1-1/4 inch

1820 to 2000

2468 to 2712

5/8 inch

150 to 180

203 to 244

1-3/8 inch

2380 to 2720

3227 to 3688

3/4 inch

270 to 324

366 to 439

1-1/2 inch

3160 to 3560

4285 to 4827

7/8 inch

400 to 480

542 to 651

1.0 inch

580 to 696

787 to 944

1-1/8 inch

800 to 880

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

Bur 8-71603

NOTE: Use thick nuts with Grade 8 bolts.

Revised 7-05

Printed in U.S.A.

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


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

Bur 8-71603


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

Revised 7-05

Printed in U.S.A.

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

Bur 8-71603

Revised 7-05

Printed in U.S.A.

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

Bur 8-71603

Revised 7-05

Printed in U.S.A.

1002

Section 1002 FLUIDS AND LUBRICANTS

CNH America LLC. 700 State Street Racine, WI 53404 U.S.A.

Bur 5-3100


1002-2

TABLE OF CONTENTS CAPACITIES AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE OIL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIESEL FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications for Acceptable No. 2 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model 821E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model 821E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 5-3100

Issued 8-06

3 4 5 5 5 5 6 6 7 7

Printed in U.S.A.

1002-3

CAPACITIES AND LUBRICANTS Engine Oil Capacity with Filter Change ............................................................................................ 21 liters (22 U.S. quarts) Type of oil ...................................... Case AKCELA No. 1 engine oil - see engine oil recommendations on page 4 Engine Cooling System Capacity...................................................................................................................40.9 liters (10.8 U.S. Gallons) Type of Coolant ............................................................................................50% water and 50% Ethylene Glycol Fuel Tank Capacity ...................................................................................................................... 288 liters (76 U.S. Gallons) Type of Fuel............................................................................................. See Diesel fuel specifications on page 5 Hydraulic System Hydraulic Reservoir Refill Capacity .............................................................................90 liters (23.8 U.S. Gallons) Total System Capacity............................................................................................... 176 liters (46.5 U.S. Gallons) Type of Oil ..............................................................................................................Case AKCELA Hy-Tran Ultra® Transmission Refill Capacity with Filter Change ............................................................................39.7 litres (10.5 U.S. Gallons) Type of Oil ................................................................................................................ Case AKCELA No. 1 15W-40 Axles Capacity Front...................................................................................................................... 37.4 litres (39.5 U.S. Quarts) Rear ......................................................................................................................... 23.7 litres (25 U.S. Quarts) Type of Lubricant .................................................................................................... Case AKCELA Transaxle Fluid NOTE: DO NOT use an alternate oil in the axles. The brake components in the axles could be damaged as a result of using an alternate oil. Machines are shipped from the factory with break-in oil. Brake System Type of Fluid (Same as Hydraulic System)................................................................ Case AKCELA Hy-Tran Ultra®

Bur 5-3100

Issued 8-06

Printed in U.S.A.

1002-4

ENGINE OIL RECOMMENDATIONS Case AKCELA No. 1 Engine oil is recommended for use in your Case engine. Case AKCELA No. 1 Engine Oil will lubricate your engine correctly under all operating conditions. If Case AKCELA No. 1 Multi-Viscosity Oil is not available, use only oil meeting API engine oil service category CH-4 (preferred) or CG-4. S e e t h e c h a r t b e l ow fo r recommended viscosity at ambient air temperature ranges.

RH99K130

BD03A102

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

BC02N250

Bur 5-3100

Issued 8-06

Printed in U.S.A.

1002-5

TRANSMISSION TEMPERATURE CHART

BC04F193

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

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

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

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

Bur 5-3100

Issued 8-06

Printed in U.S.A.

1002-6

MAINTENANCE SCHEDULE Model 821E

Variable Periodic (*)

13

Radiator Coolant Level

14

Tires

19

Hydraulic Filter

22

Alternator, AC, Drive Belt

29

Air cleaner

XX

Fire extinguisher

Every 10 Hours 1

Check Engine Oil Level

10

Check Engine Coolant Level

50

3

Check Transmission Oil Level

50

Check Hydraulic Oil Level

50

5&6

Grease Bucket Mounting Fittings

18

Bleed Fuel Filter of Condensation

Every 500 Hours

Every 1000 Hours

Every 2000 Hours Every 6000 hours Bur 5-3100

50 50

Change Engine Oil and Filters

100

18 & 26

Replace Fuel Filters

100

19

Change Hydraulic Filter

100

21

Change Oil in Axles

100

8

Lubricate The Steering Cylinder Pivots - Rod And Closed End (4 Fittings)

100

Grease Front Drive Shaft Support Bearing

100

10

Lubricate Loader Lift & Cylinder Pivots (10) Z-bar

100

11

Lubricate Loader Lift & Cylinder Pivots (18) XT

100

12 & 23

Check Cab Air Filter

13

Check Radiator Coolant Level

14

Check Tire Pressure & Wheel Torque

22

Check Drive Belt

XX

Trans Clutch Calibration (See Section 6002)

250 250 4

250

250

1000

250

15

Check Axle Oil Level

500

16

Check Battery Electrolyte Level

500

17

Change Engine Oil and Filter

500

17

Change Crankcase Filter

500

18

Drain Fuel Tank Condensation & Water Separator

26

Replace Fuel Filter

500

19

Replace Hydraulic Oil filter

1000

20

Grease Articulation Fittings

21

Change Front & Rear Axle Oil

ADJUST

REPLACE

LUBRICATE

DRAIN

CHANGE

CLEAN

*

17

Every 100 Hours 9

Every 250 Hours

* * * * * *

2

Every 50 Hours 4

First 100 Hours

SERVICE POINTS

CHECK

ITEM NUMBER

SERVICE INTERVAL

Initial Service

FREQUENCY IN HOURS

500

1000 1000

22

Replace Drive Belt

23

Replace Cab Air Filter

1000

25

Change Transmission Oil and Filter

XX

Check Injector Calibration

XX

Check Valve Adjustment (Engine Manual)

1000

XX

Trans Clutch Calibration (See Section 6002)

1000

1000 1000 1000

27

Change Hydraulic Oil

2000

28

Change Coolant

2000

29

Replace Engine Air Cleaner

XX

Valve Clearance (Engine Manual)

2000

XX

Engine Injectors (Engine Manual)

6000

XX

Fuel Pump (Engine Manual)

6000

2000 6000 Issued 8-06

Printed in U.S.A.

1002-7

MAINTENANCE POINTS Model 821E 1

29

12 23

17

11

10

5

26 18 14 21 15

19 25 24

10

8

8

21 15

6

13

2

4

16

22

11 5

17

6

9

8

20

3

18

17

28

27 BC06F531

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

Bur 5-3100

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

Issued 8-06

Printed in U.S.A.

1002-8

NOTES

Bur 5-3100

Issued 8-06

Printed in U.S.A.

1003

Section 1003 METRIC CONVERSION CHART


Bur 7-52590

Copyright © 2003 CNH Ameica LLC. All rights reserved. Printed in U.S.A. Issued April, 2003

1003-2

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

Bur 7-52590

Issued 4-03

Printed in U.S.A.

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)

Bur 7-52590

Issued 4-03

Printed in U.S.A.

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

Bur 7-52590

Issued 4-03

Printed in U.S.A.

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 87519803


Bur 5-3110


Section 2000


Bur 5-2700


2000

ENGINE AND RADIATOR REMOVAL AND INSTALLATION

2000-2

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

Bur 5-2700

Issued 8-06

3 3 10 18 18 20

Printed in U.S.A.

2000-3

ENGINE Removal

STEP 5

STEP 1

BD02N160

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

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

STEP 2

STEP 6

BD03A040

Stop engine. Actuate brake pedal several times to discharge brake accumulators. Put key switch in ON position and move loader control lever back and forth at least 30 times to release any pressure from hydraulic circuit. Put key switch in OFF position.

STEP 3 Slowly loosen the filler cap for hydraulic reservoir to release air pressure in hydraulic reservoir.

STEP 4 BD02N160

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

BD06F108

The master and hood raise switch are located in the right batter box. Raise the hood with the hood lift motor. Put master disconnect switch in OFF position. Remove both batte r y cove rs and disconn ec t batteries from the machine.

Bur 5-2700

Issued 8-06

Printed in U.S.A.

2000-4

STEP 7

STEP 10

1

2

BD03A231

BD06F109

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

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

STEP 8

STEP 11

2

1 BD03A230

BD03A227

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

STEP 9 2

BD03A226

BD03A228

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

Remove the pin from the top of the lifting motor.

Bur 5-2700

Issued 8-06

Printed in U.S.A.

2000-5

STEP 12

STEP 15

BD03A232

BD06F110

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

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

STEP 16 STEP 13

BD06F110 BD03A224

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

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

STEP 17 STEP 14

BD03A115 BD03A225

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

Bur 5-2700

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

Issued 8-06

Printed in U.S.A.

2000-6

STEP 18

STEP 21

BD06F111

BD06F112

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

Remove the air cleaner and muffler from the bracket.

STEP 22

STEP 19

BD06F113 BD03A118

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

STEP 20

BD06F114

Remove the four mounting bolts from the belt cover, remove the cover. NOTE: After removing the belt cover remove the cover mounting brackets from the machine frame. BD06F110

Loosen the exhaust clamp from the turbocharger.

Bur 5-2700

Issued 8-06

Printed in U.S.A.

2000-7

STEP 23

STEP 26

BD06F115

BD06F118

Remove the drive belt from the engine.

Tag and disconnect the wiring from the alternator.

STEP 24

STEP 27

BD06F116

BD06F119

Loosen clamps and remove lower cooler hose from the engine.

Remove bolt securing wiring harness clamp to engine.

STEP 25

STEP 28 1

1 2

2

BD06F117

BD06F120

If loader is equipped with air conditioning, identify, tag, and disconnect the engine wiring harness connectors from air compressor clutch connector (1). Remove the thre e m oun tin g b olts (2) for the compressor and set the compressor on the left battery cover.

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

Bur 5-2700

Issued 8-06

Printed in U.S.A.

2000-8

STEP 29

STEP 32

1 3

2

BD06F121

Tag and remove the wires from the starter solenoid (3), remove the ground cable (2), and ground strap (1) from the starter.

BD06F111

Tag and remove the grid heater cable.

STEP 33

NOTE: Move the starter cables away from the engine, move the wiring harness away from the engine.

STEP 30

BD03A142

Disconnect the wiring harness from the EDC 7 controller. NOTE: Lifting up on the lever will release the connector from the controller. BD06F146

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

STEP 34

STEP 31 3 2 1

BD06F123

Remove the fuel line from the top of the EDC 7 controller, plug the line and cap the fitting. BD06F122

Remove the radiator hose (1) from the rear of the engine, remove the heater hose from the rear of the engine (2), remove the clamp bolts and clamps (3) from the bell housing. Bur 5-2700

Issued 8-06

Printed in U.S.A.

2000-9

STEP 35

STEP 38

1

2

BD06F127

BD06F124

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

Remove the lower cover for the drive shaft.

STEP 39

STEP 36

BD03A172

BD06F125

Remove bolt and clamp.

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

STEP 40

STEP 37

Connect suitable lifting equipment to engine lifting brackets. Take up all slack in lifting equipment. Remove the engine mounting bolts and lift the engine enough to gain access to the drain hose, pull the drain hose with the engine.

STEP 41 Slowly raise engine from rear chassis. Be sure all h a r n e s s c o n n e c t i o n s a n d h o s e s h ave b e e n disconnected and are clear of the engine. Remove engine from machine.

BD06F126

Connect and turn on vacuum pump to hydraulic reservoir. Tag and remove the hydraulic lines from the brake system pump, plug the lines and cap the fittings.

Bur 5-2700

Issued 8-06

Printed in U.S.A.

2000-10

Installation

1 2

1

3

2 3

4 5 6

1

4

2

5

3

6 7

7 8

4 5 6 7 BS03B035

1. ENGINE MOUNT BOLT 2. WASHER

3. INSOLATOR UPPER 4. INSOLATOR LOWER

STEP 42

5. WASHER 6. WASHER

7. NUT 8. REMOTE OIL DRAIN HOSE

STEP 47

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

STEP 43 Slowly raise engine and move into position over rear chassis. Be sure all harness connections and hoses are out of the way then lower engine. Put washer (5) between front rubber isolator (4) and chassis. Install washer (2), bolt (1), washer (6), and nut (7) in engine isolators. Lower engine into position. BD03A172

STEP 44 Tighten engine mounting bolts to a torque of 244 to 298 Nm (180 to 220 lb-ft).

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

STEP 45 Disconnect lifting equipment from engine lifting brackets.

STEP 46 Connect engine oil drain hose to frame bracket.

Bur 5-2700

Issued 8-06

Printed in U.S.A.

2000-11

STEP 48

STEP 51

1

2

BD06F127

Install the lower cover for the drive shaft.

BD06F124

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

STEP 49

STEP 52

BD06F126

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

BD06F123

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

STEP 53

STEP 50

BD03A142

Connect wiring harness to EDC 7 controller. BD06F125

Install bolt and clamp for fuel return hose.

Bur 5-2700

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

Issued 8-06

Printed in U.S.A.

2000-12

STEP 54

STEP 57

1 2

3

BD06F111

BD06F121

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

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

STEP 55 STEP 58 3

1 2 2

1

BD06F122

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

STEP 56

BD06F120

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

STEP 59

BD06F146

Connect the engine coolant vent hose.

BD06F119

Install bolt securing wiring harness clamp to engine.

Bur 5-2700

Issued 8-06

Printed in U.S.A.

2000-13

STEP 60

STEP 63

BD06F118

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

BD06F115

Install the drive belt.

STEP 64 STEP 61 1 2

BD06F113 BD06F117

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

STEP 62

BD06F114

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

BD06F116

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

Bur 5-2700

Issued 8-06

Printed in U.S.A.

2000-14

STEP 65

STEP 68

BD06F112

BD06F111

Place the muffler and air cleaner on the bracket. Install mounting bolts in air cleaner and tighten, install the mounting bolts in the muffler and leave loose at this time.

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

STEP 69

STEP 66

BD03A115

BD06F110

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

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

STEP 70

STEP 67

BD06F110

BD03A118

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

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

Bur 5-2700

Issued 8-06

Printed in U.S.A.

2000-15

STEP 71

STEP 74

BD06F110

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

STEP 72

BD03A232

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

STEP 75

2

1

BD03A225

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

BD03A227

STEP 73

2

BD03A226

BD03A224

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

Bur 5-2700

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

Issued 8-06

Printed in U.S.A.

2000-16

STEP 76

STEP 78

2

1 BD03A228

BD03A221

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

NOTE: If hood strut is not adjusted properly the hood will be damaged. When a hood is removed and replaced an initial adjustment on the strut is necessary. Adjust between the top of the lift motor adjusting jam nut (1) to the top of the threads (2) to 20 mm (X). With the motor down to its lowest point take a measurement between the left hand side hood bumper and the counter weight, record this measurement (Y). Use the following table to adjust the strut (X).

STEP 77

Hood Adjustment Table Y X (MM) (MM)

BD06F109

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

Bur 5-2700

Y X (MM) (MM)

Y X (MM) (MM)

Y X (MM) (MM)

1

19

21

14

41

9

61

5

2

19

22

14

42

9

62

5

3

18

23

14

43

9

63

4

4

18

24

13

44

9

64

4

5

18

25

13

45

9

65

4

6

18

26

13

46

8

66

4

7

17

27

13

47

8

67

3

8

17

28

12

48

8

68

3

9

17

29

12

49

8

69

3

10

17

30

12

50

7

70

3

11

16

31

12

51

7

71

2

12

16

32

12

52

7

72

2

13

16

33

11

53

7

73

2

14

16

34

11

54

6

74

2

15

16

35

11

55

6

75

2

16

15

36

11

56

6

76

1

17

15

37

10

57

6

77

1

18

15

38

10

58

6

78

1

19

15

39

10

59

5

79

1

20

14

40

10

60

5

80

0

Issued 8-06

Printed in U.S.A.

2000-17

STEP 79

STEP 85

BD02N160

BD06F108

Check and make sure that drain caps are tight.

Lower the hood with the hood lift motor.

STEP 80

STEP 86

Install a new oil filter on engine. Fill engine with 14.2 liters (15 quarts) of Case AKCELA No. 1 Engine Oil (SAE 15W-40).

Put articulation lock in OPERATING position.

STEP 81 If hydraulic reservoir was drained, fill reservoir with 105.7 liters (27.9 gallons) of Case AKCELA Hy-Tran Ultra® fluid.

STEP 82 Fill engine coolant system with a solution of 50% Ethylene Glycol and 50% water. Cooling system capacity is 36.9 liters (9.75 gallons). Install the radiator cap. Fill the coolant reservoir up to the FULL mark on the reservoir.

STEP 83 Connect the batteries, install battery covers, put master disconnect switch in ON position.

STEP 84 Start engine and run the engine at low idle. Run the engine at operating temperature for approximately five minutes to completely mix the Ethylene Glycol an d wat er. Wh en the coo lan t is at o pe ra ting temperature, stop the engine. When engine has cooled, check the coolant level at the reservoir. WARNING: Hot coolant can spray out if radiator cap is removed. To remove radiator cap: Let system cool, turn to first notch, then wait until all pressure is released. Scalding can result from fast removal of radiator cap.

Bur 5-2700

Issued 8-06

Printed in U.S.A.

2000-18

RADIATOR Removal

STEP 5

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

STEP 2

BD06F128

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

STEP 6 BD03A040

Put articulation lock in LOCKED position.

STEP 3 Put master disconnect switch in OFF position.

STEP 4

BD02N160

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

STEP 7 BD03A120

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

BD03A109

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

Bur 5-2700

Issued 8-06

Printed in U.S.A.

2000-19

STEP 8

STEP 11

1 2

2

BD03A108

BD03A106

Loosen the upper radiator hose clamps, remove the hose.

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

STEP 9

BD06F129

Loose and remove the lower radiator hose from the radiator.

STEP 10

BD03A113

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

Bur 5-2700

Issued 8-06

Printed in U.S.A.

2000-20

Installation

STEP 15

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

STEP 13

1 BD06F129

2

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

2

STEP 16 BD03A106

Install four lock washers and bolts (2) to secure ra d i a t o r t o c o o li n g f ra m e. D i s c o n n e c t l i f t i n g equipment from lifting eyes. Remove lifting eyes and install screws (1).

STEP 14

BD03A108

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

STEP 17

BD03A113

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

BD06F130

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

Bur 5-2700

Issued 8-06

Printed in U.S.A.

2000-21

STEP 18

STEP 21

BD06F131

Align the whole in the fender on the bolt.

BD03A120

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

STEP 19

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

STEP 22

BD06F132

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

STEP 20 BD02N160

Check that coolant drain cap is tight.

STEP 23 Fill engine coolant system with a solution of 50% Ethylene Glycol and 50% water. Cooling system capacity is 36.9 liter (9.75 gallon). Install the radiator cap. Fill the coolant reservoir up to the FULL mark on the reservoir. DSC00105.TIF

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

Bur 5-2700

Issued 8-06

Printed in U.S.A.

2000-22

STEP 24 Put master disconnect switch in ON position.

STEP 25 Start engine and run the engine at low idle. Run the engine at operating temperature for approximately five minutes to completely mix the Ethylene Glycol an d wate r. Wh en the coo lan t is at o pe ra ting temperature, stop the engine. When engine has cooled, check the coolant level at the reservoir.

Bur 5-2700

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

STEP 26 Put articulation lock in OPERATING position.

Issued 8-06

Printed in U.S.A.

2002

Section 2002 STALL TEST


Bur 5-3120


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

Bur 5-3120

Issued 8-06

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

Printed in U.S.A.

2002-3

SPECIFICATIONS Low idle ..............................................................................................................................................875 to 925 rpm Alternate low idle .................................................................................................................................575 to 625 rpm Cold low idle ....................................................................................................................................1175 to 1225 rpm In gear low idle when in boost or auto power modes (see note) .....................................................1050 to 1150 rpm Full throttle (no load)........................................................................................................................2090 to 2225 rpm Temperature of the torque converter oil....................................................................... 82° to 104° C (180° to 220° F) Temperature of the hydraulic oil....................................................................................... 54° to 57°C (129° to 134°F) NOTE: This low idle will be held after the engine has accelerated over 1400 rpm while in gear. It will remain at this accelerated level until the transmission is placed back into neutral for two seconds.

Stall Speeds Torque converter..............................................................................................................................1750 to 1895 rpm Hydraulic system .............................................................................................................................1860 to 2175 rpm Torque converter and hydraulic system together.............................................................................1500 to 1800 rpm

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

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.

BD06F183

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 voltage level.

BD06F188

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

Bur 5-3120

Issued 8-06

Printed in U.S.A.

2002-4

BD06F169

BD06F027

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, as well as oil pressure PSI.

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

BD06F170

BD06F184

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 radiator coolant temperature.

Bur 5-3120

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

Issued 8-06

Printed in U.S.A.

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

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).

Bur 5-3120

Issued 8-06

Printed in U.S.A.

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 A. Max - Maximum power possible B. Standard - Standard operation C. Auto - Will cycle between Max and Standard D. Eco - Limited power for economy 6. High light Auto mode and press the enter key. 7. Press the escape key to return to the normal driving screen.

BD06H038

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

Bur 5-3120

Issued 8-06

Printed in U.S.A.

2002-7

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

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

5. Turn the transmission control lever to third gear.

7. Increase the engine speed to full throttle.

6. Increase the engine speed to full throttle.

8. Check the engine speed.

7. Hold the bucket control lever in the ROLLBACK position and raise the lift arms.

9. Decrease the engine speed to low idle.

NOTE: The stall speed must be read while the lift arms are in motion.

10. Place the transmission in neutral and apply the parking brake. 11. Stop the engine.

8. Check the engine speed. 9. Release the bucket control lever. 10. Decrease the engine speed to low idle. 11. Lower the bucket to the ground, place the transmission in neutral and apply the parking brake. 12. Stop the engine.

Understanding the Results of Test No. 1 1. If the engine speed was as specified, the engine, torque converter, transmission and hydraulic system are probably good.

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

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

Bur 5-3120

Issued 8-06

Printed in U.S.A.

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. NOTE: The stall speed must be read while the lift arms are in motion. 5. Check the engine speed.

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.

6. Release the bucket control lever. 7. Decrease the engine speed to low idle. 8. Lower the bucket to the ground. 9. Stop the engine.

Bur 5-3120

Issued 8-06

Printed in U.S.A.

2003

Section 2003 AFTER COOLER


Bur 6-49850

Copyright © 2004 CNH America LLC. All rights reserved. Printed in U.S.A. Issued February, 2004

2003-2

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

Bur 6-49850

Issued 2-04

3 4 4 6 6

Printed in U.S.A.

2003-3

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

STEP 2 Raise hood. Install ‘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.

BD03A118

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

STEP 6

STEP 4

BD03A119 BD03A116

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

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

STEP 7

STEP 5

BD03A109 BD03A115

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

Bur 6-49850

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 2-04

Printed in U.S.A.

2003-4

AFTERCOOLER REMOVAL Removal

STEP 4

STEP 1

BD03A118

Loosen clamps and remove air cooler outlet hose. BD03A116

Loosen clamps and remove turbocharger outlet components.

STEP 5

STEP 2

BD03112

BD03A115

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

Loosen clamps and remove air cooler inlet hose.

STEP 6

STEP 3

BD03A111 BD03A119

Remove three cover mounting bolts and lift cover off.

Loosen clamps and remove Intake hose.

Bur 6-49850

Issued 2-04

Printed in U.S.A.

2003-5

STEP 7

STEP 10

BD03A109

Unlatch air conditioning condenser clamp.

BD03A113

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

STEP 8 STEP 11 L i f t a i r c o o l e r a n d f ra m e f r o m m a c h i n e w i t h appropriate lifting devise.

STEP 12

BD03A107

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

STEP 9

BD03A111

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

BD03A117

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

Bur 6-49850

Issued 2-04

Printed in U.S.A.

2003-6

Leak Test

Installation STEP 1

BD03A111 BS03B028

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

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

STEP 2

BD03A113

Install two side mounting bolts

STEP 3

BD03A117

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

Bur 6-49850

Issued 2-04

Printed in U.S.A.

2003-7

STEP 4

STEP 7

BD03A107

BD03A116

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

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

STEP 8 STEP 5

BD03A115 BD03112

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

Tighten clamps at air cooler inlet.

STEP 9

STEP 6

BD03A119

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

Install three cover mounting bolts.

Bur 6-49850

Issued 2-04

Printed in U.S.A.

2003-8

STEP 10

STEP 11 Install ‘T’ fitting in waste gate valve hose. Attach pressure gauge. Install another pressure gauge into the intake manifold port.

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

BD03A118

Tighten clamps at air cooler outlet.

Bur 6-49850

Issued 2-04

Printed in U.S.A.

SECTION INDEX

FUEL SYSTEM Section Title

Section Number

FOR FUEL SYSTEM REPAIR, SEE THE ENGINE SERVICE MANUAL 87519803


Bur 5-3130


4001 Section 4001 REMOVAL AND INSTALLATION OF STARTER AND ALTERNATOR


Bur 5-2740


4001-2

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

Bur 5-2740

Issued 8-06

3 3 4 5 5 6 8 8 8

Printed in U.S.A.

4001-3

STARTER Removal

STEP 4

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

STEP 2

BD06F135

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

BD06F133

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

STEP 3

BD06F134

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

Bur 5-2740

Issued 8-06

Printed in U.S.A.

4001-4

Installation

STEP 7

STEP 5

1 BD06F134

2

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

Bur 5-2740

Issued 8-06

Printed in U.S.A.

4001-5

ALTERNATOR Removal

STEP 4

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

STEP 2

BD06F137

BD06F133

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

STEP 3

BD06F138

Remove four belt cover mounting bolts, remove cover.

STEP 5

BD06F136

Disconnect wires from the alternator.

BD06F139

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

Bur 5-2740

Issued 8-06

Printed in U.S.A.

4001-6

Installation

STEP 6

STEP 7

BD06F140

Remove mounting bolts for alternator, remove alternator.

BD06F140

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

STEP 8

BD06F139

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

Bur 5-2740

Issued 8-06

Printed in U.S.A.

4001-7

STEP 9

STEP 10

BD06F137

BD06F136

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

STEP 11

BD06F138

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

BD06F133

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

Bur 5-2740

Issued 8-06

Printed in U.S.A.

4001-8

BELT INSTALLATION

BC05G045

WITH OUT AIR CONDITIONING

BC05G046

WITH AIR CONDITIONING

Bur 5-2740

Issued 8-06

Printed in U.S.A.

4002

Section 4002 ELECTRICAL SPECIFICATIONS AND TROUBLESHOOTING


Bur 5-2750


4002-2

TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL WIRE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UNDERSTANDING THE TROUBLESHOOTING TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LOCATING COMPONENTS ON THE SCHEMATIC POSTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTING AND CHARGING SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crank Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crank Request Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Time Delay Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Master Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Neutral Start Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltmeter Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . POWER RELAY MODULES AND COLD STARTING SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Relay Module A, Ignition Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Relay Module B, Ignition Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Relay Module C, For Fuel Filter Heater and Water Separator Heater . . . . . . . . . . . . . . . . . . . . . . . . . Grid Heater Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grid Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit breaker Cab B+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water Separator Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Filter Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Relay Module D, Accessory Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water In Fuel Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Throttle Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Diesel Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RETURN TO TRAVEL - RETURN TO DIG - PIN ENGAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Return-To-Travel/Float Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Height Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electromagnetic Detents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Return-To-Dig Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pilot Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Height Control/Return-To-Travel Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Return to Dig Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pin Engage Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pilot Pressure Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pin Engage Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PILOT CONTROL - RIDE CONTROL - FAN CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ride Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ride Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan Reversing Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan Reverse Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pilot Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ride Control Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rollback Pressure Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rollback Jumper (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan PWM Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan Reversing Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bur 5-2750

Issued 8-06

7 8 38 38 38 39 40 40 40 41 41 41 42 42 43 43 44 44 45 46 46 46 47 47 47 47 48 48 49 50 50 51 52 53 53 54 54 55 55 55 56 56 56 57 58 58 59 59 60 60 60 61 61 61

Printed in U.S.A.

4002-3 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Output Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Transmission Solenoid Valve and Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Filter Maintenance Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Torque Converter Output Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Engine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Intermediate Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Turbine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Transmission Shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Transmission Electronic Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Transmission Enable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 FNR Switch for Joystick Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Transmission Kick-down Switch (Located In Hydraulic Controller for Joystick Option; Next to Hydraulic Levers for Single Axis Controls) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 FNR Switch for Single Axis Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Transmission Auto Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Brake Declutch Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Declutch Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Diagnostic Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 WARNING BUZZER, INSTRUMENT CLUSTER 1, PARK BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Instrument Cluster Connector 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Warning Buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Parking Brake Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Air Filter Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Parking Brake Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Radiator Coolant Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Brake Warning Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 SWITCH PAD, INSTRUMENT CLUSTER 2, PARK BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Switch Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Instrument Cluster Connector 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Hydraulic Filter Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Hydraulic Oil Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Redundant Brake Pressure Switch 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Redundant Brake Pressure Switch 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Coolant Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 BACK UP ALARM CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Back-up Alarm Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Back-up Alarm Disable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 LIGHTS - 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Work Lamps Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Door Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Rotating Beacon (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Beacon Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Left Hand Front Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Right Hand Front Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Left Hand Rear Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Right Hand Rear Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Lights Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 LIGHTS - 02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Brake Lamp Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Brake Lamps Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Flasher Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Hazard Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-4 Turn Signal, High-Low Beam, and Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Driving Lamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 LIGHTS - 03 AND HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Left Hand Front Combination Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Right Hand Front Combination Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Horn Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 LIGHTS - 04 AND BACK UP ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Right Hand Rear Combination Lamp (North America Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Right Hand Rear Combination Lamp (Europe Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Left Hand Rear Combination Lamp (North America Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Left Hand Rear Combination Lamp (Europe Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 License Plate Lamp (North America Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 License Plate Lamp (Europe Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Back-up Alarm (North America Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Back-up Alarm (Europe Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 CAB WINDOW WASHER AND WIPER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Front Wiper High Speed Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Front Wiper Cut Out Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Front Wiper Low Speed Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Rear Wiper and Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Front Wiper and Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Front Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Rear Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Rear Washer Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Front Washer Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Wiper Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 SECONDARY STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Secondary Steering Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Secondary Steering Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Secondary Steering Module (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Secondary Steering Motor (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Secondary Steering Pressure Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 CAN COMMUNICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 CAN Communication Diagnostics Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 RADIO AND POWER CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Power Relay Module E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Power Converter 24 volts to 12 volts (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Power Outlet (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 12 Volt Radio Ready (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Right Speaker (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Left Speaker (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 AIR SEAT - CIGAR LIGHTER - AIR CONDITIONING COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Seat Compressor and Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Cigar Lighter (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Compressor Clutch Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 A/C High/Low Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Compressor Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 CLIMATE CONTROL - AUTOMATIC TEMPERATURE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Electronic Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 External Air Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Internal Air Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Sun Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Blower Motor Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Blower Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Thermocouple Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Bur 5-2750

Issued 8-06

Printed in U.S.A.

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

Bur 5-2750

Issued 8-06

117 118 118 118 118 119 120 120 120 120 120 121 121 121 121 121 122 123 124 124 124 125 126

Printed in U.S.A.

4002-6

NOTES

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-7

SPECIFICATIONS Electrical System ............................................................ Two 12 volt batteries connected in series, negative ground System Voltage................................................................................................................................................24 volts Batteries Group Size ..........................................................................................................................................................31 Reserve Capacity ................................................................................................................................ 170 minutes Cold Cranking Capacity At -17° C (0° F) for 60 Seconds At 6.0 Volts................................................700 amperes Load of Capacity (Load) Test .............................................................................................................400 amperes Alternator ..................................................................................................................................... 24 volt, 65 amperes Voltage Regulator ............................................................................................................. Solid State, Not Adjustable Starter................................................................................................................................ 24 volt, Solenoid Actuated Bucket Control Valve (Joystick) Detent Electromagnets Resistance at 20° C (68° F) (Nominal)................ 68.2 ohms Bucket Control Valve (Single Axis) Detent Electromagnets Resistance at 20° C (68° F) (Nominal) ........... 305 ohms Fuel Level Sender............................................................................................................................... 33 to 240 ohms Coolant, Torque Converter, and Hydraulic Temperature Sender 20° C (68° F) ......................................... 3521 ohms Transmission Filter Restriction Switch with 510 ohms Internal Resistor (Normally Open) Closing Set point ............................................................................................................................ 2.8 Bar (40 psi) Hydraulic Filter Restriction Switch (Normally Open) Closing Set point .............................................. 2.8 Bar (40 psi) Air Filter Restriction Switch (Normally Open) Closing Set point ................................. -6.4 kPa (Gauge) (-0.928 psig) A/C Trinary Pressure Switch (Closed With Normal System Pressure) Opens With Pressure ............................................................................ Above 28.5 ± 2.5 bar (413.3 ± 36,25 psi) Below 2.5 ± 0.25 bar (36.25 ± 3.6 psi) Brake Declutch Pressure Switch (Normally Closed) Opening Set point............................................ 24 Bar (350 psi) Brake Warning Pressure Switch (Normally Closed) Opening Set point ................. 106 to 115 bar (1530 to 1670 psi) Brake Redundant Pressure Switches (Normally Open) Closing Set point 55 to 69 bar decreasing (800 to 1000 psi) Brake Lamp Pressure Switch (Normally Open) Closing Set point........................ 5 to 6 bar increasing (75 to 85 psi) Secondary Steering Pressure Switch (Form C) Closing Set point ..................................................... 2.4 Bar (35 psi) Fuel Filters Heater Resistance At 20° C (68° F) (Nominal) .......................................................................... 1.9 ohms Parking Brake Solenoid DC Resistance At 20° C (68° F) (Nominal) .......................................................... 40.3 ohms Pilot Pressure Solenoid (Joystick) DC Resistance At 20° C (68° F) (Nominal) .......................................... 29.9 ohms Pilot Pressure Solenoid (Single Axis) DC Resistance At 20° C (68° F) (Nominal) ..................................... 27.4 ohms Ride Control Solenoid DC Resistance At 20° C (68° F) (Nominal)............................................................. 22.7 ohms Pin Engage Solenoid DC Resistance At 20° C (68° F) (Nominal) .............................................................. 28.8 ohms Secondary Steering Solenoid DC Resistance At 20° C (68° F) (Nominal) ................................................. 39.3 ohms Fan Reversing Solenoid DC Resistance At 20° C (68° F) (Nominal).......................................................... 39.3 ohms Fan PWM Solenoid DC Resistance At 20° C (68° F) (Nominal) ..................................................................xx.x ohms Rollback Pressure Switch (Normally Closed) Opening Set point ....................................................... 6.2 Bar (90 psi) Fuel Temperature Sensor At 20° C (68° F) (Nominal) ............................................................................... 2500 ohms Grid Heater .................................................................................................................................................. 500 ohms Engine Control Unit ............................................................................................... Electronic Diesel Control (EDC 7) Analog Throttle ..................................................................................Idle Validation Switch Closes At 0.775V ± 0.1V Throttle Position Potentiometer.................................................................................................. 5V Reference ± 0.2V Low Idle Position .............................................................................................................................. 0.4V ± 0.025V High Idle Position ................................................................................................................................. 4.0V ± 0.1V

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-8

ELECTRICAL WIRE IDENTIFICATION Wire Identification Codes

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

Bk = Black T = Tan LU = Light Blue

1.0 mm 2.0 mm 5.0 mm DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

14

Alternator D+

42

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

AD, Alternator D+

1

ENG, Engine Cab

26

Work Lights Switched Fused Pwr R2.0 GXL

SPL-WL, Ultrasonic

A

ECC, Work Lights

23

44

Brake Lt Control Power

T 1.0 SXL

FRONT, Cab Front Chassis

23

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


20

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


13

HN1, Horn Power

1

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


Bk 1.0 SXL

SPL-A2, Ultrasonic

A

GND-FC, Ground A

1

0 AC


Bk 1.0 SXL

PXF, RTD

B

SPL-A2, Ultrasonic

A

0 AD

Ride Control Ground

Bk 1.0 SXL


2

SPL-A1, Ultrasonic

A

0 AE

Pin Engage Ground

Bk 1.0 SXL

SPL-A1, Ultrasonic

A

YPE, Pin Engage Option

B

0 AF

Horn Ground

Bk 1.0 SXL

HN2, Horn Ground

1

SPL-A1, Ultrasonic

A

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

GND-FC, Ground A

1

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 AQ

Comfort Steering Solenoid Gnd

Bk 1.0 SXL

YCS, Comfort Steer Solenoid

B

SPL-A4, Ultrasonic

A

0 AR

Front Axle Temp Sensor Ground Bk 1.0 SXL


9

HOT-FA, Front Axle Oil Temp

2

0B

Front Washer Ground

Bk 1.0 SXL

FWW, Front Washer

2

SPL-ENG-GRD, Gnd Spl 6 Pck

E

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

Bur 5-2750

Lg 1.0 SXL

Issued 8-06

Printed in U.S.A.

4002-9

Wire Identification Codes





Circuit





To Connector

Connector

Cavity

Connector

Cavity

0 B2

Back Light Ground

Bk 0.8 GXL

SFL, Return To Travel Switch

7

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

B

0 B3

Back Light Ground

Bk 0.8 GXL

SHC, Height Control Switch

7


C

0 B4

Back Light Ground

Bk 0.8 GXL

SRTD, Detent Switch

7


D

0 B5

Back Light Ground

Bk 0.8 GXL

SPE, Pin Engage Switch

9


E

0 B6

Cab2 Ground

Bk 1.0 GXL

GND-CAB2, Ground A

1


F

0 B7

Back Light Ground

Bk 0.8 GXL

SFC, Fan Control Switch

7


M

0 B8

Front Wiper Motor Ground

Bk 0.8 GXL

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

H

FWMG, Wiper Ground

A

0 B9

Back Light Ground

Bk 0.8 GXL

SCS, Comfort Steering Sw

7

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

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


L


F

0 B12 Hood Down Relay Ground

Bk 1.0 GXL


A

ECC, Work Lights

C4


Bk 1.0 GXL


A

GND-CAB2, Ground A

1


Bk 0.8 GXL

SWL, Work Lights Switch

7


B


Bk 0.8 GXL

SBE, Beacon Switch

7


C

0 B16 Hood Down Control Ground

Bk 1.0 GXL


B

ECC, Work Lights

B4


Bk 0.8 GXL

STA, Trans Auto Switch

7


E


Bk 0.8 GXL

SDC, Declutch Switch

7


F


Bk 0.8 GXL

SDR, Driving Lights Switch

7


G


Bk 0.8 GXL

SRC, Ride Control Switch

7


J


Bk 1.0 GXL

SBU, Backup Alarm Disc Sw

7


J

0 B22 Hood Up Relay Ground

Bk 1.0 GXL

SPL-HOOD-GRND, Hood Gnd 6 Pck

C

ECC, Work Lights

Bur 5-2750

Issued 8-06

C2

Printed in U.S.A.

4002-10






Circuit




Connector


To Connector Cavity

Connector

Cavity


Bk 0.8 GXL

SRWP, Rear Wiper Switch

7


L


Bk 0.8 GXL

SHZ, Hazard Switch

7


C

0 B25 Hood Up Control Ground

Bk 1.0 GXL

SPL-HOOD-GRND, Hood Gnd 6 Pck

D

ECC, Work Lights

B2

0 B26 Buzzer/Switch Pad Ground

Bk 0.8 GXL

SPL-BUZ, Ultrasonic

A


6

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


E


Bk 0.8 GXL

SETHR, Ether Switch

7


D

0 BA

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, WIF, EDC

1

0 BAE EDC7 Sender Ground

Bk 1.0 SXL

RECT, Engine Coolant Temp

B

GND-ENG7, Tranny, Cool Temp

1

0 BAF Coolant Lever Sender Ground

Bk 1.0 SXL

CLS, Cool Jump-Cool Sender

B


1

0 BAG Hood Grounds (EURO)

Bk 1.0 SXL

GND-ENG4, Rear Lighting

1

E-HD, Trans Hood

c

0 BAG Hood Grounds (NA) N

Bk 1.0 SXL

ENG-H, Engine to Hood

1


1

0 BAH QSM11 Ground

Bk 0.8 GXL


A

QSM11, Engine Controller

29

0 BAI

QSM11 Ground

Bk 0.8 GXL


A


30

0 BAJ QSM11 Ground

Bk 0.8 GXL


A


39

0 BAK QSM11 Ground

Bk 0.8 GXL


A


40

0 BAL QSM11 Ground

Bk 0.8 GXL


A


41

0 BAM Ether Relay Signal Ground

Bk 1.0 SXL

PRM-C2, PRM signal

B

GND-ENG2, WIF, EDC

1

0 BAN Ether Start Ground

Bk 1.0 SXL

ETHR, Ether Solenoid

B

GND-ENG3, Spl Pck Washer Motor

1

0 BAP QSM11 Ground

Bk 0.8 GXL


A


50

0 BAR WIF Body Ground

Bk 1.0 SXL

GND-WIF, Gnd WIF Ring Term

1

GND-ENG6, Dedicated

1

0 BAS Rear Axle Temp Sensor Ground

Bk 1.0 SXL

HOT-RA, Rear Axle Oil Temp

2


1

0 BB

Fan Reverse Solenoid Ground

Bk 1.0 SXL

YFR, Fan Reverse Sol Opt

2

SPL-FAN, Ultrasonic

A

0 BC

EDC7 Grnd

Bk 1.0 GXL


A

EDC7, Engine Controller

11

Pedestal Gnd Strap

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-11






Circuit




Connector


To Connector Cavity

Connector

Cavity

0 BD

EDC7 Grnd

Bk 1.0 GXL


A


10

0 BE

EDC7 Grnd

Bk 1.0 GXL


A


5

0 BF

EDC7 Grnd

Bk 1.0 GXL


A


6

0 BG

AIC Power Ground

Bk 0.8 GXL

ENG, Engine Cab

19

GND-ENG6, Dedicated

1

0 BH

AIC Power Ground Red

Bk 0.8 GXL

ENG, Engine Cab

20

GND-ENG6, Dedicated

1

0 BJ

AIC Sensor Ground

Bk 0.8 GXL

ENG, Engine Cab

17

GND-ENG6, Dedicated

1

0 BK

Trans Splice Grounds

Bk 1.0 GXL

ENG-T, Engine to Trans

2


1

0 BL

Rear Washer Ground

Bk 1.0 SXL

RWW, Rear Washer

2

SPL-ENG-GRD, Grd Spl 6 Pck

F

0 BM

Engine Splice Grounds

Bk 1.0 SXL


A

GND-ENG3, SPLC-PK, Washer Motor

1

0 BN

Filter Heater Control

Bk 0.8 GXL

PRM-C2, PRM Signal

B


13

0 BP

WIF Sensor Ground

Bk 1.0 SXL

GND-ENG2, 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


1

Bk 1.0 SXL

LLR-N, LH Rear Comb Lamp

D

SPL-J1, Ultrasonic

A

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

Fan Control Ground

Bk 1.0 SXL

SPL-FAN, Ultrasonic

A


D

0 BT

LH Rear Light Ground (EURO)

Bk 1.0 SXL

LLR-E, LH Rear Comb Lamp

5


1

Bk 1.0 SXL

LRR-N, RH Rear Comb Lamp

D

SPL-J1, Ultrasonic

A

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

Fuel Level Sender Ground

Bk 1.0 SXL

RFLG, Fuel Send Ground

1


1

0 BV

Grid Heater Control Grnd

Bk 0.8 TXL

GHC, Grid Heater Relay

2


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, Start, FFH, WSH

1

0 BY

Air Filter Restriction Sw Grd

Bk 1.0 SXL


B

PAF, Air Filter Restriction Sw

2

0 BZ

Sec. Steering Splice Grd

Bk 1.0 SXL

ENG-T, Engine To Trans

1

GND-ENG3, SPLC-PK, Washer Motor

1

0 CA

Sec. Steering Signal Ground

Bk 1.0 SXL

SSM, Sec. Steering Mod

11

SPL-SEC-STR, Sec. Steer 6 Pck

B

0 CB


Bk 1.0 SXL


12


A

0 CC

Sec. Steering Press Sw Ground

Bk 1.0 SXL

PSS, Sec. Steer Press Switch

B


C

0 CD

Sec. Steering Splice Ground

Bk 1.0 SXL


F

SS-TR, SS Mod Trans

D

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-12






Circuit




Connector


To Connector Cavity

Connector

Cavity

0 CE

Sec. Steering Chassis Ground

Bk 1.0 SXL


4

GND-SSMOD, Sec. Str Chas Gnd

1

0 CF

Sec. Steering Sol Ground

Bk 1.0 SXL

YSS, Sec. Strg Sol

2


D

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


Bk 0.8 TXL

CAB-E, Cab Engine

20

AIC-2, And Instr Cluster 2

15

0 DC

Time Delay Module Ground

Bk 0.8 GXL

GND-CAB-SPL2, Spl Back Light Ground

A

TDM, Time Delay Module

3

0 DD

Voltmeter Relay Control Ground

Bk 0.8 GXL


E

ECB, Elect Center B

B2

0 DE

Neutral Start Relay Control Grd

Bk 0.8 GXL


G

ECB, Elect Center B

B4

0 DF

Crank Request Relay Control Ground

Bk 0.8 GXL


F

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


M

DIA, Diagnostic

A

0 DJ

AC Relay Control Ground

Bk 0.8 GXL


K

ECD, Elect Center D

B10

0 DK

Seat Compressor Motor Ground

Bk 0.8 GXL


I

SC, Seat Comp Motor

B

0 DL

Power Converter Relay Control Ground

Bk 0.8 GXL


H

PRM-E2, PRM Signal

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


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


G

GND-CAB1, Ground A

1

0 DT

Front Wiper/Washer Sw Grd

Bk 0.8 GXL


G

SFWW, Front Wiper/Washer

2

0 DU

Pilot Pressure Sol Grd

Bk 0.8 GXL


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


6

0 DY

Front Axle Temp Sensor Grnd

Bk 1.0 GXL

CAB-F, Cab Front Chassis

9

GND-CAB3D, Ground A

1

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-13






Circuit




Connector


To Connector Cavity

Connector

Cavity

0 EA

Time Delay relay Control Grnd

Bk 0.8 GXL


B

PRM-B2, PRM Signal

B

0 EB

Ignition Relay Control Ground

Bk 0.8 GXL


C

PRM-A1, PRM Signal

B

0 EC

ACC Relay Control Ground

Bk 0.8 GXL


D

PRM-D1, 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


M

ECC, Work Lights

B6

0 EG

Flasher Module Ground

Bk 0.8 GXL

FLSHR, Flasher Module

4


L

0 EH


Bk 0.8 GXL


3


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


M

GND-CAB-SPL, Cab Grnd Spl

B

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


C

SRHSTLK, RH Stalk Switch

31

0 EQ

Splice Pack GND-CAB-SPL2 Grnd

Bk 0.8 GXL


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 GB

Starter Relay Control Ground

Bk 1.0 SXL

SRC-1, Relay

2

GND-ENG1, STRT, FFH, Water Sep Htr

1

0 HC


Bk 1.0 SXL

SPL-TRN-GND, Spl Trans Ground

A

TRAN-E, Trans to Engine

2

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


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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-14






Circuit




Connector


To Connector Cavity

Connector

Cavity

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

SPL-TRN-GRD, Spl Trans Grd

E

0 HM

Redundant Brake Switch Grnd

Bk 1.0 SXL

PRB1, Redundant Brake Sw

B


F

0 HP

Sec. Steering Splice Grnd

Bk 1.0 SXL


1

TR-SS, Sec. Steering Module Opt

D

0 HV

Coolant Level Sender Grnd

Bk 1.0 SXL

CLS, Cool Jump Cool Sender

B


D

0 HW

Hot Ground

Bk 1.0 SXL

HOT, Hydraulic Oil Temp Send

B


C

0 JA

Hood Grounds (EURO)

Bk 1.0 SXL

HD-E, Hood Trans

C

SPL-J1, Ultrasonic

A

Bk 1.0 SXL

HD-N, Hood to Engine

1

SPL-J1, Ultrasonic

A

0 JA N Hood Grounds (NA) 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

0 LA

Rear Light Grnd

Bk 1.0 SXL

HD-9, Hood to Engine

1

SPL-B1, Ultrasonic

A

0 LB

Rear Light Grnd

Bk 1.0 SXL

LLR-9, LH Rear Comb Light

5

SPL-B1, Ultrasonic

A

0 LC

Rear Light Grnd

Bk 1.0 SXL

SPL-B1, Ultrasonic

A

LRR-9, RH Rear Comb Light

5

0 LD

Rear Light Grnd

Bk 1.0 SXL

SPL-B1, Ultrasonic

A

E-HD9, Trans Hood

C

0 MA

Rear Wiper Motor Grnd

Bk 1.0 GXL

SPL-ROOF, Spl Rood Grnd

F

RWMG, Rear Wiper Motor Grnd

A

0 MB

Dome Light Grnd

Bk 0.8 GXL

LDM3, Dome Light Grnd

1


B

0 MC

Beacon Light Grnd

Bk 1.0 GXL

LBEGRD, Light Beacon Grnd

1


A

0 MD

Beacon Light Grnd

Bk 1.0 GXL

LBEE, Lgt Beacon Extension

B

LBEG, Light Beacon Grnd

1

0 ME

LH Rear Work Light Grnd

Bk 1.0 GXL

LLRW, LH Rear Work Light

B


D

0 MF

RH Rear Work Light Grnd

Bk 1.0 GXL

LRRW, RH Rear Work Light

B


E

0 MJ

RH Front Work Light Grnd

Bk 1.0 GXL

LRFW, RH Front Work Light

B


J

0 MK

Roof Grounds

Bk 1.0 GXL


G


M

0 MN

Roof Grounds

Bk 1.0 GXL


F


L

0 MU

LH Front Work Light Grnd

Bk 1.0 GXL

LLFW, LH Front Work Light

B


C

0 NB

Master Disconnect Grnd

Bk 62.0 SGR

DC2, Discon Black Grnd

1

STTR-GRN, Grid Heater Fuse

1

0 NC

Battery Disconnect

Bk 62.0 SGR

BT4, Discon Black Grnd

1

DC1, Disconnect Battery

1

0 ND

SSM Ground

Bk 62.0 SGR

242F, Chassis Grnd Sec. Strg Motor

1

GND-SSCHAS, SSM Ground Cable

1

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-15






Circuit




Connector


To Connector Cavity

Connector

Cavity

0 PA

Left Speaker Grnd

Bk 0.8 GXL

LSPK, Left Speaker

2

SPK, Speaker

8

0 PB

Right Speaker Grnd

Bk 0.8 GXL

RSPK, Right Speaker

2

SPK, Speaker

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-D1, PRM Signal

A

12ACC Power Converter PRM Control C Power

W 0.8 GXL

SPL-ACC, Ultrasonic

A

PRM-E2, PRM Signal

A

12V Pwr To Outlet 1

Or 1.0 GXL

PO1, Power Outlet

A

ECD, Elect Center D

AA4

12V A 12V Pwr To Outlet 2

Or 1.0 GXL

PO2, Power Outlet

A

ECD, Elect Center D

AA5

12V B 12V Fused Pwr to Radio

Or 1.0 GXL


N

ECD, Elect Center D

AA6

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

ECD, Elect Center D

A4

12V E Plug 2 12V Switched Power

Or 1.0 GXL

SPL-12V, Ultrasonic

A

ECD, Elect Center D

A5

12V F Radio 12V Switched Power

Or 1.0 GXL

SPL-12V, Ultrasonic

A

ECD, Elect Center D

A6

12V G 2 Way Radio 12V Switched Pwr

Or 1.0 GXL

SPL-12V, Ultrasonic

A

ECD, Elect Center D

A7

12V H 12V Fused Power to Radio

Or 0.8 GXL


N

SPL-RAD, Ultrasonic

A

12V

12V HA

12V Fused Power to Radio

Or 0.8 GXL

SPL-RAD, Ultrasonic

A

RAD, Radio Power

7

12V HB


Or 0.8 GXL

SPL-RAD, Ultrasonic

A

RAD, Radio Power

4

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

21

13C B Fuel Shutoff Fused Power

Or 1.0 SXL

CAB-E, Cab Engine

21

ECA, Elect Center A

A9

13D

Time Delay Relay Control Pwr

Or 1.0 SXL


1

PRM-B2, PRM Signal

A

13H

Time Delay Power

Or 3.0 GXL

SPL-DLY-RL, Ultrasonic

A

PRM-B1 PRM Output

C

13H B AIC Time Delay Power

Or 0.8 GXL


A

ECD, Elect Center D

A3

13H C Trans ECM Time Delay Power

Or 0.8 GXL


A

ECD, Elect Center D

A1

13H D Engine ECM Time Delay Power

Or 3.0 GXL


A

ECD, Elect Center D

A2

Ignition Switch Pwr

Or 1.0 GXL


3

SPL-PK1, Slice 3-4 Way

E

13K A Ignition Switch Pwr

Or 1.0 GXL


5


G

13K B Ignition Switch Pwr

Or 1.0 GXL


F

PRM-A1, PRM Signal

A

13K C Ignition Switch Pwr

Or 1.0 GXL


H

ECB, Elect Center B

D1

13K

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-16





Wire Identification Wire 13M

Circuit




Connector


To Connector Cavity

Connector

Cavity


Or 1.0 SXL

DC4, Fuel Sol Disconnect

1

DISC, Disconnect Engine

B

13M A Fuel Shutoff Fused Power

Or 0.8 TXL

ENG-D, Disconnect Harness

B


40

13M B Key Switch Power Disc Sw

Or 1.0 GXL

ENG-D, Disconnect Harness

B


38 D2

13V

Voltmeter Input ANALOG

Or 0.8 TXL


1

ECB, Elect Center B

14 A

Alternator D+

LG 0.8 GXL

CAB-E, Cab Engine

26

215F, Alternator Resistor

1

SW-PD, Switch Pad

9

AIC-1, Advanced Instr Cluster

25 3

17P A Switch Pad Power From AIC Pwr Or 0.8 TXL 18B

LH High Beam Fused Power

Or 1.0 SXL


7

LLF, Lights LH

18B A LH High Beam Fused Power

Or 0.8 GXL


7

ECB, Elect Center B

RH High Beam Fused Power

Or 1.0 SXL


16

LRF, Lights RH

18C A RH High Beam Fused Power

Or 0.8 GXL


16

ECB, Elect Center B

LH Low Beam Fused Power

Or 1.0 SXL


14

LLF, Lights LH

18D A LH Low Beam Fused Power

Or 0.8 GXL


14

ECB, Elect Center B

RH Low Beam Fused Power

Or 1.0 SXL


15

LRF, Lights RH

18E A RH Low Beam Fused Power

Or 0.8 GXL


15

ECB, Elect Center B

LH Position/Tail Fused Power

Or 1.0 SXL


6

LLF, Lights LH

18F A LH Position/Tail Fused Power

Or 0.8 GXL

CAB-E, Cab Engine

5

SPL-POS-L, Ultrasonic


Or 1.0 SXL

ENG, Engine Cab

5


6

18F B LH Position/Tail Fused Power

Or 1.0 SXL

ENG, Engine Cab

5

LLR-E, LH Rear Comb Light

3


Or 1.0 SXL


6

LLR-N LH Rear Combination Light

B

18F C LH Position/Tail Fused Power

Or 1.0 GXL


18F E LH Position/Tail Fused Power

Or 0.8 GXL


6


18F F LH Position/Tail Fused Power

Or 1.0 SXL

HD-9, Hoof to Engine

6


RH Position/Tail Fused Power

Or 1.0 GXL

SPL-POS-R, Ultrasonic

18G A RH Position/Tail Fused Power

Or 1.0 SXL


5

LRF, Lights RH

4


Or 1.0 SXL

SPL-POS-NA, Ultrasonic

A

LRR-N, RH Rear Combination Light

B

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

Or 1.0 SXL

LPL, Licence Plate Light

A


A

18C

18D

18E

18F

18F AN

18F BN

18G

18G CN

18G EN

Licence Plate Light Fused Pwr

Bur 5-2750

AA3 3 AA4 2 AA6 2 AA5 4

AA7

ECB, Electric Center B

AA8

ECB, Elect Center B

Issued 8-06

3

Printed in U.S.A.

4002-17






Circuit




Connector


To Connector Cavity

Connector

Cavity

18G F RH Position/Tail Fused Power

Or 0.8 GXL

CAB-E, Cab Engine

9


18G G RH Position/Tail Fused Power

Or 0.8 GXL


A


18G H RH Position/Tail Fused Power

Or 1.0 SXL

ENG, Engine Cab

9

SPL-POS, Ultrasonic

A


Or 1.0 SXL

ENG, Engine Cab

9


5

18G J RH Position/Tail Fused Power

Or 1.0 SXL

LRR-E, RH Rear Combination Light

3

SPL-POS, Ultrasonic

A


Or 1.0 SXL


5


A

18G K RH Position/Tail Fused Power

Or 1.0 SXL


5

SPL-P9, Ultrasonic

A

18G L RH Position/Tail Fused Power

Or 1.0 SXL

SPL-P9, Ultrasonic

A

E-HD9, Trans Hood

A

18G M RH Position/Tail Fused Power

Or 1.0 SXL

SPL-P9, Ultrasonic

A

LRR-9, RH Rear Combination Light

3

EDC7 Time Delay Fused Power

Or 2.0 GXL

CAB-E, Cab Engine

18

SPL-D2, Ultrasonic

A

18J A EDC7 Time Delay Fused Power

Or 2.0 GXL

ENG, Engine Cab

18


A

18J B EDC7 Time Delay Fused Power

Or 1.0 GXL


A


3

18J C EDC7 Time Delay Fused Power

Or 1.0 GXL


A


2

18J D EDC7 Time Delay Fused Power

Or 1.0 GXL


A


8

18J E EDC7 Time Delay Fused Power

Or 1.0 GXL


A


9

18J F


Or 2.0 SXL

ENG, Engine Cab

14


A

18J G EDC7 Time Delay Fused Power

Or 2.0 GXL

CAB-E, Cab Engine

14

SPL-D2, Ultrasonic

A

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


A


3

18J K EDC7 Time Delay Fused Power

Or 3.0 GXL

SPL-D2, Ultrasonic

A

ECD, Elect Center D

18J L

QSM11 Time Delay Power

Or 0.8 GXL


A

QSM11, Engine controller

17

18J M QSM11 Time Delay Power

Or 0.8 GXL


A


7

18J N QSM11 Time Delay Power

Or 0.8 GXL


A


8

18J P QSM11 Time Delay Power

Or 0.8 GXL


A


18

18J Q QSM11 Time Delay Power

Or 0.8 GXL


A


28

18K A Diagnostic Fused Power

Or 0.8 GXL

DIA, Diagnostic

B

ECC, Work Lights

A9

18L A Comfort Steer Fused Power

Or 0.8 GXL

SPL-CSTR, Ultrasonic

A

ECA, Elect Center A

A2

18L B Comfort Steer Fused Power

Or 0.8 GXL


A

ECC, Work Lights

D9

18L C Comfort Steer Fused Power

Or 0.8 GXL


A

ECC, Work Lights

B9

18G HN

18G JN

18J

Bur 5-2750

Issued 8-06

AA2

Printed in U.S.A.

4002-18






Circuit

18L D Comfort Steer Fused Power




Connector

Or 0.8 GXL

SCS, Comfort Steer Switch


To Connector Cavity 2

Connector

Cavity


A

18M

AC Relay Fused Power

Or 0.8 GXL

ECA, Elect Center A

C5

ECD, Elect Center D

B9

18N

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


A

HVAC1, HVAC1

2

18N B Blower Motor Fused Power

Or 3.0 GXL


A

HVAC2, HVAC2

1

Voltmeter Relay Fused Power

Or 2.0 SXL

ENG, Engine Cab

13

PRM-C1, PRM Output

A

18R A Voltmeter Relay Fused Power

Or 2.0 GXL

CAB-E, Cab Engine

13

ECB, Elect Center B

B1


29

OSS, Out Speed Sensor

3

18R

19A

Output Speed Sensor Fused Pwr Or 1.0 SXL

19A A Brake Declutch Sw Fused Pwr

Or 1.0 SXL


27

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


2

SPL-D15, Ultrasonic

A

19A E Trans Enable Switch Fused Pwr

Or 0.8 GXL


10

SPL-D15, Ultrasonic

A

19A F Trans Enable Switch Fused Pwr

Or 0.8 GXL


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


M

19A J Pilot Control Switched Fused Pwr

Or 0.8 GXL


2

SPL-PB1, Ultrasonic

A

19A K TECM Fused Power

Or 0.8 TXL

SPL-TRANS-PWR, Trans Pwr

J

TECM, Trans

45

19A L Park Brake Switched Fused Pwr

Or 0.8 GXL


2

SPL-PB1, Ultrasonic

A

19A M Output Speed Sensor Fused Pwr Or 0.8 TXL


29

SPL-TRNS-PWR, Trans Power

K

19A N Trans Fused Power

Or 1.0 GXL


A

ECA, Elect Center A

A1

19A P Backup Alarm Relay Control Fused Power

Bk 1.0 GXL


G

ECD, Elect Center D

AA10

19A Q Trans/Auto Switch Fused Power

Or 0.8 GXL


2


C

19A R Declutch Switch Fused Power

Or 0.8 GXL


2


H

19A S Trans Fused Power

Or 0.8 GXL


L

SPL-PB1, Ultrasonic

A

19A T Brake Declutch Switch Fused Power

Or 0.8 GXL


27


D

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-19






Circuit




Connector


To Connector Cavity

Connector

Cavity

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


E

Or 0.8 GXL


49a

ECA, Elect Center A

A8

19C A Pilot Ctrl Fused Pwr

Or 1.0 GXL

SPL-D24, Ultrasonic

A

ECA, Elect Center A

A5

19C B Pilot Ctrl Fused Pwr

Or 1.0 GXL

SPL-D24, Ultrasonic

A

ECD, Elect Center D

B5

19C C Pilot Ctrl Fused Pwr

Or 0.8 GXL

SPL-D24, Ultrasonic

A

ECD, Elect Center D

D5

19C D Ride Control Fused Pwr

Or 1.0 GXL


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


21

ECA, Elect Center A

A3

19B

Turn Signal Fused Power

19H

Backup Alarm Relay Fuse Pwr

Or 1.0 GXL

ECA, Elect Center A

C4

ECD, Elect Center D

A10

19J

Front Wiper Fused Pwr

Or 0.8 GXL

SPL-PK3, Splice 3-4 Way

K

ECA, Elect Center A

C2

19J A Front Wiper Motor Fused Pwr

Or 0.8 GXL


M

FWM, Front Wiper Motor

C

19J B Front Wip Wash Sw Fused Pwr

Or 0.8 GXL


5


J

19J C Front Wiper Relay Fused Power

Or 0.8 GXL


L

SPL-FW, Ultrasonic

A

19J D Front Wiper Relay HS Control Fused Power

Or 0.8 GXL

SPL-FW, Ultrasonic

A

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-FW, Ultrasonic

A

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 2.0 GXL

PRM-E1, PRM Output

C

SPL-CNV, Ultrasonic

A

19L A Pwr Converter Fused Power

Or 2.0 GXL


1

SPL-CNV, Ultrasonic

A

19J F

Front Wiper Relay LS Control Fused Power

19J G Wiper Cutout Relay Fused Pwr 19K

19L

Rear Wiper Fused Pwr

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-20






Circuit





To Connector

Connector

Cavity

Or 2.0 GXL


2

SPL-CNV, Ultrasonic

A

Sec. Steering Accessory Fused Pwr

Or 0.8 GXL


3

ECA, Elect Center A

C7

19M A Sec. Steering Accessory Fused Pwr

Or 1.0 SXL


3


A

19M C Sec. Steering Accessory Fused Pwr

Or 1.0 SXL

SSM, Sec. Steering Module

7

SS-TR, Sec. Steering Mod Trans

A

19L B Pwr Converter Fused Power 19M

Connector

Cavity

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


A

19P C Fan Rev Sw Fused Pwr

Or 0.8 GXL


5


C

19P D Fan Rev Relay Fused Pwr

Or 0.8 GXL


E

ECB, Elect Center B

D7

19P E Fan Rev Relay Fused Pwr

Or 0.8 GXL


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


4


B

19R C Sec. Steering Ign Fused Pwr

Or 1.0 SXL


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


4

19S1

Sec. Steering Fused Pwr

Or 1.0 GXL

SS, Sec. Steering Fused Pwr

1


26

19S1 E Sec. Steering Fused Pwr

Or 1.0 SXL


26


E

19S1 X Sec. Steering Fused Pwr

R 1.0 SXL


3

SS-TR, Sec. Steering Module Trans

E

19S B AIC Delay Fused Power

Or 0.8 GXL

SPL-DKY3, Ultrasonic

A

ECD, Elect Center D

19S C AIC Delay Fused Power

Or 0.8 TXL


A

AIC-2, Advanced Instr Cluster 2

20

19S D AIC Delay Fused Power

Or 0.8 TXL


A

AIC-2, Advanced Instr Cluster 2

14

19T A TECM Delay Fused Power

Or 0.8 TXL

TECM, Trans

23

ECD, Elect Center D

AA1

Horn Relay Fused Power

Or 0.8 GXL

SPL-HRN, Ultrasonic

A

ECC, Work Lights

A6

19U A Horn Relay Fused Power

Or 0.8 GXL

SPL-HRN, Ultrasonic

A

ECC, Work Lights

B7

19U B Beacon Dome Lt Fused Pwr

Or 1.0 GXL

SPL-LT, Ultrasonic

A

ECC, Work Lights

A1

19U C Dome Lt Fused Pwr

Or 0.8 GXL

ROOF, Roof to Cab Connection

D

LDM1, Dome Light B+

1

19U

Bur 5-2750

Issued 8-06

AA3

Printed in U.S.A.

4002-21






Circuit




Connector


To Connector Cavity

Connector

Cavity

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, Work Lights

D7

19U F Door Sw Fused Power

Bk 0.8 GXL

ROOF, Roof to Cab Connection

S

DS, Door Switch

A

19U G Door Sw Fused Power

Or 0.8 GXL

CAB-RF, Cab to Roof Connection

S

SPL-LT, Ultrasonic

A

19U H Beacon Switch Fused Power

Or 1.0 GXL

SBE, Beacon Switch

2

SPL-LT, Ultrasonic

A

19W

Cigar Lighter Pwr

Or 3.0 GXL

CL, Cigar Lighter

1

ECC, Work Lights

A8

19Y

Hood control Fused Power

Or 1.0 GXL

SPL-HOOD, Ultrasonic

A

ECC, Work Lights

A7

19Y A Hood Up Relay Fused Power

Or 1.0 GXL


A

ECC, Work Lights

D2

19Y B Hood Down Relay Fused Power

Or 1.0 GXL


A

ECC, Work Lights

D4

19Y C Hood Switch Fused Power

Or 1.0 GXL

CAB-E, Cab Engine

35


A

19Y D Hood Switch Fused Power

Or 1.0 GXL

ENG, Engine Cab

35

HD, Hood Switch

B

Driving Lights Sw Fused Power

Or 1.0 GXL


G

ECC, Work Lights

A3

19Z A Driving Lights Sw Fused Power

Or 1.0 GXL

SDR, Driving Lights Sw

2


E

19Z B Driving Lights Sw Fused Power

Or 1.0 GXL

SDR, Driving Lights Sw

5


F

19Z C High Beam Flash Fused Power

Or 1.0 GXL


56d


H

19Z

1A

Ign Switch Fused Power

R 1.0 GXL


1

SPL-DLY, Ultrasonic

A

1CB

Cab CB Protected Power

R 19.0 SXL

CB1A, Circuit Breaker

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

1DM

Time Delay/Ign Sw Fused Pwr

R 1.0 GXL

SPL-DLY, Ultrasonic

A

ECC, Work Lights

A5

1DN

Time Delay Fused Power

R 1.0 GXL


2

SPL-DLY, Ultrasonic

A

1NC

Cab CB PRM Power

R 19.0 SXL

B1, Starter Power Stud

1

CB2B, Cab B+ CB

1

1 AA

Brake Lt Sw Pwr

R 1.0 SXL


22

PBL, Brake Light Press Switch

1

1 B9

PRM C Power

R 8.0 SXL

CB3B, Cab B+ CB

1

P-C5, B+ Power from PRMC

1

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 BC

Cab CB Power

R 19.0 SXL

P-C3, B+ Power From PRMC

1

CB1B, Cab B+ CB

1

1 BE

Grid Htr Pwr

R 19.0 SXL

115 Grid Htr Pwr

1

GH, Grid Htr

1

1C

ECC Bat Power

R 8.0 GXL

P-A1, B+ Power

1

L1-ECC, ECC Battery Power

cs01

Brake Light Switch Power

R 1.0 GXL


22

SPL-FLSHR-PWR, Ultrasonic

A

1 DR

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-22





Wire Identification




To Connector

Wire

Circuit

1 DU

Flasher Module Pwr

R 1.0 GXL


1


A

1 DV

Brake Lights/Flasher Bat Pwr

R 2.0 GXL


A

ECC, Work Lights

A4

1 DW

Brake Lt Relay Bat Pwr

R 1.0 GXL


A

ECC, Work Lights

B5

Grid heater Fuse Bat Power

R 19.0 SXL

P-C2, B+ Power from PRMC

1

GHF1, Grid Heater Fuse

1

1 GA

Filter Htr Pwr

R 3.0 SXL

PRM-C1, 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


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

B3, Starter Battery

1

1 NC

B+ Power PRMC

R 19.0 SXL

B1, Starter Power Stud

1

P-C1, B+ Power From PRMC

1

1 ND

SSM Power

R 62.0 SGR

244F Starter Sec. Strg Mtr

1

B4, Starter Power

1

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 PRMC

1

195, Starter Relay Power

1

20G A EDC7 ESO-K Interface

W 0.8 TXL

ENG, Engine Cab

31


89

20G B EDC7 ESO-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 B

A10

21C C Starter Relay Signal

W 0.8 GXL

CAB-E, Cab Engine

1

SPL-CR, Ultrasonic

A

21C D Starter Relay Signal

W 1.0 SXL

SR-9, Starter Relay Signal

1

ENG, Engine Cab

1

Starter Relay Signal

W 1.0 SXL

SRC-1, Relay

1

ENG, Engine Cab

15

21D A Starter Relay Signal

W 0.8 GXL

SPL-4, Ultrasonic

A

ECB, Elect Center B

21D B Starter Relay Signal

W 0.8 GXL

140M, Diode Module

E

SPL-4, Ultrasonic

A

21D C Starter Relay Signal

W 0.8 GXL

CAB-E, Cab Engine

15

SPL-4, Ultrasonic

A

Key Switch Crank

W 0.8 GXL

CAB-E, Cab Engine

27

ECB, Elect Center B

D6

21E A Key Switch Crank

W 0.8 TXL

ENG, Engine Cab

27


32

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

11


A

1E

21C

21D

21E

21F

Bur 5-2750

Connector


Cavity

Connector

Issued 8-06

Cavity

AA9

Printed in U.S.A.

4002-23






Circuit




Connector


To Connector Cavity

Connector

Cavity

21F B EDC7 Digital Ground

W 0.8 TXL


A


29

21F C EDC7 Digital Ground

W 0.8 TXL

RTHP, Throttle Pedal

1


A

EDC7 Crank Control relay

W 0.8 GXL

CAB-E, Cab Engine

3

ECB, Elect Center B

21G A EDC7 Crank Control relay

W 0.8 TXL

ENG, Engine Cab

3


37

Crank control relay LSD

W 0.8 GXL

CAB-E, Cab Engine

4

ECB, Elect Center B

A9

21H A Crank control relay LSD

W 0.8 TXL

ENG, Engine Cab

4


17

Ign Sw Start Signal

W 0.8 GXL


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

Throttle Signal

W 0.8 TXL


3


79

24B A Throttle Signal

W 0.8 TXL


3


47

21G

21H

21K

24B

AA10

24L

Low Idle Sw

W 0.8 TXL


6


48

24R

Throttle Pos Sens Grnd

W 0.8 TXL


4


78

24R A Throttle Pos Sens Grnd

W 0.8 TXL


4


49

Throttle Supply

W 0.8 TXL


5


77

24S A Throttle Supply

W 0.8 TXL


5


48

Eng Speed Sig

W 0.8 GXL Twist


7

ESS, Engine speed Sensor

1

25A A Eng Speed Sig

LU 0.8 TXL


7

TECM, Trans

19

Int Speed Sig

W 0.8 GXL Twist


9

ISS, Int Speed Sensor

1

25B A Int Speed Sig

LU 0.8 TXL


9

TECM, Trans

42

Turbine Speed Sig

W 0.8 GXL Twist


8

TSS, Turbine Speed Sensor

1

25C A Turbine Speed Sig

LU 0.8 TXL


8

TECM, Trans

41

Output Speed Sig

LU 1.0 SXL


10

OSS, Output Speed Sensor

2

25D A Output Speed Sig

LU 0.8 TXL


10

TECM, Trans

62

24S

25A

25B

25C

25D

25F

Forward Signal

LU 0.8 TXL


B

TECM, Trans

43

25G

Brake Declutch Switch

LU 1.0 SXL


28

PBD, Declutch Pressure Switch

B

25G A Brake Declutch Switch

LU 0.8 GXL


28

SPL-DC, Ultrasonic

A

25G B Brake Declutch Switch

LU 0.8 GXL


1

SPL-DC, Ultrasonic

A

25G C Brake Declutch Switch

LU 0.8 TXL

SPL-DC, Ultrasonic

A

TECM, Trans

66

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-24






Circuit




Connector


To Connector Cavity

Connector

Cavity

25H

Trans Auto Signal

LU 0.8 TXL


3

TECM, Trans

29

25J

Trans Sol Valve Y6

LU 0.8 TXL


21

TRC, Trans Control

6

25J A Trans Sol Valve Y6

LU 0.8 TXL


21

TECM, Trans

51

Trans Sol Valve Y1

LU 0.8 TXL


16

TRC, Trans Control

1

25K 9 Trans Sol Valve Y2

LU 0.8 TXL


16

TRC, Trans Control

2

25K A Trans Sol Valve Y1

LU 0.8 TXL


16

TECM, Trans

56

25K

25L

Trans Sol Valve Y2

LU 0.8 TXL


17

TRC, Trans Control

2

25L 9

Trans Sol Valve Y1

LU 0.8 TXL


17

TRC, Trans Control

1

25L A Trans Sol Valve Y2

LU 0.8 TXL


17

TECM, Trans

10

25M

Trans Sol Valve Y3

LU 0.8 TXL


18

TRC, Trans Control

3

25M A Trans Sol Valve Y3

LU 0.8 TXL


18

TECM, Trans

32

Trans Sol Valve Y4

LU 0.8 TXL


19

TRC, Trans Control

4

25N A Trans Sol Valve Y4

LU 0.8 TXL


19

TECM, Trans

55

Trans Sol Valve Y5

LU 0.8 TXL


20

TRC, Trans Control

5

25P A Trans Sol Valve Y5

LU 0.8 TXL


20

TECM, Trans

9

25N

25P

25R

Reverse Signal

LU 0.8 TXL


C

TECM, Trans

64

25S

Output Sw Power VPS1

LU 0.8 TXL


22

TRC, Transmission Control

7

25S A Output Sw Power VPS1

LU 0.8 TXL


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

Neutral Signal

LU 0.8 GXL

SPL-NEU, Ultrasonic

A

ECB, Elect Center B

D3

25T B Neutral Signal

LU 0.8 GXL


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


B

TECM, Trans

65

25Y

Trans Kick Down Signal

LU 0.8 GXL


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

25T

25Z

1st And 4th Gear Signal

LU 0.8 TXL


C

TECM, Trans

63

26E

Trans Enable Signal

LU 0.8 TXL


3

TECM, Trans

31

26F A FNR Forward Signal

LU 0.8 GXL

197M, FNR Main Cab

2

SFNR, FNR Switch

6

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-25






Circuit

26F B FNR Forward Signal




Connector


To Connector Cavity

Connector

Cavity

LU 0.8 TXL

197F, Main Cab FNR

2

TECM, Trans

20

FNR Switch Jumper

LU 0.8 GXL

SFNR, FNR Switch

2

SFNR, 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

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

26J

28E

Ether Relay Signal

W 1.0 SXL

PRM-C2, PRM Signal

A

ENG, Engine Cab

16

28F

Filter Htrs Relay Control

W 0.8 TXL

PRM-C2,PRM Signal

A


36

28G

Grid Heater Source Dr.

W 1.0 GXL

GHC, Grid Htr Relay

1


12

28H

Ether Switch Signal

W 0.8 GXL

CAB-E, Cab Engine

16

SETHR, Ether Switch

3

28J

Ether AIC Ok Signal

W 0.8 GXL

SETHR, Ether Switch

2


19

28P

Ether Solenoid Power

W 1.0 SXL

PRM-C1, PRM Output

C

ETHR, Ether Solenoid

A

31D

Coolant Level Signal

Y 1.0 SXL


2

CLS, Cool Jump-Cool Send

A

31D A Coolant Level Signal

Y 0.8 TXL


2


26

31D B Coolant Level Sender Eng Trans Y 1.0 SXL


2


3

31D C Coolant Level Sender Eng Trans Y 1.0 SXL

CLS, Cool Jump Cool Send

A

ENG-T, Engine to Trans

3

31F

Air Filter Rest Sw Signal

Y 1.0 SXL

ENG, Engine Cab

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

Hyd Filter Rest Sw Signal

Y 1.0 SXL


23

PHF, Hyd Oil Filter Rest Sw

1

31H A Hyd Filter Rest Sw Signal

Y 0.8 GXL

SW-PD, Switch Pad

4


23

31H

31L

Pilot Control Switch High

Y 0.8 TXL


3

AIC-2, Advance Instr Cluster 2

18

32F

Trans Filter Maint Sw

Y 1.0 SXL


31

FM, Filter Maint Sw

1

32F A Trans Filter Maint Sw

Y 0.8 TXL


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


9

SPL-D16, Ultrasonic

A

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

Brake Warning Press Low

Y 1.0 SXL


26

PBW, Brake Warning Press Sw

1

33P A Brake Warning Press Low

Y 0.8 TXL


26


5

Y 0.8 TXL


1


4

33P

33R

Redundant Brake Accumulator Pressure Low

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-26






Circuit




Connector


To Connector Cavity

Connector

Cavity

33R A Redundant Brake Accumulator Pressure Low

Y 1.0 SXL


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

Parking Brake Switch

Y 0.8 TXL


3


6

35A 9 Backup Alarm Power

Y 1.0 SXL


7

E-HD9, Transmission-Hood

B

35A A Backup Alarm Relay Out

Y 0.8 GXL


L

ECD, Elect Control D

35A B Backup Alarm Disable Switch

Y 0.8 GXL

SBU, Backup Alarm Dis Sw

2


K

35A C Backup Alarm Relay Out

Y 0.8 GXL

CAB-E, Cab Engine

7


M

35A D Backup Alarm Relay Out

Y 0.8 GXL

209M, Backup Alarm Dis Jump

A


J

35A E Backup Alarm Relay Out

Y 0.8 SXL

209F, Backup Alarm Dis Jump

A

SPL-D8-C1, Ultrasonic

A

35A F Backup Alarm Relay Out

Y 0.8 SXL

CAB-E, Cab Engine

40


A

35A G Backup Alarm Relay Out

Y 0.8 SXL

ENG, Engine Cab

40

E-HD, Trans Hood

B

Backup Alarm Relay Out

Y 1.0 SXL

ENG, Engine Cab

40


7

35A H Backup Alarm Relay Out

Y 1.0 SXL

HD-E, Hood Trans

B

BU2, Backup Alarm

1

Y 1.0 SXL


7

BU2, Backup Alarm

1

35A J Revers Light

K 1.0 SXL

ENG, Engine Cab

7

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 Revers Light

K 1.0 SXL

SPL-REV, Ultrasonic

A


8

35A N Revers Light

K 1.0 SXL

SPL-REV, Ultrasonic

A


4

35A P Revers Light

K 1.0 SXL

LRR-9, RH rear Comb Light

4

SPL-REV, Ultrasonic

A

35A R Backup Alarm Relay Out

Y 1.0 SXL

ENG, Engine Cab

7


8

33U

35A GN

35A HN


AA9

35B

AIC Buzzer HSD

W 0.8 TXL

BUZ, AIC Buzzer

1


13

35C

Backup Alarm Relay Control

Y 0.8 TXL

TECM, Trans

7

ECD, Elect Center D

A9

Y 0.8 GXL

SBU, Backup Alarm Dis Sw

1


A

W 0.8 TXL


1


42

35R C Backup Alarm Sw 35W

Water In Fuel Indicator

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-27





Wire Identification Wire 35X

Circuit




Connector


To Connector Cavity

Connector

Cavity

Sec. Str Low Press Sig

Y 0.8 TXL


6


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


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


8

SPL-C3, Ultrasonic

A

Rear Axle Temp

P 0.8 TXL

CAB-E, Cab Engine

32


5

36A A Rear Axle Temp

P 1.0 SXL

ENG, Engine Cab

32

HOT-RA, Rear Axle Oil Temp

1

Front Axle Temp

P 0.8 TXL


8


8

36B A Front Axle Temp

P 1.0 SXL


8

HOT-FA, Front Axle Oil Temp

1

Radiator Cool Temp Signal

P 1.0 SXL

ENG, Engine Cab

34

RECT, Engine Coolant Temp

A

36C A Radiator Cool Temp Signal

W 0.8 TXL

CAB-E, Cab Engine

34


11

Fuel Level Analog

P 1.0 SXL

ENG, Engine Cab

33

RFL, Fuel Sender

1

36F A Fuel Level Analog

P 0.8 TXL

CAB-E, Cab Engine

33


2

Torque Conv Output Temp Signal

P 1.0 SXL


13

TCOT, TCO Sender

1

36G A Torque Conv Output Temp Signal

P 0.8 TXL


13

TECM, Trans

49

P 1.0 SXL


30

HOT, Hydraulic Oil Temp Sender

A

36H A Hydraulic Oil Temp

P 0.8 TXL


30


9

36R A Trans Temps/Filter Return

P 1.0 SXL


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


12

TECM, Trans

46

Valve Body Temp Sig

P 0.8 TXL


5

TRC, Trans Control

8

36T A Valve Body Temp Sig

P 0.8 TXL


5

TECM, Trans

39

37D A Diagnostic Signal

P 0.8 TXL


2

TECM, Trans

15

P 0.8 TXL


4

TECM, Trans

18

41H A High Beam Pwr

Or 1.0 GXL


56a


L

41H B High Beam LH Pwr

Or 0.8 GXL


K

ECB, Elect Center B

A3

41H C High Beam RH Pwr

Or 0.8 GXL


J

ECB, Elect Center B

A4

36A

36B

36C

36F

36G

36H

36T

37E

Hydraulic Oil Temp Signal

Diagnostic Signal Switched

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-28






Circuit

41H D High Beam Pwr




Connector


To Connector Cavity

Connector

Cavity

Or 0.8 TXL

SW-PD, Switch Pad

1


M

Or 1.0 GXL


6


56

41L A Low Beam Power

Or 1.0 GXL


56b

41L B Low Beam RH Power

Or 0.8 GXL

SPL-LB, Ultrasonic

ECB, Elect Center B

A6

41L C Low Beam LH Power

Or 0.8 GXL

SPL-LB, Ultrasonic

ECB, Elect Center B

A5

K 1.0 GXL


3


C

41T A Position Lights RH Switched Pwr K 1.0 GXL


D

ECB, Elect Center B

A8

41T B Position Lights LH Switched Pwr K 1.0 GXL


A

ECB, Elect Center B

A7

41T C Position Lights Switched Pwr

K 1.0 GXL

D-OR, Diode OR

B

SPL-D, Ultrasonic

41T D Position Lights Switched Pwr

K 0.8 TXL

SW-PD, Switch Pad

2

SPL-D, Ultrasonic

41T E Position Lights Switched Pwr

K 1.0 SXL


B

SPL-D, Ultrasonic

42C A Front Work Lights Fused Pwr

DU 1.0 GXL


C


42C C Front Work Lights Fused Pwr

DU 1.0 GXL


D

ECB, Elect Center B

42C D Front Work Lights Fused Pwr

DU 1.0 GXL


C

D-OR, Diode OR

A

42C E Front Work Lights Fused Pwr

DU 0.8 TXL

SW-PD, Switch Pad

3


B

42C F Front Work Lights Fused Pwr

DU 1.0 GXL


C

SPL-WRKF, Ultrasonic

A

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


A

LRFW, RH Front Work Light

A

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


A

LLFW, LH Front Work Light

A

42FS

Front Work Lights Switched Pwr

DU 1.0 GXL


3

ECB, Elect Center B

A1

42RS

Rear Work Light Switched Pwr

DU 1.0 GXL


6

ECB, Elect Center B

A2

42R C Rear Work Lights Fused Pwr

DU 1.0 GXL


B

ECB, Elect Center B

AA2

42R F Rear Work Lights Fused Pwr

DU 1.0 GXL


B

SPL-WRKR, Ultrasonic

A

42R G RH Rear Work Lt Fused Pwr

DU 1.0 SXL


A

LRRW, RH Rear Work Light

A

42R H LH Rear Work Lt Fused Pwr

DU 1.0 SXL


A

LLRW, LH Rear Work Light

A

41J

41T

Driving Light Power

Position Lights Switched Pwr

SPL-LB, Ultrasonic

A AA1

42 A

Work Lights Fused Power

R 2.0 GXL


2

SPL-WL, Ultrasonic

A

42 B


R 2.0 GXL


5

SPL-WL, Ultrasonic

A

43S A Door Open Signal

W 0.8 GXL


R

SPL-DS, Ultrasonic

A

43S B Door Open Signal

W 0.8 GXL


R

DS, Door Switch

B

43S C Door Open Signal

W 0.8 TXL

SPL-DS, Ultrasonic

A


2

43S D Time Delay Mod Door Sw Reset

W 0.8 TXL


4

SPL-DS, Ultrasonic

A

DU 0.8 TXL


A


7

43 A

Dome Light Auto Mode

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-29





Wire Identification Wire 43 B

Circuit




Connector


To Connector Cavity

Connector

Cavity

DU 0.8 GXL


A

LDM2, Dome Light Auto

44A A Brake Light Relay Out

T 0.8 GXL

SPL-BRK, Ultrasonic

A

ECC, Work Lights

D6

44A B Brake Light Relay Out

T 0.8 TXL

SPL-BRK, Ultrasonic

A


15

44A C Brake Light Relay Out

T 0.8 GXL

CAB-E, Cab Engine

8

SPL-BRK, Ultrasonic

A

44A D Brake Light Relay Out

T 1.0 SXL

ENG, Engine Cab

8

SPL-B8, Ultrasonic

A

Brake Light Relay Out

T 1.0 SXL

ENG, Engine Cab

8


2

44A E Brake Light Relay Out

T 1.0 SXL


1

SPL-B8, Ultrasonic

A


T 1.0 SXL


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 DN

44A EN


1

44A FN


T 1.0 SXL

LLR-N, LH Rear Comb Light

A


A

44A GN


T 1.0 SXL

LRR-N, RH Rear Comb Light

A


A

44A J Brake Light Power

T 1.0 SXL

SPL-L1, Ultrasonic

A


2

44A K Brake Light Power

T 1.0 SXL

SPL-L1, Ultrasonic

A


1

44A L Brake Light Power

T 1.0 SXL


1

SPL-L1, Ultrasonic

A

44 A

T 0.8 GXL


23

ECC, Work Lights

D5

45A A Left Turn Switch Power

N 0.8 GXL


9


L

45B A Right Turn Switch Power

N 0.8 GXL


10


R

Brake Light Control Power

45H

Hazard Switch Power

N 0.8 GXL


11

SHZ, Hazard Switch

3

45L

Left Turn Signal

N 1.0 SXL


1

LLF, Lights LH

5

45L 9

Left Turn Signal

N 1.0 SXL


3


2

45L A Left Turn Signal

N 1.0 SXL

ENG, Engine Cab

10


2

45L AN Left Turn Signal

N 1.0 SXL

ENG, Engine Cab

10


3

45L B Left Turn Signal

N 0.8 GXL

CAB-E, Cab Engine

10


D

45L BN Left Turn Signal

N 1.0 SXL


3

LLR-N, LH Rear Comb Light

C

45L C Left Turn Signal

N 0.8 GXL


1


C

45L D Left Turn Signal

N 0.8 GXL


8


B

45L E Left Turn Signal

N 0.8 TXL


A


9

45N A Flasher OPP Side Control

N 0.8 GXL


2

64F, Flasher Connector

1

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-30






Circuit

45N B Flasher OPP Side Control




Connector


To Connector Cavity

Connector

Cavity

N 0.8 GXL


12

64M, Flasher Connector

1

Right Turn Signal

N 1.0 SXL


3

LRF, Lights RH

5

45R 9 Right Turn Signal

N 1.0 SXL


4


2

45R A Right Turn Signal

N 1.0 SXL

ENG, Engine Cab

12

LRR-E, RH Rear Comb Light

2

Right Turn Signal

N 1.0 SXL

ENG, Engine Cab

12


4

45R B Right Turn Signal

N 0.8 GXL

CAB-E, Cab Engine

12


H

Right Turn Signal

N 1.0 SXL


4

LRR-N, RH Rear Comb Light

C

45R C Right Turn Signal

N 0.8 TXL


E


10

45R D Right Turn Signal

N 0.8 GXL


3


G

45R E Right Turn Signal

N 0.8 GXL


7


F

46 C

Beacon Switched Power

K 1.0 GXL


E

SBE, Beacon Switch

3

46 D


K 1.0 GXL


E

LBEPWR, Light Beacon power

1

46 E


K 1.0 GXL

LBEE, Light Beacon Exten

A

LBEP, Light Beacon power

1

49A

Back Light Power

S 0.8 GXL

HVAC1, HVAC1

3


F

49S

Back Light Power

S 0.8 GXL


8


J

49U

Back Light Power

S 0.8 GXL

SETHR, Ether Switch

8

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

D

49 A

Back Light Power

S 0.8 GXL


8


M

49 B

Back Light Power

S 0.8 GXL

SBE, Beacon Switch

8


L

49 C

Back Light Power

S 0.8 GXL


8


C

49 D

Back Light Power

S 0.8 GXL

SHZ, Hazard SWitch

8


C

49 E

Back Light Power

S 0.8 GXL

SPL-BCK-LGT2, Spl Back Lgt Pwr

A


K

49 F

Back Light Power

S 0.8 GXL


10


F

49 G

Back Light Power

S 0.8 GXL

SRC, Ride control Switch

8


K

49 H

Back Light Power

S 0.8 GXL


8


D

49 J

Back Light Power

S 0.8 GXL

SRTD, Detent Switch

8


C

45R

45R AN

45R BN

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-31






Circuit





To Connector

Connector

Cavity

Connector

Cavity

49 K

Back Light Power

S 0.8 GXL

SFL, Return to Travel Switch

8


E

49 L

Back Light Power

S 0.8 GXL

SBU, Back Up Alarm Dis Sw

8


E

49 M

Back Light Power

S 0.8 GXL


8


D

49 N

Back Light Power

S 0.8 GXL


8


B

49 P

Back Light Power

S 0.8 GXL


8


G

49 Q

Back Light Power

S 0.8 GXL


8


G

49 R

Back Light Power

S 0.8 GXL


8


H

49 S

Back Light Power

S 0.8 GXL


F


M

49 T

Back Light Power

S 0.8 GXL


8


H

49 U

Back Light Power

S 0.8 GXL


8


A

49 V

Back Light Power

S 0.8 GXL


8


E

51B A Comfort Steer Solenoid Power

W 0.8 GXL


6

SPL-CSS, Ultrasonic

A

51B B Comfort Steer Solenoid Power

W 0.8 GXL

SPL-CSS, Ultrasonic

A

ECC, Work Lights

51B C Comfort Steer Solenoid Power

W 0.8 GXL

SPL-CSS, Ultrasonic

A


2

51B D Comfort Steer Solenoid Power

W 1.0 SXL


2

YCS, Comfort Steer Solenoid

A

D10

51C

Comfort Steer control

W 0.8 TXL


21

ECC, Work Lights

B10

51CS

Comfort Steer Switch

W 0.8 TXL


3


17

W 1.0 SXL

SSM, Sec. Steer Module

9

PSS, Sec. Steer Pressure Switch

A

51P A Sec. Str High Press 51S

Standard Steering Signal

W 0.8 TXL


1


16

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

52AU

Fan Reverse Auto

W 0.8 TXL


3


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

22

YFR, Fan Rev Solenoid Option

Bur 5-2750

Issued 8-06

D8 1

Printed in U.S.A.

4002-32






Circuit




Connector


To Connector Cavity

Connector

Cavity

52C

Parking Brake Solenoid LSD

W 0.8 TXL


14

ECB, Elect Center B

52J

Fan Control Switch Jumper

W 0.8 GXL


4


2

52M

Fan Reverse Manual

W 0.8 TXL


6


7

52P

Parking Brk Relay Out

W 1.0 SXL


24

YPB, Park Brake Solenoid

1

52P A Parking Brk Relay Out

W 0.8 GXL


24

SPL-PB, Ultrasonic

A

52P B Parking Brk Relay Out

W 0.8 GXL

SPL-PB, Ultrasonic

A

ECB, Elect Center B

D10

52P C Parking Brk Relay Out

W 0.8 TXL

SPL-PB, Ultrasonic

A

TECM, Trans

21

B10

53A

RTD Switch Power

W 0.8 GXL

SRTD, Detent Switch

3

EM, RTD Height Control RTT

3

53B

RTD Signal

W 1.0 SXL


12

PXF, RTD

C

53B A RTD Signal

W 1.0 SXL

PXM, RTD

A

PXT, RTD

A

53B B RTD Signal

W 0.8 GXL


4


12

53C A Pilot Control Solenoid LSD

W 0.8 TXL


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


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


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


19

SPL-D25, Ultrasonic

A

53P G Pilot Control Relay Out

W 1.0 SXL


19

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


C

54A

Height Control Switch Power

W 0.8 GXL


6


2

54B

Height RTT Control Signal

W 1.0 SXL


11


A

54B A Height RTT Control Signal

W 0.8 GXL


11

SPL-D1, Ultrasonic

A

54B B Height RTT Control Signal

W 0.8 GXL


5

SPL-D1, Ultrasonic

A

54B C Height RTT Control Signal

W 0.8 GXL


6

SPL-D1, Ultrasonic

A

55A A RTT Float Sw Power

W 0.8 GXL


1

SPL-RTT, Ultrasonic

A

55A B RTT Float Sw Power

W 0.8 GXL


1

SPL-RTT, Ultrasonic

A

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-33






Circuit

55A C RTT Float Sw Power





To Connector

Connector

Cavity

Connector

Cavity

W 0.8 GXL


3

SPL-RTT, Ultrasonic

A

55B

RTT Float Switch Control

W 0.8 GXL


5


6

56 A

Fan Control PWM

W 1.0 SXL

ENG, Engine Cab

23

YFN, Fan PWM Solenoid

A

57 A

Pin Engage Sol Pwr

W 0.8 GXL


20

SPL-PINE, Ultrasonic

A

57 B

Pin Engage Sol Pwr

W 0.8 GXL


1


A

57 C

Pin Engage Sol Pwr

W 0.8 TXL


A


16

58C

Ride Control Switch Jumper

W 0.8 GXL


5


3

W 0.8 TXL

TECM, Trans

8

ECD, Elect Center D

D7

Bk 0.8 TXL

TECM, Trans

57

ECD, Elect Center D

B8

W 1.0 SXL


21


1

58H A Ride Control Sw Pwr VPS2 58L

Ride Control Relay LSD

58S E Ride Control Sol to Front Cab 58T

Ride Control Relay Sw Pwr

W 0.8 GXL


4

ECD, Elect Center D

B7

58 A


W 1.0 SXL

202M, Rollback Jumper

A

202M, Rollback Jumper

B

58 B


W 1.0 SXL


21

PRBF, Rollback Pressure Switch

B

58 C


W 0.8 GXL


21

SPL-D26, Ultrasonic

A

58 D


W 0.8 GXL

140M, Diode Module

D

SPL-D26, Ultrasonic

A

58 E


W 0.8 GXL

SPL-D26, Ultrasonic

A

ECD, Elect Center D

D8

58 F


W 0.8 GXL


6

SPL-D26, Ultrasonic

A

59D

Hood Relay Control Down

W 1.0 GXL

CAB-E, Cab Engine

37

ECC, Work Lights

D3

59D A Hood Relay Control Down

W 1.0 SXL

ENG, Engine Cab

37

HD, Hood Switch

A

Hood Relay Control Up

W 1.0 GXL

CAB-E, Cab Engine

39

ECC, Work Lights

D1

59U A Hood Relay Control Up

W 1.0 SXL

ENG, Engine Cab

39

HD, Hood Switch

C

Hood Down Relay Out

W 1.0 GXL

CAB-E, Cab Engine

36

ECC, Work Lights

B3

60D A Hood Down Relay Out

W 1.0 SXL

ENG, Engine Cab

36

HDM, Hood Lift Motor

2

Hood Up Relay Out

W 1.0 GXL

CAB-E, Cab Engine

38

ECC, Work Lights

B1

60U A Hood Up Relay Out

W 1.0 SXL

ENG, Engine Cab

38

HDM, Hood Lift Motor

1

Trinary Press Sw Input

W 1.0 SXL

ENG, Engine Cab

30

PR, Trinary Press Sw

A

61A B Trinary Press Sw Input

W 0.8 GXL

CAB-E, Cab Engine

30

HVAC1, HVAC1

1

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

2

ACT, AC Comp Clutch

1

61C B AC Relay Out

Or 1.0 SXL

ENG, Engine Cab

2

ACT-9, AC Comp Clutch

1

W 1.0 SXL

ENG, Engine Cab

29

PR, Trinary Press Sw

B

59U

60D

60U

61A

61C

61R

AC Relay Control

Bur 5-2750

Issued 8-06

D10

Printed in U.S.A.

4002-34






Circuit

61R B AC Relay Control




Connector


To Connector Cavity

Connector

Cavity

W 0.8 GXL

CAB-E, Cab Engine

29

ECD, Elect Center D

D9

63C

Front Wiper Park Control

W 0.8 GXL

FWM, Front Wiper Motor

D

ECD, Elect Center D

C4

63C2


W 0.8 GXL

ECD, Elect Center D

D4

ECD, Elect Center D

C2

63C3


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


9

SPL-HC, Ultrasonic

A

63HC Wiper Cutout Relay Control A

W 0.8 GXL

SPL-HC, Ultrasonic

A

K-WCO, Wiper Cutout

85

63HC Front Wiper High Speed Rly Ctrl B

W 0.8 GXL

SPL-HC, Ultrasonic

A

ECD, Elect Center D

B2

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

SPL-WHS, Ultrasonic

A

ECD, Elect Center D

D2

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


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


7

63W A Front Washer Pump

W 1.0 SXL

ENG, Engine Cab

25

FWW, Front Washer

1

64C

Horn Relay Control

Or 0.8 GXL


31b

ECC, Work Lights

B8

64 A

Horn Power

Or 0.8 GXL


13

ECC, Work Lights

D8

65L

Left Speaker

Or 0.8 GXL

LSPK, Left Speaker

1

SPK, Speaker

7

65R

Right Speaker

Or 0.8 GXL

RSPK, Right Speaker

1

SPK, Speaker

1

68C

Rear Wiper Park Control

Or 1.0 GXL


K


1

68C A Rear Wiper Park Control

Or 1.0 GXL


K

RWM, Rear Wiper Motor

D

Rear Wiper Switch Power

Or 1.0 GXL


2

SPL-3, Ultrasonic

A

68L A Rear Wiper Switch Power

Or 1.0 GXL


L

RWM, Rear Wiper Motor

B

68L B Rear Wiper Switch Power

Or 1.0 GXL


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


6

68W A Rear Washer Pump

W 1.0 SXL

ENG, Engine Cab

24

RWW, Rear Washer

1

CAN H CAN High

Y 0.8 TXL TWIST

CAN2, CAN Bulk Head

A


35

68L

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-35






Circuit





To Connector

Connector

Cavity

Connector

Cavity

CAN HA

CAN High

Y 0.8 TXL TWIST

SPL-CAN-HVAC, Ultrasonic

A

CAN, CAN Bulk Head

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


A

CAN HD

CAN High

Y 0.8 TXL TWIST


A

TECM, Trans

25

CAN HE

CAN High

Y 0.8 TXL TWIST

SPL-CAN, Ultrasonic

A


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


3

CAN HJ

CAN High From Engine

Y 0.8 TXL TWIST

CAN2, CAN Bulk Head

A


46

CAN HK

CAN High

Y 0.8 TXL TWIST


A

HVAC-CAN1, CAN HVAC AIC

A

CAN HM

CAN High

Y 0.8 TXL TWIST


A


A

CAN L CAN Low

G 0.8 TXL TWIST

CAN2, CAN Bulk Head

B


34

CAN LA

CAN Low

G 0.8 TXL TWIST

SPL-CAN-HVAC-L, Ultrasonic

A

CAN, CAN Bulk Head

B

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


A

CAN LD

CAN Low

G 0.8 TXL TWIST

SPL-D5, Ultrasonic

A


A

CAN LE

CAN Low

G 0.8 TXL TWIST

SPL-CAN-L, Ultrasonic

A


A

CAN LF

CAN Low

G 0.8 TXL TWIST

SW-PD, Switch Pad

8


A

CAN LG

CAN Low

G 0.8 TXL TWIST


A


4

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-36






Circuit




Connector


To Connector Cavity

Connector

Cavity

CAN LJ

CAN Low

G 0.8 TXL TWIST

SPL-D5, Ultrasonic

A

TECM, Trans

27

CAN LK

CAN Low

G 0.8 TXL TWIST

SPL-D5, Ultrasonic

A

TECM, Trans

26

CAN LL

CAN Low

G 0.8 TXL TWIST


A

HVAC-CAN1, CAN HVAC AIC

B

CAN LM

CAN Low From Engine

G 0.8 TXL TWIST

CAN2, CAN Bulk Head

B


37

CAN LN

CAN Low

G 0.8 TXL TWIST


A


A

ECC L1

Beacon/Dome Light L1 ECC

BUSS

L1-ECC, ECC Batt Power

cs01

ECC, Work Lights

J1

Trans ECM Power

ECA-BUSS

ECA-L1, B+ Power

cs01

ECA, Elect Center A

L1

J2

Trans ECM Comfort Steer

ECA-BUSS

ECA, Elect Center A

L1

ECA, Elect Center A

L1

J3

Comfort Steer 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

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

J11

Blower Motor Power

ECA-BUSS

ECA-L2, 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

AC Seat Compressor

ECA-BUSS

ECA, Elect Center A

L2

ECA, Elect Center A

L2

J18

Seat Comp Emergency Steer

ECA-BUSS

ECA, Elect Center A

L2

ECA, Elect Center A

L2

J2 ECC

Beacon/Dome Lt Work Lights

ECA-BUSS

ECC, Work Lights

L1-1

ECC, Work Lights

L1-2

J3 ECC

Work Lights Driving Lights

ECA-BUSS

ECC, Work Lights

L1-2

ECC, Work Lights

L1-3

Bur 5-2750

Issued 8-06

L1-1

Printed in U.S.A.

4002-37






Circuit




Connector


To Connector Cavity

Connector

Cavity

J4 ECC

Driving Lights Brake Lights

ECA-BUSS

ECC, Work Lights

L1-3

ECC, Work Lights

L1-4

J5 ECC

Brake Lights Delay Power

ECA-BUSS

ECC, Work Lights

L1-4

ECC, Work Lights

L1-5

J6 ECC

Delay Power Horn

ECA-BUSS

ECC, Work Lights

L1-5

ECC, Work Lights

L1-6

J7 ECC

Horn HOD Control

ECA-BUSS

ECC, Work Lights

L1-6

ECC, Work Lights

L1-7

J8 ECC

HOD Control Cigar Lighter

ECA-BUSS

ECC, Work Lights

L1-7

ECC, Work Lights

L1-8

J9 ECC

Diagnostic Power

ECA-BUSS

ECC, Work Lights

L1-9

ECC, Work Lights

L1-8

PRM A Ignition Power Fuse Sec. Steering

BUSS

PRM-A, Power Relay Mod A

PRM B Time Delay Fuse Ignition Pwr Fuse

BUSS

PRM D Accessory Pwr Fuse Spare

BUSS

PRM-D, Power Relay Mod D


BUSS

PRM-A, Power Relay Mod A


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


12

RAD-J1, Radio Power

7

RAD3 12V Fused Power to Radio

W 0.8 GXL


7

RAD-J1, Radio Power

4

RAD4 Left Speaker Ground

W 0.8 GXL


3

RAD-J2, Speaker

8

RAD5 Left Speaker

W 0.8 GXL


10

RAD-J2, Speaker

7

RAD6 Not Used

W 0.8 GXL


4

RAD-J2, Speaker

6

RAD7 Not Used

W 0.8 GXL


11

RAD-J2, Speaker

5

RAD8 Not Used

W 0.8 GXL


2

RAD-J2, Speaker

4

RAD9 Not Used

W 0.8 GXL


9

RAD-J2, Speaker

3

RAD10 Right Speaker Ground

W 0.8 GXL


1

RAD-J2, Speaker

2

RAD11 Right Speaker

W 0.8 GXL


8

RAD-J2, Speaker

1

PRM PWR

Ignition Power Fuse Accessory Power Fuse

Bur 5-2750

PRM-A, Power Relay Mod A PRM-A, Power Relay Mod A

Issued 8-06

Printed in U.S.A.

4002-38

UNDERSTANDING THE TROUBLESHOOTING TABLES 1 – Alternator

1

Check Points

Correct Reading

2

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

3

Good 12 volts

4

Possible Cause of Bad Reading

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

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

5

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

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

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-39

STARTING AND CHARGING SYSTEMS

9

3

10

8

5 1

2

7 4 11 6 12 BS06H241 / BS06H242

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

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

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

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

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-40

1 – Starting Relay Located in the right side of the engine compartment on cooling fan housing, open engine compartment to gain access. Check Points Terminal for wire 0-GB to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

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

24 volts

Check circuit to batteries.

NOTE: Put the transmission in NEUTRAL. Have another person hold the ignition switch in the START position. Terminal for wire 21D to ground

24 volts

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

Terminal for wire 1-BB to ground

24 volts

Bad starting relay.

2 – Resistor Located in the cab access panel for fuses and relays. NOTE: Turn master disconnect switch off, disconnect terminals from resistor. Check Points Between terminals of resistor

Correct Reading 75 ohms

Possible Cause of Bad Reading Bad resistor.

3 – Alternator Located on left side of engine, open engine compartment to gain access. Check Points Between housing of alternator and ground



Bad ground connection.

NOTE: Put the master disconnect switch in the ON position. Between the B+ terminal of alternator and ground

24 volts

Check circuit to positive post of left battery. Bad master disconnect switch.

Between terminal for wire 1-BA and ground

24 volts

Bad wire 1-BA.

NOTE: Put the ignition switch in the ON position. Between the B+ terminal of alternator and ground

24 volts

Check circuit to positive post of left battery.

Terminal for wire 14 to ground

20 volts

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

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-41

4 – Crank Control Relay Located in the cab access panel for fuses and relays. Check Points Terminal for wire 21H to ground


Possible Cause of Bad Reading Bad ground circuit or bad EDC7 (24).

NOTE: Put the master disconnect switch in the ON position. Put the transmission in NEUTRAL. Have another person hold the ignition switch in the START position. Terminal for wire 21C-B to ground

24 volts

Bad neutral start relay (11), check wire circuit 21C.

Terminal for wire 21G to ground

24 volts

Bad EDC7 (24), check wire circuit 21G.

Terminal for wire 21D-A to ground

24 volts

Bad crank control relay.

5 – Batteries Located on right and left rear sides of the machine. NOTE: See Section 4003 and check the batteries.

6 – Crank Request Relay Located in the cab access panel for fuses and relays. Check Points Terminal for wire 0-DF to ground



NOTE: Put the master disconnect switch in the ON position. Have another person hold the ignition switch in the START position. Terminal for wire 21C-A to ground

24 volts

Check circuit 21 to neutral start relay (11).

Terminal for wire 21E to ground

24 volts

Bad crank request relay.

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-42

7 – Time Delay Module Located in the cab access panel for fuses and relays at rear of compartment. Correct Reading

Check Points Terminal for wire 0-DC to ground

Continuity


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

Terminal for wire 1DN to ground

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

NOTE: Put the ignition switch in the ON position. 24 volts

Terminal for wire 13K-A to ground

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

NOTE: Put the ignition switch in the ON position. Turn ignition switch to the OFF position. After 30 seconds time delay an audible click will be heard. Within 30 seconds of putting the ignition switch in the OFF position, check terminal for wire 13D to ground

24 volts Key OFF 0 volt after 30 seconds

Bad time delay module.

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

0 volt

Bad time delay module.

8 – Master Disconnect Switch Located on right side battery box cover, remove battery box cover to gain access. Check Points

Correct Reading


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

Continuity

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

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

Open Circuit

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

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-43

9 – Starter Motor Located on left side of engine, open engine compartment to gain access. Check Points Between housing of starter and ground



Bad ground connection.

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

24 volts


NOTE: Put the transmission in NEUTRAL. Have another person hold the ignition switch in the START position. Terminal S to ground

24 volts

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

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

10 – Ignition Switch Located on steering column. Check Points

Correct Reading


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

24 volts

Check circuit 1A to ECC-F5 fuse.

NOTE: Disconnect the connector from the ignition switch. Turn the switch to ON. Between Bat and Ign

Continuity

Bad ignition switch.

Between Bat and Accessory

Continuity


NOTE: Hold the ignition switch in the START position. Between Bat and Starter

Continuity


Between Bat and Ign

Continuity


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

Bur 5-2750

Continuity


Issued 8-06

Printed in U.S.A.

4002-44

11 – Neutral Start Relay Located in the cab access panel for fuses and relays. Check Points Terminal for wire 0-DE to ground



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

24 volts

Check circuit 25T, check FNR switch (55).

NOTE: Have another person hold the ignition switch in the START position. Terminal for wire 21K-B to ground

24 volts

Check circuit 21K-B and ignition switch (10).

Terminal for wire 21C to ground

24 volts

Bad neutral start relay.

12 – Voltmeter Relay Located in the cab access panel for fuses and relays. Check Points Terminal for wire 0-DB to ground



NOTE: Put the master disconnect switch in the ON position. Terminal for wire 18-RA to ground

24 volts

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

NOTE: Turn ignition switch to the ON position. Terminal for wire 13K-C to ground

24 volts

Check circuit 13K or ignition switch.

Terminal for wire 13V to ground

24 volts

Bad voltmeter relay.

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-45

POWER RELAY MODULES AND COLD STARTING SYSTEMS

20 21

17

15 19 16

13 14 18 BS06H241 / BS06H242

13. 14. 15. 16. 17.

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

18. 19. 20. 21.

POWER RELAY MODULE D CIRCUIT BREAKER CAB + WATER SEPARATOR HEATER FUEL FILTER HEATER


Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-46

13 – Power Relay Module A, Ignition Power Located in the cab access panel for fuses and relays. Check Points Terminal for wire 0-EB to ground



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

24 volts

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

Terminal for wire 13K-B to ground

24 volts

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

Terminal for wire J1 BUSS to ground

24 volts

Bad power relay module A.

14 – Power Relay Module B, Ignition Power Located in the cab access panel for fuses and relays. Check Points Terminal for wire 0-EA to ground



NOTE: Put the master disconnect switch in the ON position. Turn the ignition switch to the ON position. Terminal for wire PRM-B BUSS to ground

24 volts


Terminal for wire 13D to ground

24 volts

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

Terminal for wire 13H to ground

24 volts

Bad power relay module B.

15 – Power Relay Module C, For Fuel Filter Heater and Water Separator Heater Located in the right side of the engine compartment on cooling fan housing, open engine compartment to gain access. Check Points

Correct Reading


NOTE: Make sure engine temperature is below -0 ° C (32 ° F). Terminal for wire 0-GA to ground

Continuity

Bad ground circuit or bad EDC7 (24).

Terminal for wire 1-NC to ground

24 volts

Check circuit 1 and circuit to batteries.

NOTE: Put the ignition switch in the ON position. Terminal for wire 28F to ground

24 volts

Check EDC7 (24).

Terminal for wires 1-GA ground

24 volts

Check 40 ampere fuse, bad power relay module.

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-47

16 – Grid Heater Relay Located in the right side of the engine compartment on cooling fan housing, open engine compartment to gain access. Check Points Terminal for wire 0-BV to ground


Possible Cause of Bad Reading Bad ground circuit or bad EDC7 (24).

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

24 volts

Bad 150 ampere fuse. Check wires 1-Y and 1-E.

NOTE: Have an assistant put the transmission in neutral and the ignition switch in the START position. Make sure engine temperature is below -0 ° C (32 ° F). Terminal for wire 28G to ground

24 volts

Bad EDC7 (24), also check circuit 28G.

Terminal for wire 1-BE to ground

24 volts

Bad grid heater relay.

17 – Grid Heater Located in the right side of the engine in intake manifold, open engine compartment to gain access. Check Points

Correct Reading


NOTE: Disconnect terminal for wire 1-BE from grid heater. Terminal for wire 0-ES to ground

Continuity

Bad ground circuit.

Terminal for wire 1-BE of grid heater to ground

Resistance

If an open or short circuit is obtained, replace the grid heater.

18 – Circuit breaker Cab B+ Located in the right side of the engine compartment on cooling fan housing, open engine compartment to gain access. Check Points

Correct Reading

Between terminal A and B on circuit breaker

Continuity


Bad circuit breaker

19 – Water Separator Heater Located in the right side of the engine compartment on water separator housing, open engine compartment to gain access. Check Points Terminal for wire 0-BW to ground



NOTE: Disconnect connector WSH from water separator heater. Between terminals A and B of heater

1.9 ohms

Bad heater.

NOTE: If the readings are good, check circuit 1-G between water separator heater connector WSH and power relay module C connector PRM-C1.

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-48

20 – Fuel Filter Heater Located in the right side of the engine compartment on fuel filter housing, open engine compartment to gain access. Check Points Terminal for wire 0-BX to ground



NOTE: Disconnect connector FFH from fuel filter heater. Between terminals A and B of heater

1.9 ohms

Bad heater.

NOTE: If the readings are good, check circuit 1-G between fuel filter heater connector FFH and power relay module C connector PRM-C1.

21 – Power Relay Module D, Accessory Power Located in the cab access panel for fuses and relays. Check Points Terminal for wire 0-EC to ground



NOTE: Put the master disconnect switch in the ON position. Turn ignition switch to the Accessory or the ON position. Terminal for wire PRM-D BUSS to ground

24 volts


Terminal for wire ACC-B to ground

24 volts

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

Terminal for wire J11 BUSS-ECA to ground

24 volts

Bad power relay module D.

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-49

ENGINE CONTROLLER

24

22 23

BS06H241 / BS06H242

22. WATER IN FUEL SENSOR 23. THROTTLE POTENTIOMETER 24. ENGINE CONTROLLER


Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-50

22 – Water In Fuel Sensor Located in the right side of the engine compartment on water separator housing, open engine compartment to gain access. Correct Reading

Check Points

Continuity

Terminal for wire 0-BP to ground


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

Terminal for wire 18J-H to ground

Check fuse ECD-F2, power relay module B (14), also check circuit 18J.

NOTE: Remove sensor from filter and place probes in water. 24 volts

Terminal for wire 35W to ground

Bad water separator sensor.

23 – Throttle Potentiometer Located below cab under throttle pedal. Check Points

Correct Reading


NOTE: Put the master disconnect switch in the ON position and the ignition switch in ON position. Terminal for wire 24S to 24R Terminal for wire 24R to ground

5 volts

Bad EDC7 (24). Also check wire 24S.

Continuity

Bad EDC7 (24). Also check wire 24R.

NOTE: Throttle pedal in low idle position. Terminal for wire 24B to 24R

0.4 ± 0.025 volts

Bad potentiometer.

NOTE: Throttle pedal in high idle position. Terminal for wire 24B to 24R

4.0 ± 0.1 volts

Bad potentiometer.

NOTE: Put the ignition switch in OFF position and the master disconnect switch in the OFF position. Disconnect connector RTHP. Throttle pedal in low idle position. Between pin 1 and 6 at pedal

Open

Bad potentiometer.

NOTE: Throttle pedal in high idle position.

Between pin 1 and 6 at pedal

1000 ± 400 ohms at 20° C (68° F)

Bad potentiometer.

1200 ± 400 ohms at 20° C (68° F)

Bad potentiometer.

NOTE: Throttle pedal in any position.

Between pin 4 and 5 at pedal

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-51

24 – Electronic Diesel Control Located on right side of engine, open engine compartment to gain access. Check Points

Correct Reading


NOTE: Put the ignition switch in the OFF position. Put the master disconnect switch in the OFF position. Disconnect connector EDC7. Terminal for wire 0-BE pin 5 to ground

Continuity

Bad ground circuit.

Terminal for wire 0-BF pin 6 to ground

Continuity

Bad ground circuit.

Terminal for wire 0-BD pin 10 to ground

Continuity

Bad ground circuit.

Terminal for wire 0-BC pin 11 to ground

Continuity

Bad ground circuit.

NOTE: Put the master disconnect switch in the ON position. Put the ignition switch in the ON position. Terminal for wire 18J-C pin 2 to ground

24 volts

Bad fuse ECD-F2, bad wire 18J.

Terminal for wire 18J-B pin 3 to ground

24 volts


Terminal for wire 18J-D pin 8 to ground

24 volts


Terminal for wire 18J-E pin 9 to ground

24 volts


NOTE: Use diagnostic service tool for additional tests on EDC7.

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-52

RETURN TO TRAVEL - RETURN TO DIG - PIN ENGAGE 28

30

25 26 31 32

29

27 33

34 BS06H241 / BS06H242

25. 26. 27. 28. 29.

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

30. 31. 32. 33. 34.

HEIGHT CONTROL/RETURN TO TRAVEL PROXIMITY SWITCH RETRUN TO DIG SWITCH PIN ENGAGE SWITCH (OPTION) PILOT PRESSURE SOLENOID PIN ENGAGE SOLENOID (OPTION)


Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-53

25 – Return-To-Travel/Float Switch Located on right side console. Check Points

Correct Reading


Terminal for wire 0-B2 to ground

Continuity

Bad ground circuit.

Terminal for wire 0-29 to ground

Continuity

Bad ground circuit.

NOTE: Disconnect the wiring harness connector from the return-to-travel/float switch. Put the return-totravel/float switch in FLOAT position. Between switch terminals 1 and 2

Continuity

Bad return-to-travel/float switch.

NOTE: Put the return-to-travel/float switch in the TRAVEL position. Between switch terminals 2 and 3

Continuity

Bad return-to-travel/float switch.

NOTE: Put ignition switch in OFF position. Connect wiring harness connector to return-to-travel/float switch. Put ignition switch in ON position. Put driving lamp switch (95) in position 3.

Terminal for wire 49-K to ground

24 volts

Bad circuit 49-K. Also check driving lamp switch (95). If return-to-travel/float switch illumination LED is not ON with 24 volts at check point, replace return-to-travel/float switch.

Correct Reading


26 – Height Control Switch Located on right side console. Check Points Terminals for wire 0-B3 to ground

Continuity

Bad ground circuit.

NOTE: Turn the master disconnect to the ON position, the ignition switch to the ON position and the pilot control switch to the ON position. Terminal for wire 53P-D to ground.

24 volts

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

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

Bur 5-2750

24 volts

Bad height control switch.

Issued 8-06

Printed in U.S.A.

4002-54

27 – Electromagnetic Detents Located under right side console. Check Points

Correct Reading


NOTE: For joystick controller. Between pins 3 and 4

74 ohms @ 20° C (68° F)

Bad electromagnetic detent

Between pins 2 and 5

74 ohms @ 20° C (68° F)



74 ohms @ 20° C (68° F)



328 ohms @ 20° C (68° F)



328 ohms @ 20° C (68° F)



328 ohms @ 20° C (68° F)


NOTE: For single axis controller.

NOTE: Put the master disconnect switch and ignition switch in ON position. Put pilot control switch (39) in OFF position and return to travel/float switch (25) in ON position. Wiring harness connector EM, pin 1 to ground

24 volts

Bad return to travel/float switch (25). Also check wires 55A.

NOTE: Place the height control switch in the ON position. Wiring harness connector EM, pin 2 to ground

24 volts

Bad height control switch. Also check wires 54A.

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

24 volts

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

28 – Return-To-Dig Proximity Switch Located on bucket cylinder. Check Points

Correct Reading


NOTE: Disconnect the connector from the return-to-dig proximity switch. Put the master disconnect switch and the ignition switch in the ON position. Put the pilot control switch (39) in the OFF position and the return to dig switch in the ON position. Terminal B for wire 0-AC to ground

Continuity

Terminal A for wire 53B to ground

24 volts

Bad bucket control valve detent electromagnets (27) or return to dig switch. Also check circuit 53B.

Terminal C for wire 53P-H to ground

24 volts

Bad pilot relay (29), also check circuit 53P.

Bad ground circuit.

NOTE: If the readings are good, replace the return-to-dig proximity switch. Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-55

29 – Pilot Control Relay Located in the cab access panel for fuses and relays. Check Points

Correct Reading


NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure pilot control switch (39) is OFF. Terminal for wire 19C-C to ground

24 volts

Terminal for wire 53C-A to ground

0 volt

Terminal for wire 53P-A to ground

24 volts

Bad fuse ECA-F5, also check circuit 19C. Bad instrument cluster (62). Also check circuit 53C. Bad pilot control relay.

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

24 volts

Bad instrument cluster (62). Also check circuit 53C.

30 – Height Control/Return-To-Travel Proximity Switch Located on left front frame at lift arm pivot. Check Points

Correct Reading


NOTE: Disconnect the connector from the height control/return-to-travel proximity switch. Put the master disconnect switch and the ignition switch in the ON position. Put the pilot control switch (39) in the OFF position and the return to travel switch in the ON position. Terminal B for wire 0-AA to ground

Continuity

Terminal A for wire 54B to ground

24 volts

Bad bucket control valve detent electromagnets (27) or return to travel switch. Also check circuit 54B.

Terminal C for wire 53P-J to ground

24 volts

Bad pilot relay (29), also check circuit 53P.

Bad ground circuit.

NOTE: If the readings are good, replace the height control/return-to-travel proximity switch.

31 – Return to Dig Switch Located on right side console. Check Points Terminals for wire 0-B4 to ground



NOTE: Turn the master disconnect to the ON position, the ignition switch to the ON position and the pilot control switch to the ON position. Terminal for wire 53P-E to ground.

24 volts

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

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

Bur 5-2750

24 volts

Bad return to dig switch.

Issued 8-06

Printed in U.S.A.

4002-56

32 – Pin Engage Switch (Option) Located on right side console. Check Points Terminal for wire 0-B5 to ground



NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put pin engage switch in OFF position. Terminal for wire 19P-A to ground Terminal for wire 57-B to ground

24 volts 0 volt

Bad fuse ECA-F7 or power relay module A. Also check circuit 19P. Bad pin engage switch.

NOTE: Put the pin engage switch in the ON position. Terminal for wire 57-B to ground

24 volts

Bad pin engage switch.

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

Terminal for wire 49-F to ground

24 volts

Check the driving lamp switch (95). Also check circuit 49. If LED in pin engage switch is not ON with 24 volts at check point, replace pin engage switch.

Correct Reading


33 – Pilot Pressure Solenoid Located on bottom side of pilot controls. Check Points Terminal for wire 0-DU to ground

Continuity

Bad ground circuit.

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the pilot control switch (39) is OFF. Terminal A for wire 53P-A to ground

24 volts

Bad pilot control relay (29), also check circuit 53P.

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

34 – Pin Engage Solenoid (Option) Located on. Check Points Terminal for wire 0-AE to ground



NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the pin engage switch (32) in the ON position. Terminal for wire 57 to ground

24 volts

Bad pin engage switch (32), also check circuit 57.

NOTE: If the readings are good, replace the pin engage solenoid.

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-57

PILOT CONTROL - RIDE CONTROL - FAN CONTROL

43 44

35 37 39

36 38

40 41 42 BS06H241 / BS06H242

35. 36. 37. 38. 39.

RIDE CONTROL SWITCH (OPTION) RIDE CONTROL RELAY (OPTION) FAN CONTROL SWITCH (OPTION) FAN REVERSE RELAY (OPTION) PILOT CONTROL SWITCH

40. 41. 42. 43. 44.

RIDE CONTROL SOLENOID (OPTION) ROLLBACK PRESSURE SWITCH (OPTION) ROLLBACK JUMPER FAN PWM SOLENOID FAN REVERSE SOLENOID (OPTION)


Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-58

35 – Ride Control Switch Located on right side console. Check Points

Correct Reading


NOTE: Disconnect connector SRC from ride control switch. Connector SRC pin 7 to ground

Continuity

Bad ground circuit.

Ride control switch terminal 6 (positive) to terminal 7 (negative)

Continuity

Bad ride control switch.

NOTE: Connect connector SRC to ride control switch. Put master disconnect switch and ignition switch in ON position. Put ride control switch in OFF position. Terminal for wire 19C-D to ground Terminal for wire 58C to ground

24 volts 0 volt

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

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

24 volts

Bad ride control switch.

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

Terminal for wire 49-G to ground

24 volts

Check driving lamp switch (95). Also check circuit 49. If LED in ride control switch is not ON with 24 volts at check point, replace ride control switch.

36 – Ride Control Relay Located in the cab access panel for fuses and relays. Check Points

Correct Reading


Terminal 85 for wire 58L to connector TECM pin 57

Continuity

Check wire 58L.

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

Continuity

Check wire 58H-A.

Terminal 87 for wire 58-E to ride control switch (35) pin 6

Continuity

Check wire 58-E

NOTE: Put master disconnect switch and ignition switch in ON position. Put ride control switch in ON position. Terminal for wire 58T to ground

24 volts

Bad ride control switch. Also check wire 58T.

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-59

37 – Fan Reversing Switch (Option) Located on right side console. Check Points Terminal for wire 0-B7 to ground



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

24 volts

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

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

24 volts

Bad fan reversing switch.

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

24 volts

Bad fan reversing switch.

NOTE: Put driving lamp switch in position 3.

Terminal for wire 49-Q to ground

24 volts

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

38 – Fan Reverse Relay Located in the cab access panel for fuses and relays. Check Points

Correct Reading


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

24 volts

Check fuse ECA-F7 and circuit 19P.

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

Bur 5-2750

24 volts

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

Issued 8-06

Printed in U.S.A.

4002-60

39 – Pilot Control Switch Located on steering column pedestal. Check Points Terminal for wire 0B1 to ground



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

24 volts

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

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

24 volts

Bad pilot control switch.

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

24 volts

Check driving lamp switch (95) and fuse ECC-F3. Also check circuit 49.

NOTE: If the readings are correct replace the pilot control switch.

40 – Ride Control Solenoid Located on ride control valve inside of front frame. Check Points

Correct Reading


NOTE: Disconnect connector YRC from ride control solenoid. Connector YRC pin 2 to ground Between terminals 1 and 2 of ride control solenoid

Continuity 20 to 26 ohms

Bad ground circuit. Bad ride control solenoid.

41 – Rollback Pressure Switch (Option) Located inside of front frame. Check Points

Correct Reading


NOTE: Switch opens at 6.2 bar (90 psi). Release all hydraulic pressure from the system, disconnect the wiring harness from the rollback pressure switch. Between terminals A and B on switch Terminal for wire 58S to ground

Continuity

Bad rollback pressure switch.

37 to 43 ohms

Bad ride control solenoid (40).

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the ride control switch (35) in the ON position. Accelerate the machine to at least 5 km/hr (3 m.p.h.).

Terminal for wire 58-B to ground

Bur 5-2750

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

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

Issued 8-06

Printed in U.S.A.

4002-61

42 – Rollback Jumper (Option) Located inside of front frame. Check Points Between terminals A and B on switch



Bad rollback jumper.

43 – Fan PWM Solenoid (Option) Located on fan control valve. Check Points

Correct Reading


NOTE: Disconnect wiring harness connector YFN from fan PWM solenoid. Between pins 1and 2 of fan PWM solenoid

26 to 32 ohms

Pin 2 of wiring harness connector YFN to ground

Continuity

Bad fan reversing solenoid.

Bad ground circuit.

NOTE: In the options menu of the instrument cluster select auto for the fan. Stall the transmission to raise transmission temperature to high operating range. Pin 1 of wiring harness connector YFN to ground

24 volts

Bad instrument cluster. Also check wire 56.

44 – Fan Reversing Solenoid (Option) Located on fan control valve. Check Points

Correct Reading


NOTE: Disconnect wiring harness connector YFR from fan reversing solenoid. Between pins 1and 2 of fan reversing solenoid Pin 2 of wiring harness connector YFR to ground

36 to 42 ohms

Continuity

Bad fan reversing solenoid.

Bad ground circuit.

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put fan reversing switch in ON position (hold rocker in momentary position). Pin 1 of wiring harness connector YFR to ground

Bur 5-2750

24 volts

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

Issued 8-06

Printed in U.S.A.

4002-62

TRANSMISSION

46

48

52 55 56 57 60

49 50 51

45 53 54 47 61 58 BS06H241 / BS06H242

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

OUTPUT SPEED SENSOR TRANSMISSION SOLENOID VALVE AND TEMPERATURE SENSORS FILTER MAINTENANCE SWITCH TORQUE CONVERTER OUTPUT TEMPERATURE SENDER ENGINE SPEED SENSOR INTERMEDIATE SPEED SENSOR TURBINE SPEED SENSOR TRANSMISSION SHIFTER TRANSMISSION ELECTRONIC CONTROL MODULE

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

TRANSMISSION ENABLE SWITCH FNR SWITCH FOR JOYSTICK CONTROLS TRANSMISSION KICK-DOWN SWITCH FNR SWITCH FOR SINGLE AXIS CONTROLS TRANSMISSION AUTO SWITCH BRAKE DECLUTCH PRESSURE SWITCH DECLUTCH SWITCH DIAGNOSTIC CONNECTOR


Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-63 NOTE: If you have transmission shifting problems, see Section 6002 for complete troubleshooting information for Items 45 through 61.

45 – Output Speed Sensor 46 – Transmission Solenoid Valve and Temperature Sensors 47 – Filter Maintenance Switch 48 – Torque Converter Output Temperature Sender 49 – Engine Speed Sensor 50 – Intermediate Speed Sensor 51 – Turbine Speed Sensor 52 – Transmission Shifter 53 – Transmission Electronic Control Module 54 – Transmission Enable Switch 55 – FNR Switch for Joystick Controls 56 – Transmission Kick-down Switch (Located In Hydraulic Controller for Joystick Option; Next to Hydraulic Levers for Single Axis Controls) 57 – FNR Switch for Single Axis Controls 58 – Transmission Auto Switch 59 – Brake Declutch Pressure Switch 60 – Declutch Switch 61 – Diagnostic Connector

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-64

WARNING BUZZER, INSTRUMENT CLUSTER 1, PARK BRAKE

66 62 63

67 69

65

68

64 BS06H241 / BS06H242

62. 63. 64. 65.

INSTRUMENT CLUSTER CONNECTOR 1 WARNING BUZZER PARKING BRAKE RELAY FUEL LEVEL SENDER

66. 67. 68. 69.

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


Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-65

62 – Instrument Cluster Connector 1 Located on instrument cluster. Check Points

Correct Reading


NOTE: Disconnect the connector AIC-1 from the instrument cluster and SW-PD from the switch pad. Connector terminal SW-PD 5 to ground

Open Circuit

Bad air filter restriction switch (66). Also check circuit 31F-A.

Connector terminal SW-PD 4 to ground

Open Circuit

Bad hydraulic filter restriction switch (72). Also check circuit 31H-A.

Connector terminal AIC-1 6 and 12 to ground

Continuity

Bad ground circuit. Check wires 0-DW and 0-DX.

Connector terminal AIC-1 11to ground

130 to 9500 ohms

Bad engine coolant temperature sender (68). Also check circuit circuit 36C-A and ground circuit at sender.

Connector terminal AIC-1 2 to ground

33 to 240 ohms

Bad fuel level sender (65). Also check circuit 36F-A and ground circuit at sender.

Connector terminal AIC-1 9to ground

130 to 9500 ohms

Bad hydraulic oil temperature sender (73). Also check circuit 36H-A and ground circuit at sender.

Connector terminal AIC-1 25 to connector terminal SW-PD 9

Continuity


Open Circuit

Bad wire 17P-A.

Bad redundant brake switche(s) (75). Also check circuit 33R.

Connector terminal AIC-1 4 and SW-PD 8 to terminals 26 and 27 on the transmission electronic control module (53)

Continuity

Bad circuit CAN-L.

Connector terminal AIC-1 3 and SW-PD 7 to terminal 25 on the transmission electronic control module (53)

Continuity

Bad circuit CAN-H.


Continuity

Check LH and RH stop lamps and circuit 44A-B. Also check ground circuit at lamps.

NOTE: Put the parking brake switch in the ON position. Connector terminal AIC-1 14to ground

24 volts

Bad parking brake switch. Also check fuse ECA-F6 and circuit 19D and 52C.

NOTE: Put the blower switch in any position other than OFF and thermostat switch fully clockwise. Connector terminal 10 to ground

Bur 5-2750

24 volts

Check fuse G, blower switch, thermostat switch, and A/C low pressure switch. Also check circuits 61R, 61A, and 61T.

Issued 8-06

Printed in U.S.A.

4002-66 NOTE: Put the driving lamp switch in position four or five. Put the high/low beam switch in HIGH BEAM position. Connector terminal SW-PD 1to ground

24 volts

Check high/low beam switch, driving lamp switch, and fuse ECC-F3. Also check circuit 41H-D.

NOTE: Press pilot control switch to turn ON switch LED. Connector terminal AIC-1 14 to ground

24 volts

Bad parking brake relay or fuse ECA-F6. Also check circuits 52C and 19D.


24 volts

Bad pilot control relay or fuse ECA-F5. Also check circuits 53C and 19C.

63 – Warning Buzzer Located on steering column under instrument cluster. Check Points

Correct Reading


NOTE: Buzzer sounds for five seconds during self test when ignition switch is turned on. Terminal for wire 0_B27 to ground

Continuity

Bad ground circuit.

NOTE: Turn the ignition switch to the ON position Terminal for wire 35B to ground

24 volts

Bad instrument cluster

NOTE: If all readings are good, replace buzzer.

64 – Parking Brake Relay Located in the cab access panel for fuses and relays. Check Points

Correct Reading


NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the parking brake switch (74) is OFF. Terminal for wire 19D-B and 19D-C to ground Terminal for wire 52C to ground Terminal for wire 52P-B to ground

24 volts 0 volt 24 volts

Bad fuse ECA-F6, also check circuit 19D. Bad instrument cluster (62). Also check circuit 52C. Bad parking brake relay.

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

Bur 5-2750

24 volts

Bad instrument cluster (62). Also check wire 52C.

Issued 8-06

Printed in U.S.A.

4002-67

65 – Fuel Level Sender Located on the fuel tank top right side. Correct Reading

Check Points

Continuity

Terminal for wire 0-BU to ground


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

Approximately 5 volts

Check the instrument cluster (62).

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

33 to 240 ohms

Bad fuel level sender.

66 – Air Filter Restriction Switch Located on the air filter left side. Correct Reading

Check Points


NOTE: Air filter restriction switch closes at -6.4 kPa (Gauge) (-0.928 psig). Continuity

Terminal for wire 0-BY to ground

Bad ground circuit.

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Terminal for wire 31F to ground

Approximately 11.5 volts


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

67 – Parking Brake Solenoid Located on the foot brake valve. Check Points Terminal for wire 0-AL to ground



NOTE: Put the master disconnect switch and ignition switch in ON position. Put parking brake switch in OFF position. Terminal 1 for wire 52P to ground

24 volts

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

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-68

68 – Radiator Coolant Temperature Sender Located on the lower radiator hose to engine on left side of engine compartment. Check Points Terminal for wire 0-BAE to ground



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

3521 ohms at 20° C (68° F)

Replace radiator coolant temperature sender.

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



69 – Brake Warning Pressure Switch Located on the foot brake valve. Check Points

Correct Reading


NOTE: Brake warning pressure switch opens at 110.3 bar (1600 psi). NOTE: Put the master disconnect switch and the ignition switch in the ON position. Terminal 2 for wire 0-AL to ground

Continuity

Bad ground circuit.

Terminal 1 for wire 33P to ground


Check circuit 33P.

NOTE: With engine not running pump brakes at least 12 times. Disconnect the wires from the brake warning pressure switch. Between terminals 1 and 2 of the switch

Continuity

Bad brake warning pressure switch.

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

Bur 5-2750

Open Circuit

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

Issued 8-06

Printed in U.S.A.

4002-69

SWITCH PAD, INSTRUMENT CLUSTER 2, PARK BRAKE 77 70 71 74

75 76

72 73 BS06H241 / BS06H242

70. 71. 72. 73.

SWITCH PAD INSTRUMENT CLUSTER CONNECTOR 2 HYDRAULIC FILTER RESTRICTION SWITCH HYDRAULIC OIL TEMPERATURE SENDER

74. 75. 76. 77.

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


Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-70

70 – Switch Pad Located on steering column. Check Points

Correct Reading


NOTE: Disconnect switch pad connector, put master disconnect switch and ignition switch in ON position. Terminal for wire 17P-A to ground.

24 volts

Bad instrument cluster (62).

NOTE: Disconnect instrument cluster connector 1. Between terminals for wire 17P-A

Bur 5-2750

Continuity

Bad wire 17P-A.

Issued 8-06

Printed in U.S.A.

4002-71

71 – Instrument Cluster Connector 2 Located on instrument cluster. Check Points

Correct Reading


NOTE: Disconnect the connector AIC-2 from the instrument cluster and SW-PD from the switch pad. Connector terminal AIC-2 5 to ground

Continuity

Bad brake warning pressure switch (69). Also check circuit 33P-A and ground circuit at brake warning pressure switch.


Continuity

Bad coolant level sender (77). Also check circuit 31D-A and ground circuit at coolant level sender.


Continuity

Bad secondary steering pressure switch (118). Also check circuit 35X and ground circuit at pressure switch.


Open Circuit

Bad air filter restriction switch (66). Also check circuit 31F-A.


Open Circuit

Bad hydraulic filter restriction switch (72). Also check circuit 31H-A.

Connector terminal AIC-2 15 and 22 to ground. Connector terminal AIC-2 4 to ground

Continuity

Open Circuit

Bad ground circuit. Check wires 0-DB and 0-D-A.

Bad redundant brake switche(s) (75). Also check circuit 33R.

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Connector terminal AIC-2 14 and 20 to ground

24 volts

Bad fuse ECD-F3. Also check circuit 19S-C and 19S-D. Also check power relay module B (14).


24 volts

Bad fuse ECA-F3. Also check circuit 19E-A. Also check power relay module A (13).

NOTE: Put the blower switch in any position other than OFF and thermostat switch fully clockwise. Connector terminal 10 to ground

24 volts

Check fuse G, blower switch, thermostat switch, and A/C low pressure switch. Also check circuits 61R, 61A, and 61T.

NOTE: Put the driving lamp switch in position four or five. Put the high/low beam switch in HIGH BEAM position. Connector terminal SW-PD 1to ground

24 volts

Check high/low beam switch, driving lamp switch, and fuse ECC-F3. Also check circuit 41H-D.

NOTE: Put the turn signal switch in the LEFT TURN position. Connector terminal AIC-2 9to ground

24 volts on and off every 1-2 seconds

Check fuse ECA-F8, turn signal switch, and flasher module. Also check wire 19B, circuit 45A-A to flasher module, and circuit 45L from flasher module to instrument cluster.

NOTE: Put the turn signal switch in the RIGHT TURN position. Connector terminal AIC-2 10to ground

24 volts on and off every 1-2 seconds

Check fuse ECA-F8, turn signal switch, and flasher module. Also check wire 19B, circuit 45B-A to flasher module, and circuit 45R from flasher module to instrument cluster.

NOTE: Press pilot control switch to turn ON switch LED. Connector terminal AIC-2 18to ground

Bur 5-2750

24 volts

Bad pilot control switch or fuse ECA-F1. Also check wire 31L and circuit 19A.

Issued 8-06

Printed in U.S.A.

4002-72 ]

72 – Hydraulic Filter Restriction Switch Located on hydraulic filter block. Check Points

Correct Reading


NOTE: Hydraulic filter restriction switch closes at 2.8 bar (40 psi). Check between the housing of the hydraulic filter restriction switch and ground

Continuity

Bad ground connection between the hydraulic filter restriction switch and ground.

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Terminal for wire 31H to ground.



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

73 – Hydraulic Oil Temperature Sender Located on hydraulic filter block. Check Points Terminal for wire 0-HW to ground



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

3521 ohms at 20° C (68° F)

Replace hydraulic oil temperature sender.

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

Bur 5-2750



Issued 8-06

Printed in U.S.A.

4002-73

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



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

24 volts

Check fuse ECA-F1, also check circuit 19A.

24 volts

Bad parking brake switch.

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

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

24 volts

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

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

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

Correct Reading


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

Continuity

Bad ground circuit.

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


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

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

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

Correct Reading


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

Continuity

Bad ground circuit.

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


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

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-74

77 – Coolant Level Sender Located on radiator top tank. Check Points Terminal for wire 0-HV to ground



NOTE: Put the master disconnect switch and the ignition switch in the ON position. Terminal A for wire 31D to ground

Approximately 1.6 volts AC

Check circuit 31D, also check the instrument cluster (62).

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-75

BACK UP ALARM CONTROLS

79

78 BS06H241 / BS06H242

78. BACK UP ALARM RELAY

79. BACK UP ALARM DISABLE SWITCH


Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-76

78 – Back-up Alarm Relay Located in the cab access panel for fuses and relays. Check Points

Correct Reading


NOTE: Disconnect the transmission electronic control module (53) connector TECM. Terminal for wire 35C to terminal 7 of connector TECM

Continuity

Bad wire 35C.

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

24 volts

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

Terminal for wire 19H to ground

24 volts

Bad fuse ECA-F14, also check wires 19H, power relay module D, accessory power (21).

NOTE: Put parking brake switch in OFF position. Depress brake pedal once and put gear selector in REVERSE. Terminal for wire 35A-A to ground

24 volts

Bad back-up alarm relay.

79 – Back-up Alarm Disable Switch Located on right side console. Check Points Terminal for wire 0-B21 to ground



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

24 volts

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

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

Bur 5-2750

24 volts

Bad back-up alarm disable switch.

Issued 8-06

Printed in U.S.A.

4002-77

LIGHTS - 01 87 82 85 81

86 88 83 80 84

89 BS06H241 / BS06H242

80. 81. 82. 83. 84.

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

85. 86. 87. 88. 89.

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


Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-78

80 – Work Lamps Switch Located on right side console. Check Points Terminal for wire 0-B14 to ground


Possible Cause of Bad Reading Bad ground circuit

NOTE: Put master disconnect witch in the ON position. Terminal for wire 42-A and 42-B to ground

24 volts

Bad fuse ECC-F2.

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

24 volts

Bad work lamps switch.

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

24 volts

Bad work lamps switch.

81 – Door Switch Located above door in cab. Check Points

Correct Reading


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

24 volts

Bad fuse ECC-F1.

NOTE: Disconnect connector DS at door switch. Between pins on door switch with door open

Continuity

Bad door switch.

Between pins on door switch with door closed

Open circuit

Bad door switch

82 – Rotating Beacon (Option) Plug is located on left side front of cab. Check Points

Correct Reading


Bulb

Continuity

Bad bulb.

Terminal for wire 0-MC to ground

Continuity

Bad ground circuit.

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

24 volts

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

NOTE: If readings are good replace the rotating beacon.

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-79

83 – Dome Lamp Located in top of cab. Correct Reading

Check Points


Bulb

Continuity

Bad bulb.

Terminal for wire 0-MB to ground

Continuity

Bad ground circuit.

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

Terminal for wire 19U-C to ground Terminal for wire 43-B to ground

24 volts 3 to 5 seconds

Check fuse ECC-F1, also check circuit 19U. Check circuit 43, also check advanced instrument cluster (62) and time delay module (7).

NOTE: If readings are good, replace dome lamp.

84 – Beacon Switch (Option) Located on right side console. Check Points Terminal for wire 0-B15 to ground



NOTE: Put master disconnect switch in ON position and driving lamp switch (95) in position 3. Terminal for wire 19U-H to ground

24 volts

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

NOTE: Put the beacon switch in the ON position. Terminal for wire 46-C to ground

24 volts

Bad beacon switch.

85 – Left Hand Front Work Lamp Located on left front side of cab. Check Points

Correct Reading


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

Continuity

Bad lamp bulb.

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

Continuity

Bad ground circuit.

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

Terminal for wire 42C-H to ground

Bur 5-2750

24 volts

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

Issued 8-06

Printed in U.S.A.

4002-80

86 – Right Hand Front Work Lamp Located on right front side of cab. Check Points

Correct Reading


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

Continuity

Bad lamp bulb.

NOTE: Connect wiring harness connector LRFW to RH front work lamp connector. Terminal for wire 0-MJ to ground

Continuity

Bad ground circuit.


Terminal for wire 42C-G to ground

24 volts

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

87 – Left Hand Rear Work Lamp Located on left rear side of cab. Check Points

Correct Reading


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

Continuity

Bad lamp bulb.

NOTE: Connect wiring harness connector LLRW to LH rear work lamp connector. Terminal for wire 0-ME to ground

Continuity

Bad ground circuit.

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

Terminal for wire 42R-H to ground

24 volts

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

88 – Right Hand Rear Work Lamp Located on right rear side of cab. Check Points

Correct Reading


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

Continuity

Bad lamp bulb.

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

Continuity

Bad ground circuit.


Terminal for wire 42R-G to ground

Bur 5-2750

24 volts

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

Issued 8-06

Printed in U.S.A.

4002-81

89 – Lights Diodes Located in the cab access panel for fuses and relays, rear of compartment. Check Points

Correct Reading


NOTE: Disconnect wiring harness connector D-OR from diode connector. Multimeter positive on pin A to pin C

None

Bad diode.

Multimeter positive on pin B to pin C

None

Bad diode.

Multimeter positive on pin C to pin A

Continuity

Bad diode.

Multimeter positive on pin C to pin B

Continuity

Bad diode.

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-82

LIGHTS - 02 93 94

95

92 91 90 BS06H241 / BS06H242

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

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


Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-83

90 – Brake Lamp Pressure Switch Located on the foot brake valve. Check Points

Correct Reading


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

24 volts 0 volt

Check fuse ECC-F4, also check wires 1-AA and 1-DR. Bad brake lamp pressure switch.

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

24 volts

Bad brake lamp pressure switch.

91 – Brake Lamps Relay Located in the cab access panel for fuses and relays. Check Points Terminal for wire 0-EF to ground



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

24 volts

Check fuse ECC-F4 and wires 1-DW and 1-DV.

Terminal for wire 44A to ground

0 volt

Bad brake lamp pressure switch (90).

Terminal for wire 44A-A to ground

0 volt

Bad brake lamps relay.

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

24 volts

Bad brake lamp pressure switch (90).

Terminal for wire 44A-A to ground

24 volts

Bad brake lamps relay.

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-84

92 – Flasher Module Located in the cab access panel for fuses and relays, rear of compartment. Check Points

Correct Reading


NOTE: Wiring harness connectors 64F and 64M must be connected for North American Machines for opposite side steady on operation and disconnected for European machines for opposite side off operation. Terminal for wire 0-EG to ground

Continuity

Bad ground circuit.

Terminal for wire 0-EH to ground

Continuity

Bad ground circuit.

Terminal for wire 45N-A to terminal for wire 45N-B (North American machines only)

Continuity

Bad 45N circuit.

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

24 volts

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

NOTE: Put ignition switch in the ON position. Put the hazard switch (93) ON. Terminal for wire 45H to ground

24 volts

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

Terminal for wire 45L-D to ground

Intermittent 24 volts

Bad flasher module.

Terminal for wire 45R-E to ground


Bad flasher module.

NOTE: Put hazard switch (93) in OFF position. Put turn signal switch (94) in RIGHT turn position. Terminal for wire 45B-A to ground

24 volts

Terminal for wire 45R-E to ground


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

NOTE: Put turn signal switch (94) in LEFT turn position. Terminal for wire 45A-A to ground

24 volts

Terminal for wire 45L-D to ground


Bur 5-2750

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

Issued 8-06

Printed in U.S.A.

4002-85

93 – Hazard Switch Located on steering column. Check Points Terminal for wire 0-B24 to ground

Correct Reading


Continuity

Bad ground circuit.

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

24 volts

Check fuse ECC-F6. Also check wires 1-KA and 1-DV.

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

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

24 volts

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

Terminal for wire 49-D to ground

Check driving lamp switch (95). Also check circuit 49 to lamp switch (95). If hazard switch LED is not ON with 24 volts at check point, replace hazard switch.

24 volts

94 – Turn Signal, High-Low Beam, and Horn Switch Located on steering column. Check Points

Correct Reading

Possible Cause of Bad Reading HORN SWITCH

Terminal for wire 0-EP to ground

Continuity

Bad ground circuit.

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

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

24 volts

NOTE: If readings are good, replace the switch. TURN SIGNAL NOTE: Put master disconnect switch and ignition switch in ON position. Terminal for wire 19B to ground

24 volts

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

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

24 volts

Bad turn signal switch.

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

24 volts

Bad turn signal switch.

HIGH-LOW BEAM SWITCH Terminal for wire 0-EP to ground

Bur 5-2750

Continuity

Bad ground circuit.

Issued 8-06

Printed in U.S.A.

4002-86

95 – Driving Lamp Switch Located on right side console. Check Points

Correct Reading


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

24 volts

Check fuse ECC-F3, also check circuit 19Z.

NOTE: Put the driving lamp switch in position 2. Terminal for wire 41T to ground

24 volts

Bad driving lamp switch.

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

Bur 5-2750

24 volts

Bad driving lamp switch.

Issued 8-06

Printed in U.S.A.

4002-87

LIGHTS - 03 AND HORN 96 99

97

98 BS06H241 / BS06H242

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

98. HORN RELAY 99. HORN


Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-88

96 – Left Hand Front Combination Lamp Located on the left front of the machine. Check Points

Correct Reading


NOTE: Disconnect wiring harness connector LF from LH front combination lamp connector. Combination lamp connector pin 3 to pin 1

Continuity

Bad high beam lamp bulb.

Combination lamp connector pin 4 to pin 1

Continuity

Bad position lamp bulb.


Continuity

Bad low beam lamp bulb.


Continuity

Bad turn signal lamp bulb.

NOTE: Connect wiring harness connector LF to LH front combination lamp connector. Terminal for wire 0-AJ to ground

Continuity

Bad ground circuit.

NOTE: Put master disconnect switch in ON position and driving lamp switch (95) in position 2. Terminal for wire 18F to ground

24 volts

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

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

Terminal for wire 18B to ground

24 volts

Check fuse ECB-F3, high/low beam relay (80), driving lamp switch (95), and high/low beam switch (94). Also check circuit 18B and wire 41H.

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

24 volts

Check fuse ECB-F6, driving lamp switch (95), and high/low beam switch (94). Also check circuit 18D and wire 41L-A.

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


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

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-89

97 – Right Hand Front Combination Lamp Located on the right front of the machine. Check Points

Correct Reading


NOTE: Disconnect wiring harness connector RF from RH front combination lamp connector. Combination lamp connector pin 3 to pin 1

Continuity

Bad high beam lamp bulb.


Continuity

Bad position lamp bulb.


Continuity

Bad low beam lamp bulb.


Continuity

Bad turn signal lamp bulb.

NOTE: Connect wiring harness connector RF to RH front combination lamp connector. Terminal for wire 0-AH to ground

Continuity

Bad ground circuit.

NOTE: Put master disconnect switch in ON position and driving lamp switch (95) in position 3. Terminal for wire 18G-A to ground

24 volts

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

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

24 volts

Check fuse ECB-F4, driving lamp switch (95), and high/low beam switch (94). Also check circuit 18C and wire 41H.

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

24 volts

Check fuse ECB-F5, driving lamp switch (95), and high/low beam switch (94). Also check circuit 18E and wire 41L-C.

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


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

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-90

98 – Horn Relay Located in the cab access panel for fuses and relays. Check Points

Correct Reading


Terminal for wire 19U-A to ground

24 volts

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

Terminal for wire 19U-E to ground

24 volts

Check wire 19U-E.


24 volts

Bad horn relay.

NOTE: Have another person push and hold the horn switch. Terminal for wire 64C to ground

0 volt

Terminal for wire 64-A to ground

24 volts

Bad horn switch. Bad horn relay.

99 – Horn Located on the left front of the machine with combination lamps. Check Points Terminal for wire 0-AF to ground



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

24 volts

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

NOTE: If the readings are good replace the horn.

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-91

LIGHTS - 04 AND BACK UP ALARM

101 103

100 102

BS06H241 / BS06H242

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

102.LICENSE PLATE LAMP 103.BACK UP ALARM


Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-92

100 – Right Hand Rear Combination Lamp (North America Only) Located on the right rear of the machine. Check Points

Correct Reading


NOTE: Disconnect wiring harness connector LRR-N from RH rear combination lamp connector. Combination lamp connector pin A to pin D

Continuity

Bad stop lamp bulb.

Combination lamp connector pin C to pin D

Continuity

Bad turn lamp bulb.

Combination lamp connector pin B to pin D

Continuity

Bad tail lamp bulb.

NOTE: Connect wiring harness connector LRR-N to RH rear combination lamp connector. Terminal for wire 0-BT to ground

Continuity

Bad ground circuit.

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

24 volts

Check brake lamps relay (91). Also check circuit 44 to brake lamps relay (91).

NOTE: Put turn signal lever in RIGHT turn position. Terminal for wire 45R-BN to ground



NOTE: Put driving lamp switch (95) in position 2 or 3. Terminal for wire 18G-CN to ground

24 volts

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

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-93

100 – Right Hand Rear Combination Lamp (Europe Only) Located on the right rear of the machine. Check Points

Correct Reading


NOTE: Disconnect wiring harness connector LRR-E from RH rear combination lamp connector. Combination lamp connector pin 1 to pin 5

Continuity

Bad stop lamp bulb.


Continuity

Bad turn lamp bulb.


Continuity

Bad tail lamp bulb.


Continuity

Bad reverse lamp bulb.

NOTE: Connect wiring harness connector LRR-E to RH rear combination lamp connector. Terminal for wire 0-BR to ground

Continuity

Bad ground circuit.

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

24 volts


NOTE: Have assistant put transmission in reverse. Terminal for wire 35A-K to ground

24 volts

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

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



NOTE: Put driving lamp switch (95) in position 2 or 3. Terminal for wire 18G-A to ground

24 volts

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

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-94

101 – Left Hand Rear Combination Lamp (North America Only) Located on the left rear of the machine. Check Points

Correct Reading


NOTE: Disconnect wiring harness connector LLR-N from LH rear combination lamp connector. Combination lamp connector pin A to pin D

Continuity

Bad stop lamp bulb.

Combination lamp connector pin C to pin D

Continuity

Bad turn lamp bulb.

Combination lamp connector pin B to pin D

Continuity

Bad tail lamp bulb.

NOTE: Connect wiring harness connector LLR-N to LH rear combination lamp connector. Terminal for wire 0-BR-N to ground

Continuity

Bad ground circuit.

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

24 volts


NOTE: Put turn signal lever in LEFT turn position. Terminal for wire 45L-BN to ground



NOTE: Put driving lamp switch (95) in position 2 or 3. Terminal for wire 18F-BN to ground

24 volts

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

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-95

101 – Left Hand Rear Combination Lamp (Europe Only) Check Points

Correct Reading


NOTE: Disconnect wiring harness connector LLR-E from LH rear combination lamp connector. Combination lamp connector pin 1 to pin 5

Continuity

Bad stop lamp bulb.


Continuity

Bad turn lamp bulb.


Continuity

Bad tail lamp bulb.


Continuity

Bad reverse lamp bulb.

NOTE: Connect wiring harness connector LLR-E to LH rear combination lamp connector. Terminal for wire 0-BT to ground

Continuity

Bad ground circuit.

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

24 volts


NOTE: Have assistant put transmission in reverse. Terminal for wire 35A-L to ground

24 volts

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

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



102 – License Plate Lamp (North America Only) Located on the right rear of the machine with combination lamp. Check Points

Correct Reading


Bulb

Continuity

Bad bulb.

Terminal for wire 0-JC to ground

Continuity

Bad ground circuit.

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

Bur 5-2750

24 volts

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

Issued 8-06

Printed in U.S.A.

4002-96

102 – License Plate Lamp (Europe Only) Located on the right rear of the machine with combination lamp. Check Points

Correct Reading


Bulb

Continuity

Bad bulb.

Terminal for wire 0-JC to ground

Continuity

Bad ground circuit.

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

24 volts

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

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



NOTE: Put the master disconnect switch and the ignition switch in the ON position and the park brake to the OFF position. Depress brake pedal once. Move the transmission shift lever to REVERSE. If machine is a TUV model, depress back-up alarm switch to turn LED ON (back-up alarm enabled). Terminal for wire 35A to ground

24 volts

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

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

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



NOTE: Put the master disconnect switch and the ignition switch in the ON position and the park brake to the OFF position. Depress brake pedal once. Move the transmission shift lever to REVERSE. If machine is a TUV model, depress back-up alarm switch to turn LED ON (back-up alarm enabled). Terminal for wire 35A to ground

24 volts

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

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-97

CAB WINDOW WASHER AND WIPER SYSTEM 110

109

111 107 108

112

104 106 113

105 BS06H241 / BS06H242

104.FRONT WIPER HIGH SPEED RELAY 105.WIPER CUT OUT RELAY 106.FRONT WIPER LOW SPEED RELAY 107.REAR WIPER/WASHER SWITCH 108.FRONT WIPER/WASHER SWITCH

109.FRONT WIPER MOTOR 110.REAR WIPER MOTOR 111.REAR WASHER MOTOR 112.FRONT WASHER MOTOR 113.DIODES


Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-98

104 – Front Wiper High Speed Relay Located in the cab access panel for fuses and relays. Check Points

Correct Reading


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

24 volts

Bad fuse ECA-F12, check circuit 19J, also check power relay module D (21).

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

Continuity 24 volts

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

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

24 volts

Bad wiper high speed relay.

105 – Front Wiper Cut Out Relay Located in the cab access panel for fuses and relays. Check Points

Correct Reading


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

24 volts

Check fuse ECA-F12, check circuit 19J, also check power relay module D (21).

Terminal for wire 63L-B to ground

24 volts

Bad wiper cut out relay.

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

Bur 5-2750

Continuity 0 volts

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

Issued 8-06

Printed in U.S.A.

4002-99

106 – Front Wiper Low Speed Relay Located in the cab access panel for fuses and relays. Check Points

Correct Reading


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

24 volts

Bad fuse ECA-F12, check circuit 19J, also check power relay module D (21).

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

24 volts

Bad wiper low speed relay.

NOTE: Put the front wiper switch in the HIGH position. Terminals for wire 63LC to ground Terminals for wire 63C3 to ground

Continuity 24 volts

Bad front wiper and washer switch (108). Bad wiper low speed relay, also check high speed wiper relay (104).

107 – Rear Wiper and Washer Switch Located on right side console. Check Points Terminal for wire 0-B23 to ground



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

24 volts

Bad fuse ECA-F13 or power relay module D (21). Also check circuit 19K.

Terminal for wire 19K-A to ground

24 volts

Bad fuse ECA-F13 or power relay module D (21). Also check circuit 19K.

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

24 volts

Bad rear wiper and washer switch.

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

24 volts

Bad rear wiper and washer switch.

NOTE: Put the driving lamp switch in position 3.

Terminal for wire 49-C to ground

Bur 5-2750

24 volts

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

Issued 8-06

Printed in U.S.A.

4002-100

108 – Front Wiper and Washer Switch Located on right side console. Check Points Terminal for wire 0-DT to ground



NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the front wiper and washer switch is in the OFF position. Terminal for wire 19J-B to ground

24 volts

Check fuse ECA-F12, check circuit 19J, also check power relay module D (21).

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

Continuity

Bad front wiper and washer switch also check grounding circuit.

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

Continuity

Bad front wiper and washer switch also check grounding circuit.

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

Bur 5-2750

24 volts

Bad front wiper and washer switch.

Issued 8-06

Printed in U.S.A.

4002-101

109 – Front Wiper Motor Located in front of steering column. Check Points Terminal for wire 0-B8 to ground



NOTE: Make sure the front wiper and washer switch (108) is in the OFF position. Between terminals B and D for wires 63C and 63L

Continuity

Bad front wiper motor.

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

24 volts

Check fuse ECA-F12, also check circuit 19J.

NOTE: Put the front wiper and washer switch (108) in the LOW position. Terminal for wire 63L-A to ground Terminal for wire 63C to ground

24 volts 0 volt

Check fuse ECA-F12, also check circuit 19J. Bad front wiper and washer switch (108), low speed relay or cut out relay. Bad front wiper and washer switch (75)

NOTE: Put the front wiper and washer switch (108) in the HIGH position. Terminal for wire 63H-A to ground Terminal for wire 63C to ground

24 volts 0 volt

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

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

24 volts pulse

Bad front wiper and washer switch (108).


24 volts pulse

Bad front wiper and washer switch (108).

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-102

110 – Rear Wiper Motor Located in top of rear cab head liner. Check Points Terminal for wire 0-MA to ground



NOTE: Make sure the rear wiper and washer switch (107) is in the OFF position. Between terminals for wires 68C-A and 68L-A

Continuity

Bad rear wiper and washer switch (107).

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

24 volts

Check fuse ECA-F13, also check circuit 19K.

NOTE: Put the rear wiper and washer switch (107) in the ON position. Terminal for wire 68C-A to ground

24 volts


Terminal for wire 68L-A to ground

0 volt


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

111 – Rear Washer Pump Motor Located in left side engine compartment. Check Points Terminal for wire 0-BL to ground



NOTE: Put master disconnect switch and ignition switch in ON position. Depress and hold rear wiper and washer switch (107) in WASH position. Terminal for wire 68W-A to ground

24 volts

Bad rear wiper and washer switch (107) Also check wires 68W-A and 68W.

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

112 – Front Washer Pump Motor Located in left side engine compartment. Check Points Terminal for wire 0-B to ground



NOTE: Put the master disconnect switch and the ignition switch in the ON position. Connect volt meter to check point then push down on front wiper and washer switch (108). Terminal for wire 63W-A to ground

24 volts

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

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-103

113 – Wiper Diodes Located in the cab access panel for fuses and relays, rear of compartment. Check Points

Correct Reading


NOTE: Disconnect wiring harness connector 140M from diode connector. Multimeter positive on pin A to pin C

None

Bad diode.


None

Bad diode.

Multimeter positive on pin D to pin C

None

Bad diode.

Multimeter positive on pin E to pin C

None

Bad diode.

Multimeter positive on pin F to pin C

None

Bad diode.


Continuity

Bad diode.


Continuity

Bad diode.

Multimeter positive on pin C to pin D

Continuity

Bad diode.

Multimeter positive on pin C to pin E

Continuity

Bad diode.

Multimeter positive on pin C to pin F

Continuity

Bad diode.

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-104

SECONDARY STEERING

114 116

118

115 117 BS06H241 / BS06H242

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

117.SECONDARY STEERING MOTOR 118.SECONDARY STEERING PRESSUR SWITCH


Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-105

114 – Secondary Steering Diodes Located in the cab access panel for fuses and relays, rear of compartment. Correct Reading

Check Points


NOTE: Disconnect wiring harness connector DM from diode connector. Multimeter positive on pin A to pin C

None

Bad diode.


None

Bad diode.


Continuity

Bad diode.


Continuity

Bad diode.

115 – Secondary Steering Solenoid (Option) Located in the rear frame of the machine. Check Points

Correct Reading


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

36 to 42 ohms

Between pin 2 of connector YSS and ground

Continuity

Bad secondary steering solenoid.

Bad ground circuit.

NOTE: Disconnect wire 51-B from secondary steering motor relay; make sure that wire does not touch any metal part of machine during the remainder of this check. Put the master disconnect switch in ON position. Start and run engine for two or three minutes while turning steering wheel left and right several times. DO NOT TURN STEERING WHEEL TO STEERING STOPS. Turn ignition switch to OFF position to stop engine, then immediately to ON position. Between pin 1 of connector YSS and ground

Bur 5-2750

24 volts

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

Issued 8-06

Printed in U.S.A.

4002-106

116 – Secondary Steering Module (Option) Located in the rear frame of the machine. Check Points

Correct Reading


NOTE: Disconnect the wiring harness connector SSM from the secondary steering module.

Pin 2 of connector SSM to ground

Continuity

Bad relay on secondary steering motor (117) or bad secondary steering solenoid (115). Also Check wires 51-A, 51-B, and 51-C and ground circuit connections (wires 0-ND and 0-CF).


Continuity

Bad ground circuit.


Continuity

Bad secondary steering pressure switch (118). Also check wires 35X-D, 35X-C, and 35X-A.


Open Circuit


Continuity

Bad ground circuit.


Continuity

Bad ground circuit.

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

NOTE: Put the master disconnect switch and the ignition switch in ON position. Pin 3 of connector SSM to ground

24 volts

Bad wire 19S1-X to power relay module A fuse 2 (13).


24 volts

Bad fuse ECA-F17 or ignition switch. Also check circuit 19M.


24 volts

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

NOTE: Start and run engine at idle speed. Pin 9 of connector SSM to ground

Continuity


11 volts

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

NOTE: Put ignition switch in OFF position to stop engine. Connect wiring harness connector SSM to secondary steering module. Disconnect wire 51-B from secondary steering motor (117) relay terminal. Start and run engine at idle speed. Disconnect wiring harness connector PSS from secondary steering pressure switch (118). Apply a ground to pin C of connector PSS. Terminal for wire 51-B to ground

Bur 5-2750

24 volts

Bad secondary steering module.

Issued 8-06

Printed in U.S.A.

4002-107

117 – Secondary Steering Motor (Option) Located in the rear frame of the machine. Check Points

Correct Reading


Motor ground stud to ground

Continuity

Bad ground circuit.

Secondary steering motor relay ground terminal to ground

Continuity

Bad ground circuit.

Terminal for wire 51-B to ground.

10 to 45 ohms

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

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

24 volts


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

Terminal for wire 51-B to ground

24 volts

Check fuses ECA-F4 and F17, secondary steering module (116), and secondary steering pressure switch (118). If 24 volts is obtained the secondary steering motor is bad. If fuse ECA-F4 or F17 was replaced: if fuse F4 blows again, secondary steering module is bad; if fuse F17 blows again, secondary steering module is bad or secondary steering motor relay or secondary steering solenoid is shorted.

118 – Secondary Steering Pressure Switch (Option) Located in the cab access panel for fuses and relays, rear of compartment. Check Points

Correct Reading


NOTE: Disconnect wiring harness connector PSS from secondary steering pressure switch. Pressure switch pin B to pin C

Continuity

Bad secondary steering pressure switch.

Pressure switch pin B to pin A

Open Circuit


Pressure switch pin A to pin C

Open Circuit


NOTE: Start and run engine at idle speed. Pressure switch pin B to pin A

Continuity


Pressure switch pin B to pin C

Open Circuit


Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-108

CAN COMMUNICATION

119

BS06H241 / BS06H242

119.DIAGNOSTIC CONNECTOR


Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-109

119 – CAN Communication Diagnostics Connector Located in the cab access panel for fuses and relays. Check Points

Correct Reading

Terminal A for wire 0-DH to ground

Continuity

Terminal B for wire 18K-A to ground

24 volts

Bur 5-2750

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

Issued 8-06

Printed in U.S.A.

4002-110

RADIO AND POWER CONVERTER 125

122 123

124

120 121 BS06H241 / BS06H242

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

123.RADIO 124.RIGHT SPEAKER 125.LEFT SPEAKER


Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-111

120 – Power Relay Module E Located in the cab access panel for fuses and relays. Check Points Terminal for wire 0-DL to ground



NOTE: Put the master disconnect switch in the ON position. Turn ignition switch to the Accessory or the ON position. Terminal for wire PRM-E BUSS to ground

24 volts


Terminal for wire 19L to ground

24 volts

Bad power relay module E, bad fuse F1.

121 – Power Converter 24 volts to 12 volts (Option) Located in the cab access panel for fuses and relays. Check Points Terminal for wire 0-EJ to ground



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

24 volts

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

Terminal for wire 12V-C to ground

12 volts

Bad power converter.

122 – Power Outlet (Option) Located in the cab. Check Points

Correct Reading

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

Continuity

Terminal for wire 12V or 12V-A to ground

12 volts


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

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-112

123 – 12 Volt Radio Ready (Option) Located in the cab. Check Points

Correct Reading

Terminal in radio connector for wire 0-EN to ground

Continuity


Bad ground circuit.

NOTE: Put master disconnect switch and ignition switch in ON position. Terminal in radio connector for wire 12V-HA to ground

12 volts

Check fuse ECD-F6, also check circuit 12V. Also check the remote radio power converter (121).

124 – Right Speaker (Option) Located in the cab. Check Points

Correct Reading


NOTE: Disconnect connector from right speaker. Put master disconnect switch and ignition switch in ON position. Turn radio (123) on. Put balance control for RH and LH speakers to center position. Pin 1 in wiring harness connector RSPK to ground

Voltage

Pin 2 in wiring harness connector RSPK to ground

Continuity

Bad circuit between the right speaker and the radio or a bad radio (123). Bad circuit between the right speaker and the radio (123).

NOTE: If the readings are good, replace the right speaker.

125 – Left Speaker (Option) Located in the cab. Check Points

Correct Reading


NOTE: Disconnect connector from left speaker. Put master disconnect switch and ignition switch in ON position. Turn radio (123) on. Put balance control for RH and LH speakers to center position. Pin 1 in wiring harness connector LSPK to ground

Voltage

Pin 2 in wiring harness connector LSPK to ground

Continuity

Bad circuit between the left speaker and the radio or a bad radio (123). Bad circuit between the left speaker and the radio (123).

NOTE: If the readings are good, replace the left speaker.

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-113

AIR SEAT - CIGAR LIGHTER - AIR CONDITIONING COMPRESSOR 130

126

129 127

128 BS06H241 / BS06H242

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

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


Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-114

126 – Seat Compressor and Switch (Option) Located in the cab. Check Points Terminal for wire 0-DK to ground



NOTE: Put the master disconnect switch and the ignition switch in the ON position. Terminal for wire 19N at seat switch

24 volts

Check fuse ECA-F16 and power relay module A (13). Also check wire 19N.

NOTE: Put the seat compressor switch in the ON position. Terminal for wire from seat switch at compressor

24 volts

Bad seat switch, also check circuit from seat switch to compressor.

NOTE: If the readings are good replace the seat compressor.

127 – Cigar Lighter (Option) Located in the cab. Check Points

Correct Reading

Terminal for wire 19W to ground

24 volts

Terminal for wire 0-DV to ground

Continuity

Possible Cause of Bad Reading Check fuse ECC-F8, also check circuit 19W. Bad ground circuit.

NOTE: If the readings are good replace the cigar lighter.

128 – Compressor Clutch Relay Located in the cab access panel for fuses and relays. Check Points Terminal for wire 0-DJ to ground



NOTE: Put master disconnect switch and ignition switch in ON position. Put blower switch (149) to HIGH and thermostat switch to COLD. Terminal for wire 61R-B to ground

24 volts

Check thermostat switch, also check wire 61R-B.


24 volts

Bad compressor clutch relay.

NOTE: Put ignition switch in OFF position. Disconnect wiring harness connector PR from A/C trinary pressure switch. Connect a jumper wire between pins A and B of connector PR. Put ignition switch in ON position. Terminal for wire 61R-C to ground

Bur 5-2750

24 volts

Check wires 61R-B and 61R.

Issued 8-06

Printed in U.S.A.

4002-115

129 – A/C High/Low Pressure Switch Located on the rear frame in front of the rear axle. Check Points

Correct Reading


NOTE: Put master disconnect switch and ignition switch in ON position. Put the blower switch (149) to HIGH and the thermostat switch to COLD. Terminal B for wire 61A to ground

24 volts

Check the thermostat switch, also check circuit 61A.

NOTE: Disconnect the wiring harness connector PR from the A/C trinary pressure switch. Between terminals of trinary pressure switch

Continuity

Bad A/C low pressure switch, also check refrigerant charge level. (Pressure must be above 2.75 bar (40 psi) or below 26 bar (377 psi) for switch to be closed.)

130 – Compressor Clutch Located on the left side of the engine. Check Points

Correct Reading


NOTE: Put master disconnect switch and ignition switch in ON position. Put blower switch (149) to HIGH and thermostat switch to COLD. Terminals for wire 61C-A to ground

Bur 5-2750

24 volts

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

Issued 8-06

Printed in U.S.A.

4002-116

CLIMATE CONTROL - AUTOMATIC TEMPERATURE CONTROL 135 136 137 140 141 137

131

139 132 133 134 138 142 BS06H241 / BS06H242

131.ELECTRONIC PANEL 132.EXTERNAL AIR TEMPERATURE SENSOR 133.INTERNAL AIR TEMPERATURE SENSOR 134.SUN SENSOR 135.BLOWER FAN RESISTOR 136.BLOWER MOTORS

137.THERMOCOUPLE SENSOR 138.MIXED AIR SENSOR 139.COMPRESSOR RELAY 140.RECYCLING MOTOR 141.ELETRONIC WATER VALVE 142.24 TO 12 VOLT CONVERTER


Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-117

131 – Electronic Panel Check Points

Correct Reading


NOTE: No information at time of print.

132 – External Air Temperature Sensor Check Points

Correct Reading



133 – Internal Air Temperature Sensor Check Points

Correct Reading


Correct Reading


Correct Reading


Correct Reading


Correct Reading


Correct Reading



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

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

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

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

138 – Mixed Air Sensor Check Points NOTE: No information at time of print. Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-118

139 – Compressor Relay Check Points

Correct Reading


Correct Reading


Correct Reading


Correct Reading



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

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

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-119

STANDARD CLIMATE CONTROL 143 144 145 146 147 148 137

149 150 151 152 153

BS06H241 / BS06H242

143.AIR RECIRCULATION MOTOR 144.DRIVER 145.ELETRONIC WATER VALVE 146.BLOWER FAN RESISTOR 147.BLOWER MOTOR 148.THERMOSTAT

149.FAN SPEED SWITCH 150.AIR CONDITIONING SWITCH 151.CONTROL PANEL LIGHTS 152.WATER VALVE POTENTIOMETER 153.AIR RECIRCULATING SWITCH


Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-120

143 – Air Recirculation Motor Check Points

Correct Reading


Correct Reading


Correct Reading



144 – Driver Check Points NOTE: No information at time of print.

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

146 – Blower Motor Speed Resistors with Thermal Fuse Check Points

Correct Reading


NOTE: Disconnect the wiring harness connector DNS RESISTOR from the resistor. Between terminals 1 and 4 of blower motor connector

Approximately x.x ohms

Bad blower motor resistor.

Between terminals 2 and 4 of blower motor connector



Between terminals 3 and 4 of blower motor connector



147 – Blower Motor Check Points

Correct Reading

Terminals for wire DNS66 to ground

Continuity


NOTE: Put the master disconnect switch and the ignition switch in the ON position. Turn the blower switch (149) to position 4. Terminal for wire DNS65 to ground

24 volts

Check the blower switch (149).

NOTE: If the readings are correct and the blower motor does not run, replace the blower motor. Turn the blower switch (149) to position 1. If the blower motor ran in position 4 but not in position 1, 2,or 3, check the blower motor resistor (146).

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-121

148 – Thermostat Check Points

Correct Reading


Correct Reading



149 – Blower Switch Check Points

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Terminal for wire DNS74 to ground

24 volts

Check fuse ECA-F11.

NOTE: Turn the blower switch to position 1. Terminal for wire DNS61 to ground

24 volts

Bad blower switch.


24 volts

Bad blower switch.


24 volts

Bad blower switch.


24 volts

Bad blower switch.

150 – Air Conditioning Switch Check Points

Correct Reading


Correct Reading



151 – Control Panel Lights Check Points NOTE: No information at time of print.

152 – Water Valve Potentiometer Check Points

Correct Reading



Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-122

153 – Air Recirculating Switch Check Points

Correct Reading



Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-123

HOOD RAISE AND LOWER SYSTEM

157

156

154 155 BS06H241 / BS06H242

154.HOOD UP RELAY 155.HOOD DOWN RELAY

156.HOOD SWITCH 157.HOOD MOTOR


Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-124

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



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

24 volts

Check fuse ECC-F7, check circuit 19Y.

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

24 volts

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

Terminal for wire 60U

24 volts

Bad hood up relay.

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



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

24 volts


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

24 volts

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

Terminal for wire 60D

24 volts

Bad hood down relay.

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

Correct Reading


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

24 volts


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

Continuity

Bad hood switch.

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

Continuity

Bad hood switch.

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-125

157 – Hood Motor Located in the left side of the engine compartment. Check Points

Correct Reading


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

24 volts

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

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

24 volts

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

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-126

CONNECTORS CONNECTOR 108F - DIAGNOSTIC CONNECTOR

CONNECTOR 197F - MAIN CAB FNR

291663A1

CAV

WIRE IDENT

CIRCUIT

225350C1

CAV

WIRE IDENT

CIRCUIT

1

19A-W

Diagnostic Conn. Fused Power

1

19A-C

FNR Switch Fused Power

2

37D-A

Diagnostic Signal

2

26F-B

FNR Forward Signal

3

0-DAV

Diagnostic TECM Ground

3

26N-B

FNR Neutral Signal

4

37E


4

26R-B

FNR Reverse Signal

5

Not Used

5

32J-E

Trans Enable Indication Lamp

6

Not Used

6

25Y-B


CONNECTOR 140M - DIODE MODULE

CONNECTOR 197M - FNR MAIN CAB

225351C1 245488C1

CAV

WIRE IDENT

CIRCUIT

CAV

WIRE IDENT

1

19A-B

CIRCUIT FNR Switched Fused Power

A

63H-C

Front Wiper High Speed

2

26F-A

FNR Forward Signal

B

63L-C

Front Wiper Low Speed

3

26N-A

FNR Neutral Signal

C

0-EE

Diode Suppression Grounds

4

26R-A

FNR Reverse Signal

D

58-D

Ride Control Solenoid Power

5

32J-A

Trans Enable Indication Lamp

6

25Y-C


E

21D-B


F

68L-C


Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-127 CONNECTOR 202M - ROLLBACK JUMPER

CONNECTOR 20M - TRANSMISSION KICK-DOWN SWITCH

245482C1

CAV

WIRE IDENT

CIRCUIT

225316C1

A

58-A


CAV

B

58-A


1

19A-U

Trans Kick Down Switched Pwr

2

25Y-C


CONNECTOR 209F - BACKUP ALARM DISABLE JUMPER

WIRE IDENT

CIRCUIT

CONNECTOR 215F - ALTERNATOR RESISTOR

199436A1

245481C1

CAV A

WIRE IDENT 35A-E

CAV

CIRCUIT

1


CONNECTOR 209M - BACKUP ALARM DISABLE JUMPER

WIRE IDENT 14-A

CIRCUIT Alternator D+

CONNECTOR 216F - ALTERNATOR RESISTOR

199436A1 245480C1

CAV A

WIRE IDENT 35A-D

B

Bur 5-2750

CIRCUIT

CAV 1

WIRE IDENT 19R-D

CIRCUIT Alternator Resistor Fused Pwr

Backup Alarm Relay Out Not Used

Issued 8-06

Printed in U.S.A.

4002-128 CONNECTOR 64F - FLASHER CONNECTOR

CONNECTOR AIC1 - ADV INSTRUMENT CLUSTER 1

245481C1

CAV 1

WIRE IDENT 45N-A

CIRCUIT Flasher Optional Side Control 87419488

CAV

CONNECTOR 64M - FLASHER CONNECTOR

245480C1

CAV 1

WIRE IDENT 45N-B

CIRCUIT Flasher Optional Side Control

CONNECTOR ACT - AIR CONDITIONING COMPRESSOR CLUTCH

WIRE IDENT

1

13V


2

36F-A

Fuel Level ANALOG

3

CAN-HG

CAN High

4

CAN-LG

CAN Low

5

36A

Rear Axle Temperature

6

0-DX

AIC Sensor Ground

7

43-A


8

36B

Front Axle Temperature

9

36H-A

Hydraulic Oil Temperature

10

Not Used

11

36C-A

Radiator Coolant Temp Signal

12

0-DW

AIC Power Ground

13

35B

AIC Buzzer HSD

14

52C

Park Brake Solenoid LSD

15

44A-B


16

51S


17

51CS

Comfort Steering Switch

18

8602417

CAV 1

WIRE IDENT 61C-A

CIRCUIT AC relay out

Not Used

19

28J

Ether AIC OK Signal

20

53C-A

Pilot Control Solenoid LSD

21

51C

Comfort Steering Control

22 23

Not Used 52

24

Bur 5-2750

CIRCUIT

Fan Reverser LSD Not Used

25

17P-A

Switch Pad Pwr From AIC Pwr

26

56

Fan Control PWM

Issued 8-06

Printed in U.S.A.

4002-129 CONNECTOR AIC2 - ADV INSTRUMENT CLUSTER 2

CONNECTOR BUZ - AIC BUZZER

222136A1 87410948

CAV

WIRE IDENT

1 2

CIRCUIT Not Used

43S-C

Door Open Signal

4

33R

Redundant Brk Accm Press Low

5

33P-A

Brake Low Pressure Warning

6

33U

Park Brake Switch

7

52M

Fan Reverse Manual

8

52AU

Fan Reverse Auto

9

45L-E

Left Turn Signal

10

45R-C

Right Turn Signal

11

35X

Sec. Steering Low Press Signal

3

WIRE IDENT

CIRCUIT

1

35B

AIC Buzzer HSD

2

0-B27

Buzzer Ground

Not Used

12

Not Used

13

Not Used

14

19S-D

AIC Delay Fused Power

15

0-DB


16

57-C

Pin Engage Solenoid Power

17

21K-A

Ignition Switch Start Signal

18

31L


19

Not Used

20

19S-C


21

19E-A

AIC Wake Up Ignition

22

0-DA

AIC Chassis Ground

23

Not Used

24

Not Used

25

Not Used

26

CAV

31D-A

Bur 5-2750


Issued 8-06

Printed in U.S.A.

4002-130 CONNECTOR CAB-E - CAB TO ENGINE

CAV

WIRE IDENT

CIRCUIT

37

59D

Hood Down Relay Control

38

60U

Hood Up Relay Out

39

59U

Hood Up Relay Control

40

35A-F


225415C1

CAV

WIRE IDENT

CIRCUIT

1

21C-C


2

61C

AC Relay Out

3

21G

EDC7 Crank Control Relay

4

21H

Crank Control Relay LSD

5

18F-A


6

Not Used

7

35A-C


8

44A-C


9

18G-F


10

45L-B

Left Turn Signal

11

21F

EDC7 Digital Ground

12

45R-B

Right Turn Signal

13

18R-A


14

18J-G


15

21D-C


16

28H

Ether Switch Signal

17

0-DX

AIC Sensor Ground

18

18J


19

0-DW

AIC Power Ground

20

0-DB


21

13C-B


22

52A-A

Fan Reverse Relay Out

23

56

Fan Control PWM

24

68W

Rear Washer Pump

25

63W

Front Washer Pump

26

14-A

Alternator D+

27

21E

Key Switch Crank

28

31F-A

Air Filter Restriction Sw Signal

29

61R-B

AC Relay Control

30

61A-B

Trinary Pressure Switch Input

31

20G-B

EDC7 ISO-K Interface

32

36A


33

36F-A

Fuel Level ANALOG

34

36C-A


35

19Y-C

Hood Switch Fused Power

36

60D

Hood Down Relay Out

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-131 CONNECTOR CAB-F - CAB FRONT CHASSIS

CONNECTOR CAB-RF - CAB TO ROOF CONNECTION

388710A1

CAV

1

43-A


B

42R-C

Rear Work Light Fused Power

Left Turn Signal

C

42C-A

Front Work Lights Fused Power

19U-D

Dome Light Fused Power

WIRE IDENT 45L-C

CIRCUIT

A

291661A1

CAV

WIRE IDENT

CIRCUIT

2

51B-C

Comfort Steering Solenoid Pwr

D

3

45R-D

Right Turn Signal

E

46-C

Beacon Switch Power

Not Used

F

0-DR

Roof Splice Grounds

Position RH Fused Power

G

0-DS

Roof Splice Grounds

19K-C

Rear Wiper Motor Fused Power

4 5

18G-G

6

18F-E

Position LH Fused Power

J

7

18B-A

High Beam LH Fused Power

K

68C


8

36B


L

68L-B


9

O-DY

Front Axle Temperature Ground

M

0-EM

Radio Ground

Not Used

N

12V-B


10 11

54B-A

Height-RTT Signal

R

43S-A

Door Open Signal

12

53B-B

RTD Signal

S

19U-G

Door Switch Fused Power

13

64A

Horn Power

14

18D-A

Low Beam LH Fused Power

15

18E-A

Low Beam RH Fused Power

16

18C-A

High Beam RH Fused Power

17

Not Used

18

Not Used

19

53P-F


20

57-A

Pin Engage Sol Pwr

21

58-C


22

1-DR

Brake Lamp Switch Power

23

44-A

Brake Lamp Control Power

24

52P-A

Park Brake Relay Out

25

Not Used

26

33P-A

Low Brake Pressure Warning

27

19A-T

Brake Declutch Switch Fused Power

28

25G-A

Brake Declutch Switch Control

29

Not Used

30

Not Used

31

Not Used

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-132 CONNECTOR CAB-T - CAB TO TRANMISSION

CONNECTOR CAN - CAN BULK HEAD

380839A1

CAV

WIRE IDENT

CIRCUIT

1

33R

Front Brake Accumulator Pressure Low

2

31D-A


3

19M

Secondary Steering Accessory Fused Power

4

19R-E

Sec. Steering Ignition Fused Power

A

CAN-HA

CAN High

36T-A

Valve Body Temp Signal

B

CAN-LA

CAN Low

6

35X

Secondary Steer Low Press Signal

7

25A-A

Engine Speed Signal

8

25C-A

Turbine Speed Signal

9

25B-A

Intermediate Speed Signal

10

25D-A

Output Speed Signal

5

11

0-DM

Speed Sensor Ground

12

36R-E

Trans Temp/Filter Return

13

36G-A

TCO Temp Signal

14

CAV

WIRE IDENT

CIRCUIT

CONNECTOR CAN2 - CAN BULK HEAD

Not Used

15

Not Used

16

25K-A

Trans Solenoid Valve Y1

17

25L-A


18

25M-A


19

25N-A


20

25P-A


21

25J-A


22

25S-A


23

31H-A

Hyd Filter Restriction Switch Sig

24

Not Used

25

Not Used

26

87315266

19S1

27

87315267

CAV

WIRE IDENT

CIRCUIT

A

CAN-H

CAN High

A

CAN-HJ

CAN High From Engine

B

CAN-L

CAN Low

B

CAN-LM

CAN Low From Engine

Sec. Steering Fused Power Not Used

28

0-DN


29

19A-M

Output Speed Sen. Fused Pwr

30

36H-A

Hydraulic Oil Temp

31

32F-A

Trans Filter Maint Switch

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-133 CONNECTOR CL - CIGAR LIGHTER

CONNECTOR D-OR - DIODE OR

245485C1

CAV 3227856R1

CAV

WIRE IDENT

CIRCUIT

1

19W

Cigar Lighter Fused Power

2

0-DV

Cigar Lighter Ground

WIRE IDENT

CIRCUIT

A

42C-D


B

41T-C

Position Lights Switched Power

C

49

Back Light Power

CONNECTOR DIA - DIAGNOSTIC

CONNECTOR CLS - COOL JUMP - COOL SEND

194788A1

CAV A

WIRE IDENT 31D

B

0-HV

CIRCUIT

310057A1


CAV

Coolant Level Sender Ground

A

0-DH

Ground

B

18K-A

Diagnostics Fused Power

C

CAN-HB

Controller Area Network High

D

CAN-LB

Controller Area Network Low

E

20G-B


CONNECTOR CNV - 24V TO 12V POWER CONVERTER

WIRE IDENT

CIRCUIT

CONNECTOR DISC - DISCONNECT ENGINE

225351C1

CAV 1

WIRE IDENT

CIRCUIT

19L-A

Power Converter Fused Power

2

19L-B

Power Converter Fused Power

3

0-EJ


CAV

Not Used

A

13C


B

13M


4 5

12V-C

12V Switched Power

6

0-ER


Bur 5-2750

245482C1

WIRE IDENT

CIRCUIT

Issued 8-06

Printed in U.S.A.

4002-134 CONNECTOR DM - DIODE OR

CAV

WIRE IDENT

21

DNS7

23

DNS12

26

DNS19

CIRCUIT

CONNECTOR DNS-COMPRESSOR-RELAY

245485C1

CAV A

WIRE IDENT 19RR

B C

CIRCUIT Sec. Steering Ignition Fused Pwr Not Used

19R

Sec. Steering Ignition Fused Pwr

CAV

WIRE IDENT

85

DNS19

86

DNS20

30

DNS16

87

DNS14

CIRCUIT

CONNECTOR DNS-AC-SWITCH CONNECTOR DNS-EXTERNAL-AIR-TEMP-SNS

CAV 1

WIRE IDENT

CIRCUIT CAV

DNS72

2

DNS68

4

DNS71

DNS2

2

DNS1

WIRE IDENT

5

DNS48

6

DNS49

CIRCUIT

CONNECTOR DNS-HVAC-CAN1

CONNECTOR DNS-ACTUATOR

CAV

WIRE IDENT

1

CIRCUIT

CONNECTOR DNS-BLUE - ATC CONTROL PANEL 225294C1

CAV CAV

WIRE IDENT

1

DNS8

3

DNS10

5

DNS11

6

DNS2

7

DNS4

9

DNS3

10

DNS6

14

DNS9

15

DNS31

16

DBS13

17

DNS18

Bur 5-2750

CIRCUIT

WIRE IDENT

A

DNS9

B

DNS8

CIRCUIT

Issued 8-06

Printed in U.S.A.

4002-135 CONNECTOR DNS-NOT-USED

CONNECTOR DNS-HVAC1

225326C1 225294C1

CAV

WIRE IDENT

CIRCUIT

CAV

WIRE IDENT

1

DNS12

A

DNS14

2

DNS10

B

DNS15

3

DNS11

C

DNS13

CONNECTOR DNS-YELLOW - ATC CONTROL PANEL

CONNECTOR DNS-HVAC2

CAV

225315C1

CAV

WIRE IDENT

CIRCUIT

WIRE IDENT

1

DNS25

2

DNS24

5

DNS47

6

DNS43

8

DNS44

9

DNS21

1

DNS36

10

DNS23

2

DNS35

14

DNS28

15

DNS26

16

DNS22

17

DNS27

18

DNS29

21

DNS22

23

DNS45

24

DNS46

CONNECTOR DNS-INTERNAL-AIR-TEMP-SNS

CAV

WIRE IDENT

1

DNS4

2

DNS3

3

DNS17

4

DNS5

Bur 5-2750

CIRCUIT

CIRCUIT

CIRCUIT

Issued 8-06

Printed in U.S.A.

4002-136 CONNECTOR DNS-PWM-BLOWER-PIN4

CONNECTOR DNS-VOLTAGE-CONVERTER

CAV

WIRE IDENT

1

DNS34

2

DNS33

3

DNS32

4

DNS31

CIRCUIT

CONNECTOR DNS-ELECT-WATER-VALVE HIRSCHMANN 772717-001

CAV

WIRE IDENT

CIRCUIT

1

DNS38

CAV

2

DNS47

1

DNS30

3

DNS37

2

DNS29

3

DNS28

4

DNS27

6

DNS26

CONNECTOR DNS-PWM-BLOWER-PIN2

CAV

WIRE IDENT

1

DNS41

2

DNS42 CAV

CAV

WIRE IDENT

1

DNS41

2

DNS42

CIRCUIT

CIRCUIT

CONNECTOR DNS-RECYCLING-MOTOR

CIRCUIT

CONNECTOR DNS-PWM-BLOWER

WIRE IDENT

WIRE IDENT

1

DNS21

2

DNS22

3

DNS23

5

DNS24

6

DNS25

CIRCUIT

CONNECTOR DNS-SPEED-SELECTOR CONNECTOR DNS-THERMOCOUPLE-SENSO CAV CAV 1

WIRE IDENT

CIRCUIT

DNS46

2

DNS40

WIRE IDENT

1

DNS74

2

DNS61

3

DNS62

4

DNS63

5

DNS73

CIRCUIT

CONNECTOR DNS-MIXED-AIR-SENSOR

CAV

WIRE IDENT

1

DNS39

2

DNS45

Bur 5-2750

CIRCUIT

Issued 8-06

Printed in U.S.A.

4002-137 CONNECTOR DNS-CTRL-PANEL-LIGHT

CAV

WIRE IDENT

CIRCUIT

CONNECTOR DNS-RESISTOR

CAV

WIRE IDENT

1

DNS69

1

DNS61

2

DNS70

2

DNS62

3

DNS63

4

DNS64

CIRCUIT

CONNECTOR DNS-WATER-VALVE-POT CONNECTOR DNS-ELECT-WATER-VALVE-S CAV

WIRE IDENT

1

DNS55

2

DNS54

CIRCUIT CAV

CONNECTOR DNS-RECIRCULATING-SWITCH

CAV

WIRE IDENT

1

DNS51

2

DNS53

WIRE IDENT

1

DNS60

3

DNS56

4

DNS57

5

DNS58

6

DNS59

CIRCUIT

CIRCUIT

CONNECTOR DNS-DRIVER

CONNECTOR DNS-THERMOSTAT-1

CAV 1

WIRE IDENT

CIRCUIT

DNS67

CAV

CONNECTOR DNS-THERMOSTAT-2

CAV 1

WIRE IDENT

CIRCUIT

DNS68

CONNECTOR DNS-ELECTRIC-FAN

CAV

WIRE IDENT

1

DNS65

2

DNS66

Bur 5-2750

411311A1

CIRCUIT

WIRE IDENT

2

DNS50

3

DNS52

4

DNS49

5

DNS48

6

DNS55

7

DNS57

8

DNS58

9

DNS59

11

DNS51

12

DNS53

13

DNS54

14

DNS56

CIRCUIT

Issued 8-06

Printed in U.S.A.

4002-138 CONNECTOR DNS-HVAC1-S

CONNECTOR DS - DOOR SWITCH

245482C1 225294C1

CAV A

WIRE IDENT

CAV

CIRCUIT

DNS67

B

DNS76

C

DNS69

WIRE IDENT

CIRCUIT

A

19U-F


B

43S-B

Door Open Signal

CONNECTOR E-HD - TRANSMISSION HOOD CONNECTOR DNS-HVAC2-S

245485C1

CAV 225315C1

CAV

WIRE IDENT

1

DNS74

2

DNS75

Bur 5-2750

CIRCUIT

WIRE IDENT

CIRCUIT

A

18G-D

Lic Plate Light Fused Power

B

35A-G


C

0-BAG

Hood Ground (EURO)

Issued 8-06

Printed in U.S.A.

4002-139 CONNECTOR ECA - ELECTRICAL CENTER A

87315248

CAV CAV

WIRE IDENT

CIRCUIT

WIRE IDENT

CIRCUIT

L1

J6

Pltem Dtnts Park Brake Sol

J7

Park Brake Solenoid Horn

A1

19A-N

Transmission Fused Power

L1

A2

18L-A

Comfort Steering Fused Power

L1

J8

Fan Reverse/Turn Signal

A3

19E-A

AIC Wake Up Ignition

L1

J9

Turn Signal Engine Shutdown

A4

19RR


L2

J11

Blower Motor Power

L2

J12

Blower Mtr Front Wiper Washer

A5

19C-A

Pilot Control Relay Fused Pwr

L2

J13

Front Wiper Rear Wiper Washer

A6

19D-A

Park Brake Relay Fused Power

L2

J14

Rear Wiper Washer Backup

A7

19P

Pin Engage/Fan Fused Power

L2

J15

Backup AC

A8

19B


L2

J16

AC Seat Compressor

A9

13C-B


C1

18N


L2

J18

Seat Compressor Emergency Steering

C2

19J

Front Wiper Fused Power

C3

19K

Rear Wiper Fused Power

C4

19H

Backup Alarm Relay Fused Pwr

C5

18M


C6

19N


C7

19M

Sec. Steering ACC Fused Pwr

L1

J1

Transmission ECM Power

L1

J2

Trans ECM Comfort Steering

L1

J3

Comfort Steering AIC Power

L1

J4

Emergency Steering AIC Pwr

L1

J5

Emergency Strg Plt Em Dtnts

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-140 CONNECTOR ECB - ELECTRICAL CENTER B

87312843

CAV CAV

WIRE IDENT

CIRCUIT

WIRE IDENT

CIRCUIT

B3

21K-B

Ignition Switch Start Signal Neutral Start Relay Control Gnd

A1

42FS

Front Work Lights Power

B4

0-DE

A2

42RS

Rear Work Lights Power

B5

21F

EDC7 Digital Ground

0-DF

Crank Request Relay Ctrl Gnd

A3

41H-B

High Beam LH Power

B6

A4

41H-C

High Beam RH Power

B7

19P-E

Fan Reverse Relay Fused Pwr

A5

41L-C

Low Beam LH Power

B8

52

Fan Reverser LSD

A6

41L-B

Low Beam RH Power

B9

19D-C

Park Brake relay Fused Pwr

52C

Park Brake Solenoid LSD

A7

41T-B

Position Lights LH Sw Power

B10

A8

41T-A

Position Lights RH Sw Power

D1

13K-C

Ignition Switch Power

A9

21H


D2

13V


A10

21C-B


D3

25T

Neutral Signal

21C


AA1

42C-C


D4

AA2

42R-C

Rear Work Lights Fused Power

D5

21C-A


AA3

18B-A

High Beam LH Fused Power

D6

21E

Key Switch Crank

AA4

18C-A

High Beam RH Fused Power

D7

19P-D


52A-A


AA5

18E-A

Low Beam RH Fused Power

D8

AA6

18D-A

Low Beam LH Fused Power

D9

19D-B

Park Brake Relay Fused Pwr

AA7

18F-C

Pos Tail Lights LH Fused Power

D10

52P-B


AA8

18G

Pos Tail Lights RH Fused Power

AA9

21D-A


AA10

21G


B1

18R-A


B2

0-DD

Voltmeter Relay control Ground

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-141 CONNECTOR ECC - WORK LIGHTS

87315249

CAV

WIRE IDENT

CIRCUIT

A1

19U-B

Beacon/Dome Lt Fused Pwr

A2

42

Work Lights Sw Fused Pwr

A3

19Z

Driving Lights Sw Fused Pwr

A4

1-DV

Brake Lts/Flasher Bat Pwr

A5

1DM

Time Delay/Ign Sw Fused Pwr

A6

19U


A7

19Y

Hood Control Fused Power

A8

19W

Cigar Lighter Fused Power

A9

18K-A

Diagnostic Fused Power

B1

60U

Hood Up Relay Out

CAV D4

WIRE IDENT 19Y-B

CIRCUIT Hood Down Relay Fused Power

D5

44-A

Brake Light Control Power

D6

44A-A


D7

19U-E

Horn relay Fused Power

D8

64-A

Horn Power

D9

18L-B


D10

51B-B


L1-1

ECC-L1

Beacon/Dome Lights LI ECC

L1-1

J2-ECC


L1-2

J2-ECC


L1-2

J3-ECC


B2

0-B25

Hood Up Control Ground

B3

60D

Hood Down Relay Out

L1-3

J3-ECC


B4

0-B16

Hood Down Control Ground

L1-3

J4-ECC


B5

1-DW

Brake Light Relay Bat Power

L1-4

J4-ECC


J5-ECC


B6

0-EF

Brake Light Relay Control Gnd

L1-4

B7

19U-A


L1-5

J5-ECC


B8

64C

Horn Relay Control

L1-5

J6-ECC

Delay Power Horn

B9

18L-C

Comfort Steering Fused Pwr

L1-6

J6-ECC

Delay Power horn

J7-ECC

Horn HOD Control

B10

51C

Comfort Steering Control

L1-6

C2

0-B22

Hood Up Relay Ground

L1-7

J7-ECC

Horn HOD Control

C4

0-B12

Hood Down Relay Ground

L1-7

J8-ECC


D1

59U


L1-8

J8-ECC


J9-ECC

Diagnostic Power

J9-ECC

Diagnostic Power

D2

19Y-A

Hood Up Relay Fused Power

L1-8

D3

59D


L1-9

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-142 CONNECTOR ECD - ELECTRICAL CENTER D

87312843

CAV CAV

WIRE IDENT

CIRCUIT

WIRE IDENT

CIRCUIT

B5

19C-B

Pilot Control Relay Fused Pwr

53C-A

Pilot Control Solenoid LSD

A1

13H-C

Trans ECM Time Delay Pwr

B6

A2

13H-D

Engine ECM Time Delay Pwr

B7

58T

Ride Control Relay Switch Pwr

A3

13H-B

AIC Time Delay Power

B8

58L


A4

12V-D

Plug 1 12V Switched Power

B9

18M


0-DJ


A5

12V-E

Plug 2 12V Switched Power

B10

A6

12V-F

Radio 12V Switched Power

C2

63C2


A7

12V-G

2 Way Radio 12V Sw Power

C4

63C


A9

35C


D1

19J-D

A10

19H

Backup Alarm Relay Fused Pwr

Front Wiper Relay HS Ctrl Fused Pwr

AA1

19T-A

TECM Delay Fused Power

D2

63H-B

Front Wiper HS Relay Out

AA2

18J-K


D3

19J-F

Front Wiper Relay LS Ctrl Fused Pwr

AA3

19S-B


D4

63C2


AA4

12V

12V Power to Outlet 1

D5

19C-C

Pilot control Relay Fused Pwr

AA5

12V-A

12V Power to Outlet 2

D6

53P-C


AA6

12V-B


D7

58H-A

Ride Ctrl Switched Pwr VPS2

AA9

35A-A


D8

58-E


19A-P

Backup Alarm Relay Ctrl Fused Pwr

D9

61R-B

AC Relay Control

D10

61C

AC Relay Out

AA10 B1

19J-E

Front Wiper Relay Fused Power

B2

63HC-B

Front Wiper HS Relay Control

B3

63C3


B4

63LC

Front Wiper LS Relay Control

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-143 CONNECTOR EDC7 - ENGINE CONTROLLER

CAV

WIRE IDENT

CIRCUIT

42

35W

Water In Fuel Indicator

48

24L

Low Idle Switch

75

0-BV

Grid Heater Control Ground

77

24S

Throttle Supply

78

24R

Throttle Ground

79

24B

Throttle Signal

89

20G-A


CONNECTOR EM - HEIGHT CONTROL RTD - RTT

225351C1

CAV

BOSCH-89-POLE

CAV

WIRE IDENT

CIRCUIT

1

55A-A

RTT/Float Switched Power

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


CIRCUIT

2

18J-C


3

18J-B


5

0-BE

EDC7 Ground

6

0-BF

EDC7 Ground

8

18J-D


9

18J-E


10

0-BD

EDC7 Ground

11

0-BC

EDC7 Ground

12

28G

Grid Heater Source DR

13

0-BN


17

21H-A


29

21F-B

EDC7 Digital Ground

32

21E-A

Key Switch Crank

34

CAN-L

CAN Low

35

CAN-H

CAN High

36

28F

Fuel Filter Heater Relay Control

37

21GA


40

13M-A


Bur 5-2750

WIRE IDENT

Issued 8-06

Printed in U.S.A.

4002-144 CONNECTOR ENG - ENGINE TO CAB

CAV

225414C1

CAV

WIRE IDENT

CIRCUIT

WIRE IDENT

CIRCUIT

30

61A


31

20G-A


32

36A-A


33

36F

Fuel Level ANALOG

34

36C


35

19Y-D


36

60D-A

Hood Down Relay Out

37

59D-A


1

21C-D

Starter Relay signal

38

60U-A

Hood Up Relay Out

2

61C-A

AC Relay Out

39

59U-A


2

61C-B

AC Relay Out

40

35A-G



40

35A-GN


3

21GA

4

21H-A


5

18F-AN

LH Position/Tail Fuse Power

5

18F-B

LH Position/Tail Fuse Power

6

CONNECTOR ENG-D - DISCONECT HARNESS

Not Used

7

35A-R


7

35A-J

Reverse Light

8

44A-D


8

44A-DN


9

18G-H

RH Position/Tail Fuse Power

9

18G-HN

RH Position/Tail Fuse Power

10

45L-A

Left Turn Signal

10

45L-AN

Left Turn Signal

11

21F-A

EDC7 Digital Ground

12

45R-A

Right Turn Signal

12

45R-AN

Right Turn Signal

13

18R


14

18J-F


15

21D


16

28E

Ether Relay Signal

17

0-BJ

AIC Sensor Ground

18

18J-A


19

0-BG

AIC Power Ground

20

0-BH


21

13C-A


22

52A-B


23

56-A

Fan Control PWM

24

68W-A

Rear Washer Pump

25

63W-A

Front Washer Pump

26

14

Alternator D+

27

21E-A

Key Switch Crank

28

31F

Air Filter Restriction Sw Signal

29

61R

AC Relay Control

Bur 5-2750

245483C1

CAV

WIRE IDENT

CIRCUIT

A

13C-A


B

13M-A


B

13M-B

Key Switch Power Disc Switch

Issued 8-06

Printed in U.S.A.

4002-145 CONNECTOR ENG-H - ENGINE TO HOOD

CONNECTOR ESS - ENGINE SPEED SENSOR

291718A1

CAV 225320C1

CAV

WIRE IDENT

CIRCUIT

1

0-BAG-N

2

44A-DN


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

7

35A-GN


8

35A-R


WIRE IDENT

CIRCUIT

1

25A

Engine Speed Signal

2

0-HF

Engine Speed Sensor Ground

Hood Ground (NA)

CONNECTOR FFH - FULE FILTER HEATER

CONNECTOR ENG-T - ENGINE TO TRANSMISSION 182069A1

CAV

WIRE IDENT

CIRCUIT

A

1-GB

Fuel Filter Heater Power

B

0-BX

Fuel Filter Heater Ground

225326C1

CAV

WIRE IDENT

CIRCUIT

1

0-BZ


2

0-BK

Transmission Splice Grounds

3

31D-C

Coolant Level Sender Eng Transmission

4

Bur 5-2750

Not Used

Issued 8-06

Printed in U.S.A.

4002-146 CONNECTOR FLSHR - FLASHER MODULE

CONNECTOR FRONT - CAB FRONT CHASSIS

225389C1

CAV

WIRE IDENT

CIRCUIT 373358A1

1

1-DU

Flasher Module Power

2

45N-A

Flasher Optional Side Control

3

0-EH


4

0-EG


5

Not Used

6 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 Optional Side Control

CONNECTOR FM - FILTER MAINTENANCE SWITCH

371614A1

1 2

WIRE IDENT 32F 36R-B

Bur 5-2750

WIRE IDENT

CIRCUIT Trans Filter Maint Sw Trans FM Switch Return

CIRCUIT

1

45L

Left Turn Signal

2

51B-D

Comfort Steering Sol Power

3

45R

Right Turn Signal

4

Not Used

CAV

CAV

Not Used

5

18G-A


6

18F


7

18B

LH High Beam Fused Power

8

36B-A


9

0-AR

Front Axle Temp Sensor GND

10

Not Used

11

54B

Height-RTT Control Signal

12

53B

RTD Control Signal

13

64

Horn Power

14

18D

LH Low Beam Fused Power

15

18E

RH Low Beam Fused Power

16

18C

RH High Beam Fused Power

17

Not Used

18

Not Used

19

53P-G


20

57

Pin Engage Sol Pwr

21

58-B


21

58S-E

Ride Control Solenoid to Front Cab

22

1-AA


23

44


24

52P

25

Park Brake Relay Out Not Used

26

33P

Low Brake Pressure Warning

27

19A-A

Brake Declutch Sw Fused Pwr

28

25G


29

Not Used

30

Not Used

31

Not Used Issued 8-06

Printed in U.S.A.

4002-147 CONNECTOR FWM - FRONT WIPER MOTOR

CONNECTOR FWW - FRONT WASHER

245715C1

CAV

WIRE IDENT

CIRCUIT

3227856R1

CAV

WIRE IDENT

CIRCUIT

A

63H-A

Front Wiper High Speed Rly Out

1

63W-A

Front Washer Pump

B

63L-A

Front Wiper Low Speed Rly Out

2

0-B

Front Washer Ground

C

19J-A

Front Wiper Motor Fused Power

D

63C


CONNECTOR GHC - GRID HEATER RELAY

CONNECTOR FWMG - FRONT WIPER MOTOR GROUND

3227856R1

CAV 245480C1

CAV 1

WIRE IDENT 0-B8

Bur 5-2750

CIRCUIT

WIRE IDENT

CIRCUIT

1

28G

Grid Heater Source DR

2

0-BV

Grid Heater Control Ground

Front Wiper Ground

Issued 8-06

Printed in U.S.A.

4002-148 CONNECTOR GND-CAB-SPL - CAB GROUND SPLICE

CAV

WIRE IDENT

CIRCUIT

E

0-DD

Voltmeter Relay Control Gnd

F

0-DF

Crank Request Relay Control Gnd

G

0-DE

Neutral Start Relay Control Gnd

H

0-EQ

Splice Pack Gnd Cab SPL2 GND

J

Not Used

K

0-EH


L

0-EG


M

0-EF

Brake Lights Relay Control Gnd

CONNECTOR HD - HOOD SWITCH 87324393

CAV

WIRE IDENT

CIRCUIT

A

0-EE

Diode Suppression Grounds

B

0-EM

Radio Ground

C

0-EP

Horn Switch Ground

D

Not Used

E

Not Used

F

0-DG

Cab Splice Grounds

G

0-DT

Front Wiper/Washer Sw Gnd

H

0-DL

Power Converter Relay Ctrl Gnd

CAV

59D-A

Hood Relay Control Down

245485C1

WIRE IDENT

CIRCUIT

I

0-DK


A

K

0-DJ


B

19Y-D


L

0-DU

Pilot Pressure Solenoid Gnd

C

59U-A

Hood Relay Control Up

M

0-DH

Diagnostic Connector Ground

CONNECTOR HD-E - HOOD HARNESS TO TRANSMISSION HARNESS

CONNECTOR GND-CAB-SPL2 - SPLICE BACK LIGHT GROUND

245484C1

CAV

87324393

CAV

WIRE IDENT

CIRCUIT

A

18G-E

License Plate Light Fused Pwr

B

35A-H


C

0-JA

Hood Ground (EURO)

CIRCUIT

A

0-DC


B

0-EA

Time Delay Relay Control Gnd

C

0-EB


D

0-EC


Bur 5-2750

WIRE IDENT

Issued 8-06

Printed in U.S.A.

4002-149 CONNECTOR HD-N - HOOD TO ENGINE

CONNECTOR HOT - HYDRAULIC OIL TEMPERATURE SENDER

194788A1

CAV

225319C1

CAV

WIRE IDENT

WIRE IDENT

A

36H

B

0-HW

CIRCUIT Hydraulic Oil Temp Signal Hydraulic Oil Temp Ground

CIRCUIT

CONNECTOR HVAC1 - HVAC1

1

0-JA-N

Hood Grounds (NA)

2

44A-EN

Brake Light relay Out

3

45L-BN

Left Turn Signal

4

45R-BN

Right Turn Signal

5

18G-JN


6

18F-BN


7

35A-HN


225295C1

CONNECTOR HDM - HOOD LIFT MOTOR CAV 1

WIRE IDENT

CIRCUIT

61A-B


2

18N-A


3

49A

Back Light Power

CONNECTOR HVAC2 - HVAC2

225316C1

CAV

WIRE IDENT

CIRCUIT

1

60U-A

Hood Up Relay Out

2

60D-A

Hood Down Relay Out

87552622

CAV

Bur 5-2750

WIRE IDENT

CIRCUIT

1

0-ED

HVAC Grounds

2

18N-B


Issued 8-06

Printed in U.S.A.

4002-150 CONNECTOR HVAC-CAN1 - CAN-HVAC-ATC

CONNECTOR K-WCO - WIPER CUTOUT

245731C1

CAV 87315267

CAV

WIRE IDENT

CIRCUIT

A

CAN-HK

CAN High

B

CAN-LL

CAN Low

WIRE IDENT

CIRCUIT

30

63L-B

Front Wiper LS Relay Out

85

63HC-A

Wiper Cut Out Relay Control

86

19J-G

Wiper Cut Out Relay Fused Pwr

87 87A

Not Used 63C3


CONNECTOR ISS - INT-SPEED-SENSOR CONNECTOR LBEE - LIGHT BEACON EXTESION

291718A1

CAV

WIRE IDENT

CIRCUIT

1

25B

INT Speed Signal

2

0-HG

INT Speed Sensor Ground

Bur 5-2750

291730A1

CAV

WIRE IDENT

CIRCUIT

A

46-E

Beacon Light Power

B

0-MD

Beacon Light Ground

Issued 8-06

Printed in U.S.A.

4002-151 CONNECTOR LLF - LH FRONT LIGHTS

CONNECTOR LLR-E - LH REAR COMBINATION LAMP

225351C1

CAV

WIRE IDENT

225351C1

CIRCUIT

1

0-AJ

Lights Ground LH

CAV

WIRE IDENT

CIRCUIT

2

18D

Low Beam LH

1

44A-E


45L-A

Left Turn Signal

3

18B

High Beam LH

2

4

18F

Position LH Fused Power

3

18F-B

Left Tail Fused Power

5

45L

Left Turn Signal

4

35A-L

Reverse Lamp

Not Used

5

0-BT

6

6

LH Ground (EURO) Not Used

CONNECTOR LLFW - LH FRONT WORK LAMP CONNECTOR LLR-N - LH REAR COMBINATION LAMP

245483C1

CAV

WIRE IDENT

CIRCUIT

A

42C-H

LH Front Work Lamp Power

B

0-MU

LH Front Work Lamp Ground

245715C1

CAV

Bur 5-2750

WIRE IDENT

CIRCUIT

A

44A-FN

Brake Lamp Relay Out

B

18F-BN

LH Tail Lamp Fused Pwr

C

45L-BN

Left Turn Signal

D

0-BR-N

LH Rear Light Ground (NA)

Issued 8-06

Printed in U.S.A.

4002-152 CONNECTOR LLRW- LH REAR WORK LAMP

CONNECTOR LRF - RH FRONT COMBINATION LAMP

245483C1

CAV

WIRE IDENT

CIRCUIT

A

42R-H

LH Rear Work Lamp Fused Pwr

B

0-ME

LH Rear Work Lamp Ground

CONNECTOR LPL - LICENSE PLATE LAMP

225351C1

CAV

WIRE IDENT

CIRCUIT

1

0-AH

RH Front Lights Ground

2

18E

RH Low Beam Fused Pwr

3

18C

RH High Beam Fused Pwr

4

18G-A

RH Position/Tail Fused Pwr

5

45R

Right Turn Signal

6

Not Used

CONNECTOR LRFW - RH FRONT WORK LAMP

245482C1

CAV

WIRE IDENT

CIRCUIT

A

18G-E

License Plate Lamp Fused Pwr

A

18G-EN

License Plate Lamp Fused Pwr

B

0-JC

License Plate Lamp Ground 245483C1

CAV

Bur 5-2750

WIRE IDENT

CIRCUIT

A

42C-G

RH Front Work Lamp Fused Pwr

B

0-MJ

RH Front Work Lamp Ground

Issued 8-06

Printed in U.S.A.

4002-153 CONNECTOR LRR-E - RH REAR COMBINATION LAMP

CONNECTOR LRRW - RH REAR WORK LAMP

245483C1

CAV 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

6

WIRE IDENT

CIRCUIT

A

42R-G

RH Rear Work Lamp Fused Pwr

B

0-MF

RH Rear Work Lamp Ground

CONNECTOR LSPK - LEFT SPEAKER

Ground (EURO) Not Used

CONNECTOR LRR-N - RH REAR COMBINATION LAMP 195552A1

CAV

WIRE IDENT

CIRCUIT

A

65L

Left Speaker Signal

B

0-PA

Left Speaker Ground

CONNECTOR OSS - OUTPUT SPEED SENSOR

245715C1

CAV

WIRE IDENT

CIRCUIT

A

44A-GN

Brake Lamp Relay Out

B

18G-CN

RH Position/Tail Lamp Fused Pwr

C

45R-BN

Right Turn Signal

D

0-BT-N

RH Rear Light Ground (NA) 291719A1

CAV 1

Bur 5-2750

WIRE IDENT 0-HE

CIRCUIT Output Speed Ground

2

25D

Output Speed Signal

3

19A

Output Speed Fused Pwr

Issued 8-06

Printed in U.S.A.

4002-154 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


2

44


CONNECTOR PBW - BRAKE PRESSURE WARNING SWITCH CONNECTOR PBD - BRAKE DECLUTCH PRESSURE SWITCH

225316C1 245482C1

CAV

WIRE IDENT

CIRCUIT

A

19A-A


B

25G


Bur 5-2750

CAV

WIRE IDENT

CIRCUIT

1

33P

Low Brake Press Warning

2

0-AL

Brake Press Warn Sw Ground

Issued 8-06

Printed in U.S.A.

4002-155 CONNECTOR PO1 - POWER OUTLET

CONNECTOR PR - TRINARY PRESSURE SWITCH

182068A1

CAV

WIRE IDENT

CIRCUIT

12176446

CAV A

WIRE IDENT 12V

B C

CIRCUIT 12V Pwr to Outlet 1

A

61-A


B

61R

AC Relay Control

Not Used 0-EK

CONNECTOR PRB1 - REDUNDANT BRAKE SWITCH

Aux Power Outlet 1 Gnd

CONNECTOR PO2 - POWER OUTLET

245483C1

CAV

WIRE IDENT

CIRCUIT

A

33R-C

RDNT Brake Accumulator Press Low

B

0-HM

Ground

12176446

CAV A

WIRE IDENT 12V

B C

CIRCUIT

CONNECTOR PRB2 - REDUNDANT BRAKE SWITCH

12V Pwr to Outlet 2 Not Used

0-EK

Aux Power Outlet 2 Gnd

245483C1

CAV

Bur 5-2750

WIRE IDENT

CIRCUIT

A

33R-B

RDNT Brake Accumulator Press Low

B

0-HL

Ground

Issued 8-06

Printed in U.S.A.

4002-156 CONNECTOR PRBF - ROLLBACK PRESSURE SWITCH

CONNECTOR PRM-B2 - PRM SIGNAL

245483C1

CAV

WIRE IDENT

CIRCUIT

256340A1

A

58


CAV

B

58-B


A

13D

Time Delay Relay Control Pwr

B

0-EA

Time Delay Relay Control Gnd

WIRE IDENT

CIRCUIT

CONNECTOR PRM-A1 - PRM SIGNAL CONNECTOR PRM-C1 - PRM OUTPUT

409084A1 256340A1

CAV

WIRE IDENT

CIRCUIT

CAV

WIRE IDENT

CIRCUIT

A

18R

Voltmeter Relay Fused Pwr

A

13K-B


C

28P

Ether Solenoid Power

B

0-EB


C

1-GA

Filter Heater Power

CONNECTOR PRM-B1 - PRM SIGNAL

409084A1

CAV

WIRE IDENT

A C

CIRCUIT Not Used

13H

Bur 5-2750

Time Delay Power

Issued 8-06

Printed in U.S.A.

4002-157 CONNECTOR PRM-C2 - PRM SIGNAL

ONNECTOR PRM-E1 - PRM SIGNAL

409084A1

CAV 256340A1

CAV

WIRE IDENT

A C

CIRCUIT

A

28E

Ether Relay Signal

A

28F

Fuel Filter Heater Relay Control

B

0-BAM

Ether Relay Signal Ground

B

0-BN


WIRE IDENT

CIRCUIT Not Used

19L

Power Converter FSD Power

CONNECTOR PRM-E2 - PRM SIGNAL

CONNECTOR PRM-D1 - PRM SIGNAL

256340A1

CAV

WIRE IDENT

CIRCUIT

A

12ACC-C

Pwr Converter PRM Control Pwr

B

0-DL

Pwr Converter Relay Ctrl Gnd

256340A1

CAV

WIRE IDENT

CIRCUIT

A

12ACC-B

ACC PRM Control Power

B

0-EC


CONNECTOR PSS - SECONDARY STEERING PRESSURE SWITCH

245485C1

CAV

Bur 5-2750

WIRE IDENT

CIRCUIT

A

51P-A

Secondary Steer High Pressure

B

0-CC

Sec. Steer Press Switch Ground

C

35X-A

Secondary Steer Low Press Sig

Issued 8-06

Printed in U.S.A.

4002-158 CONNECTOR PXF - RTD

CONNECTOR PXT - RTD

245485C1

CAV

WIRE IDENT

CIRCUIT

245485C1

CAV

WIRE IDENT

CIRCUIT

A

53B

RTD Signal

A

53B-A

RTD Control Signal

B

0-AC

Proximity Switch Ground

B

0-AM

RTD Ground

C

53P-H


C

53P-I


CONNECTOR PXH - HEIGHT CONTROL RTT

CONNECTOR RAD - RADIO POWER

245485C1

CAV

WIRE IDENT

CIRCUIT

A

54B

RTT Signal

B

0-AA

Proximity Switch Ground

CAV

C

53P-J


1

Not Used

2

Not Used

3

Not Used

292495A1

CONNECTOR PXM - RTD

4

WIRE IDENT

12V-HB

5

CIRCUIT

12V Fused Power to Radio Not Used

6

Not Used

7

12V-HA


8

0-EN

Radio Ground

245485C1

CAV A

WIRE IDENT 53B-A

CIRCUIT RTD Control Signal

B

0-AM

RTD Ground

C

53P-I


Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-159 CONNECTOR RAD-J1 - RADIO POWER

CONNECTOR RAD-J3 - RADIO JUMPER

411311A1

CAV

292497A1

CAV

WIRE IDENT

CIRCUIT

WIRE IDENT

CIRCUIT

1

RAD10

Right Speaker Ground

2

RAD8

Not Used

3

RAD4

Left Speaker Ground

4

RAD6

Not Used

RAD1

1

Not Used

5

2

Not Used

6

3

Not Used

7

RAD3



8

RAD11

Right Speaker

5

Not Used

9

RAD9

Not Used

6

Not Used

10

RAD5

Left Speaker

4

RAD3

Radio Ground Not Used

7

RAD2


11

RAD7

Not Used

8

RAD1

Radio Ground

12

RAD2


CONNECTOR RAD-J2 - SPEAKER

13

Not Used

14

Not Used

CONNECTOR RECT - ENGINE COOLANT TEMPERATURE

194788A1 292501A1

CAV

WIRE IDENT

CIRCUIT

1

RAD11

Right Speaker

2

RAD10


3

RAD9

Not Used

4

RAD8

Not Used

5

RAD7

Not Used

6

RAD6

Not Used

7

RAD5

Left Speaker

8

RAD4

Left Speaker Ground

Bur 5-2750

CAV

WIRE IDENT

CIRCUIT

A

36C


B

0-BAE

EDC7 Sender Ground

Issued 8-06

Printed in U.S.A.

4002-160 CONNECTOR ROOF - ROOF TO CAB CONNECTION

CONNECTOR RTHP - THROTTLE PEDAL

388708A1

CAV

WIRE IDENT

CIRCUIT

225351C1

A

43-B


CAV

B

42R-F

Rear Work Light Fused Power

1

WIRE IDENT 21F-C

CIRCUIT EDC7 DIGITAL Ground

C

42C-F


2

Not Used

D

19U-C

Done Light Fused Power

3

24B

Throttle Signal

E

46-D

Beacon Switch Power

3

24B-A

Throttle Signal

F

0-MN

Roof Grounds

4

24R

Throttle Position Sensor Ground

24R-A

Throttle Position Sensor Ground

G

0-MK

Roof Grounds

4

J

19K-D


5

24S

Throttle Supply

K

68C-A


5

24S-A

Throttle Supply

L

68L-A

Rear Wiper Switched Power

6

24L

Low Idle Switch

M

0-EN

Radio Ground

N

12V-H


R

43S-B

Door Open Signal

S

19U-F


CONNECTOR RWM - REAR WIPER MOTOR

CONNECTOR RSPK - RIGHT SPEAKER

245715C1

CAV 195552A1

CAV

WIRE IDENT

WIRE IDENT

A

CIRCUIT Not Used

CIRCUIT

B

68L-A


A

65R

Right Speaker Signal

C

19K-D


B

0-PB


D

68C-A


Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-161 CONNECTOR RWMG - REAR WIPER MOTOR GROUND

CONNECTOR S-KEY - IGNITION SWITCH TO PEDESTAL HARNESS

245480C1

CAV 1

WIRE IDENT 0-MA

225253C1

CIRCUIT Rear Wiper Motor Ground

CONNECTOR RWW - REAR WASHER

CAV

WIRE IDENT

CIRCUIT

1

1A

Ign Sw Fused Power

2

21K

Ign Switch Start Signal

3

13K


4

12ACC

Ign Switch Accessory Power

5

Not Used

6

Not Used

CONNECTOR SBE - BEACON SWITCH

3227856R1

CAV

WIRE IDENT

CIRCUIT

1

68W-A

Rear Washer Pump

2

0-BL

Rear Washer Ground

382391A1

CAV

WIRE IDENT

1

Not Used

2

19U-H

Beacon Switch Fused Power

3

46-C


4

Not Used

5

Not Used

6

Bur 5-2750

CIRCUIT

Not Used

7

0-B15

Back Light Ground

8

49-B

Back Light Power

9

Not Used

10

Not Used

Issued 8-06

Printed in U.S.A.

4002-162 CONNECTOR SBU - BACKUP ALARM DISABLE SWITCH

CONNECTOR SCS - COMFOR STEER SWITCH

382391A1 382391A1

CAV

WIRE IDENT

CIRCUIT

1

35R-C

Backup Alarm Switch

2

35A-B

Backup Alarm Disable Switch

CAV

WIRE IDENT

CIRCUIT

1

51S


2

18L-D


3

51CS

Comfort Steering Switch

3

Not Used

4

Not Used

5

Not Used

6

51B-A


6

Not Used

4

Not Used

5

Not Used

7

0-B9

Back Light Ground

7

0-B21

Back Light Ground

8

49-U

Back Light Power

8

49-L

Back Light Power

9

Not Used

9

Not Used

10

Not Used

10

Not Used

CONNECTOR SDC - DECLUTCH SWITCH CONNECTOR SC - SEAT COMPRESSOR MOTOR

245482C1

CAV

WIRE IDENT

CIRCUIT

A

19N


B

0-DK


382391A1

CAV

WIRE IDENT

1

25G-B


2

19A-R

Declutch Switch Fused Power

3

Not Used

4

Not Used

5

Not Used

6

Bur 5-2750

CIRCUIT

Not Used

7

0-B18

Back Light Ground

8

49-R

Back Light Power

9

Not Used

10

Not Used

Issued 8-06

Printed in U.S.A.

4002-163 CONNECTOR SDR - DRIVING LIGHTS SWITCH

CONNECTOR SFC - FAN CONTROL SWITCH

382391A1

382391A1

CAV

WIRE IDENT

1

CAV

CIRCUIT Not Used

1

WIRE IDENT

CIRCUIT Not Used

2

19Z-A

Driving lights Switch Fused Pwr

2

52J


3

41T

Position Lights Switch Power

3

52-AU

Fan Reverse Auto

Not Used

4

52J


4

19P-C

Fan Reverse Switch Fused Pwr

19Z-B

Driving Lights Switch Fused Power

5

5

6

52M

Fan Reverse Manual

6

41J

Driving Lights Power

7

0-B7

Back Light Ground

7

0-B19

Back Light Ground

8

49-Q

Back Light Power

8

49-P

Back Light Power

9

Not Used

9

Not Used

10

Not Used

10

Not Used

CONNECTOR SFL - RETURN-TO-TRAVEL SWITCH

CONNECTOR SETHR - ETHER SWITCH

382391A1

382391A1

CAV

WIRE IDENT

1

CIRCUIT

CAV

WIRE IDENT

CIRCUIT

Not Used

1

55A-B

RTT/Float Switch Power

2

28J

Ether AIC OK Signal

2

53P-B


3

28H

Ether Switch Signal

3

55A-C

RTT/Float Switch Power

Not Used

4

0-29

RTT/Float Ground

5

Not Used

5

55B


6

Not Used

6

54B-C

HC-RTT Control Signal

4

7

0-B30

Back Light Ground

7

0-B2

Back Light Ground

8

49U

Back Light Power

8

49-K

Back Light Power

9

Not Used

9

Not Used

10

Not Used

10

Not Used

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-164 CONNECTOR SFNR - FNR SWITCH

CONNECTOR SHC - HEIGHT CONTROL SWITCH

382391A1

CAV

WIRE IDENT

CIRCUIT

382391A1

CAV

WIRE IDENT

CIRCUIT

1

26R-A

FNR Reverse Signal

1

2

26J

FNR Switch Jumper

2

3

26N-A

FNR Neutral Signal

3

Not Used

4

26J

FNR Switch Jumper

4

Not Used

5

19A-V


5

Not Used

6

26F-A

FNR Forward Signal

6

54A

HC Control Switch Power

7

32J-A

Trans Enable Indication

7

0-B3

Back Light Ground

8

19A-G


8

49-M

Back Light Power

9

Not Used

9

Not Used

10

Not Used

10

Not Used

CONNECTOR SFWW - REAR WIPER AND WASHER SWITCH

Not Used 53P-D


CONNECTOR SHZ - HAZARD SWITCH

382391A1

87345132

CAV

WIRE IDENT

CIRCUIT

CAV

WIRE IDENT

CIRCUIT

Not Used

1

2

0-DT

Front Wiper/Washer Sw Gnd

2

1-KA

Hazard Switch Power

3

63LC

Front Wiper LS Relay Control

3

45H

Hazard Switch Power

Not Used

4

Not Used

INT Wiper/Washer Sw Fused Pwr

5

Not Used

6

Not Used

1

4 5

19J-B

6

Not Used

7

63W

Front Washer Pump

8

49-T

Back Light Power

9

63HC

Front Wiper HS Relay Control

10

Bur 5-2750

Not Used

7

0-b24

Back Light Ground

8

49-D

Back Light Power

9

Not Used

10

Not Used

Not Used

Issued 8-06

Printed in U.S.A.

4002-165 CONNECTOR SPB - PARKING BRAKE SWITCH

CONNECTOR SPE - PIN ENGAGE SWITCH

382391A1

CAV

WIRE IDENT

1

CIRCUIT Not Used

382391A1

CAV

WIRE IDENT

CIRCUIT

1

57-B

2

19A-L

Park Brk Switch Fused Power

2

19P-A

3

33U

Park Brake Switch

3

Not Used

4

Not Used

4

Not Used

5

Not Used

5

Not Used

6

Not Used

6

Not Used

7

Not Used

8

Not Used

7

0-B29

RTT/Float Ground

8

49-v

Back Light Power

9

Not Used

10

Not Used

Pin Engage Solenoid Power Pin Engage Sw Fused Power

9

0-B5

Back Light Ground

10

49-F

Back Light Power

CONNECTOR SPC - PILOT CONTROL SWITCH

CONNECTOR SPK - SPEAKER

382391A1

CAV

WIRE IDENT

1

CIRCUIT

292494A1

Not Used

CAV

WIRE IDENT

CIRCUIT

2

19A-j

Pilot Control Switch Fused Pwr

1

65R

Right Speaker

3

31L

0-PB



2

4

Not Used

3

Not Used

5

Not Used

4

Not Used

6

Not Used

5

Not Used Not Used

7

0-B1

Back Light Ground

6

8

49-N

Back Light Power

7

65L

Left Speaker

9

Not Used

8

0-PA

Left Speaker Ground

10

Not Used

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-166 CONNECTOR SPL-BCK-LGT - SPLICE BACK LIGHT POWER

CAV

WIRE IDENT

D

49-M

Back Light Power

E

49-K

Back Light Power

F

49-F

Back Light Power

G

49-Q

Back Light Power

H

49-T

Back Light Power

J K

Not Used 49-G

L M

87324393

CAV A

WIRE IDENT 49

B

CIRCUIT

Back Light Power Not Used

49-S

Back Light Power

CONNECTOR SPL-BCK-LT-GD - SPLICE BACK LIGHT GROUND

CIRCUIT Back Light Power Not Used

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

K

49-E

Back Light Power

L

49-B

Back Light Power

M

49-A

Back Light Power

87324393

CAV

CONNECTOR SPL-BCK-LGT2 - SPLICE BACK LIGHT POWER

WIRE IDENT

CIRCUIT

A

0-B13

Back Light Ground

B

0-B14

Back Light Ground

C

0-B15

Back Light Ground

E

0-B17

Back Light Ground

F

0-B18

Back Light Ground

G

0-B19

Back Light Ground

H

0-B8

Front Wiper Motor Ground

J

0-B21

Back Light Ground

K

0-DAP

Back Light Ground

L

0-B23

Back Light Ground

D

M

Not Used

Not Used

87324393

CAV A

WIRE IDENT 49-E

B C

CIRCUIT Back Light Power Not Used

49-J

Bur 5-2750

Back Light Power Issued 8-06

Printed in U.S.A.

4002-167 CONNECTOR SPL-BCK-LT-GD2 - SPLICE BACK LIGHT GROUND

CAV

WIRE IDENT

CIRCUIT

D

0-BS

Fan Control Ground

E

0-B

Front Washer Ground

F

0-BL

Rear Washer Ground

CONNECTOR SPL-HOOD-GND - HOOD GROUND 6 PACK

87324393

CAV

WIRE IDENT

A

CIRCUIT Not Used

B

0-B2

Back Light Ground

C

0-B3

Back Light Ground

D

0-B4

Back Light Ground

E

0-B5

Back Light Ground

87324391

CAV

F

0-B6

CAB2 Ground

G

0-B26

Buzzer Switch Pad Ground

H J

Not Used 0-B20

Back Light Ground

K

0-29

RTT/Float Ground

L

0-B11

Back Light Ground

M

0-B7

Back Light Ground

WIRE IDENT

CIRCUIT

A

0-B12

Hood Down Relay Ground

B

0-B16

Hood Down Control Ground

C

0-B22

Hood Up Relay Ground

D

0-B25

Hood Up Control Ground

E

0-B10

Hood Ground

F

Not Used

CONNECTOR SPL-ENG-GND - GROUND SPLICE 6 PACK

87324391

CAV

WIRE IDENT

CIRCUIT

A

0-BM

Engine Splice Grounds

B

0-BY

Air Filter Restriction Switch Gnd

C

Bur 5-2750

Not Used

Issued 8-06

Printed in U.S.A.

4002-168 CONNECTOR SPL-PED-BL - SPL BACK LIGHT POWER 6 PACK

CONNECTOR SPL-PIN - SPL BACK LIGHT POWER 6 PACK

87324391

CAV

WIRE IDENT

CIRCUIT

87324391

CAV

WIRE IDENT

CIRCUIT

A

49-U

Back Light Power

A

19P-A

Pin Engage Switch Fused Pwr

B

49-N

Back Light Power

B

19P

Pin Engage/Fan Fused Power

19P-C

Ran Reverse Switch Fused Pwr

C

49-D

Back Light Power

C

D

49U

Back Light Power

D

E

49-V

Back Light Power

E

19P-D


F

49-S

Back Light Power

F

19P-E


Not Used

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

87324391

CAV

WIRE IDENT

CIRCUIT

A

0-B9

Back Light Ground

B

0-B1

Back Light Ground

C

0-B24

Back Light Ground

D

0-B30

Back Light Ground

E

0-B29

RTT/Float Ground

F

0-B11

Back Light Ground

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-169 CONNECTOR SPL-PK1 - SPLICE 3 - 4 WAY

CONNECTOR SPL-PK2 - SPLICE 3 - 4 WAY

87324462

CAV

WIRE IDENT

CIRCUIT

87324462

CAV

WIRE IDENT

CIRCUIT

A

42C-A

Front Work Lights Fused Pwr

A

41T-B

Position Lights LH Switch Pwr

B

42C-E


B

41T-E

Position Lights Switch Pwr

C

42C-D


C

41T


D

42C-C


D

41T-A

Position Lights RH Switch Pwr

E

13K


E

19Z-A

Driving Light Switch Fused Pwr

F

13K-B


F

19Z-B


G

13K-A


G

19Z


H

13K-C


H

19Z-C

High Beam Flash Fused Pwr

J

35A-D


J

41H-C

High Beam RH Power

K

35A-B

Backup Alarm Disable Switch

K

41H-B

High Beam LH Power

L

35A-A


L

41H-A

High Beam Power

M

35A-C


M

41H-D

High Beam Power

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-170 CONNECTOR SPL-PK3 - SPLICE 3 - 4 WAY

CAV

WIRE IDENT

CIRCUIT

E

0-MF

RH Rear Work Light Ground

F

0-MA

Rear Wiper Motor Ground

G

Not Used

H

Not Used

J

0-MJ

K

RH Front Work Light Ground Not Used

L

0-MN

Roof Grounds

M

0-MK

Roof Grounds

CONNECTOR SPL-SEC-STR - SEC STR 6PK 87324462

CAV

WIRE IDENT

CIRCUIT

A

45L-E

Left Turn Signal

B

45L-D

Left Turn Signal

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

Front Wiper Fused Power

CAV

L

19J-C

Front Wiper Relay Fused Power

A

M

19J-A

Front Wiper Motor Fused Power

CONNECTOR SPL-ROOF - SPLICE ROOF GROUND

87324391

WIRE IDENT

CIRCUIT

0-CB


B

0-CA


C

0-CC

Sec. Steering Press Switch Gnd

D

0-CF

Sec. Steering Solenoid Ground

E F

Not Used 0-CD


87324393

CAV

WIRE IDENT

CIRCUIT

A

0-MC

Beacon Light Ground

B

0-MB

Dome Light Ground

C

0-MU

LH Front Work Light Ground

D

0-ME

LH Rear Work Light Ground

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-171 CONNECTOR SPL-TRN-GRD - SPLICE TRANSMISSION GROUND

CAV

WIRE IDENT

CIRCUIT

K

19A-M

Output Speed Sensor Fused Pwr

L

19A-S

Trans Fused Pwr

M

19A-H

Trans Shifter Fused Pwr

CONNECTOR SRC - RIDE CONTROL SWITCH

87324391

CAV A

WIRE IDENT 0-HC

B

CIRCUIT Transmission Splice Grounds Not Used 382391A1

C

0-HW

HOT Ground

D

0-HV

Coolant Level Sender Ground

E

0-HL

Redundant Brake Switch Grd

F

0-HM

Redundant Brake Switch Grd

CONNECTOR SPL-TRNS-PWR - TRANSMISSION POWER

CAV

WIRE IDENT

1

CIRCUIT Not Used

2

19C-D

Ride Ctrl Switch Fused Pwr

3

58C

Ride Ctrl Switch Jumper

4

58T

Ride Ctrl Relay Switch Pwr

5

58C

Ride Ctrl Switch Jumper

6

58-F

Ride Ctrl Solenoid Pwr

7

0-B20

Back Light Ground

8

49-G

Back Light Power

9

Not Used

10

Not Used

CONNECTOR SRC-1 - STARTER RELAY

87324393

CAV

WIRE IDENT

CIRCUIT

A

19A-N

Trans Fused Power

B

19A-F

Trans Enable Switch Fused Pwr

C

19A-Q

Trans/Auto Switch Fused Pwr

225316C1

D

19A-T


CAV

E

19A-W

Diagnostic Conn. Fused Pwr

1

21D


F

19A-C

FNR Switch Fused Pwr

2

0-GB

Starter Relay Control Ground

G

19A-P

Backup Alarm Rly Ctrl Fused Pwr

H

19A-R

Declutch Switch Fused Pwr

J

19A-K

TECM Fused Pwr

Bur 5-2750

WIRE IDENT

CIRCUIT

Issued 8-06

Printed in U.S.A.

4002-172 CONNECTOR SRHSTLK - RH STALK SWITCH

CONNECTOR SRWP - REAR WIPER SWITCH

382391A1

CAV

WIRE IDENT

CIRCUIT

1

68C


2

68L


3

19K-A

Rear Wiper Switch Fused Power

87318288

CAV

WIRE IDENT

CIRCUIT

31b

64C

Horn Relay Control

49a

19B


56a

41H-A

High Beam Power

4

56b

41L-A

Low Beam Power

56d

19Z-C

High Beam Flash Fused Power

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

Not Used

5

19K-B

Rear Wiper Switch Fused Power

6

68W

Rear Washer Pump

7

0-B23

Back Light Ground

8

49-C

Back Light Power

9

Not Used

10

Not Used

CONNECTOR SS-TR - SS-MOD-TRANS CONNECTOR SRTD - DETENT SWITCH

245489C1

CAV

382391A1

CAV

WIRE IDENT

1

CIRCUIT Not Used

2

53P-E


3

53A

RTD Switched Power

4

Not Used

5

Not Used

6

Not Used

7

0-B4

Back Light Ground

8

49-J

Back Light Power

9

Not Used

10

Not Used

Bur 5-2750

WIRE IDENT

CIRCUIT

A

19M-C

Sec. Str Accessory Fused Pwr

B

19R-C

Sec. Str Ignition Fused Pwr

C

35X-C

Sec. Str Low Press Signal

D

0-CD

Sec. Str Splice Ground

E

19S1-X

Sec. Str Fused Power

F

Not Used

Issued 8-06

Printed in U.S.A.

4002-173 CONNECTOR SSM - SECONDARY STEERING MODULE

CAV

WIRE IDENT

CIRCUIT

7

0-B17

Back Light Ground

8

49S

Back Light Power

9

Not Used

10

Not Used

CONNECTOR STE - TRANSMISSION ENABLE SWITCH

225389C1

CAV

WIRE IDENT

CIRCUIT

1

19R-C


2

51-A

Secondary Steer Control

3

19S1-X

Secondary Steer Fused Power

4

0-CE

Secondary Steer Chassis Grnd

5

Not Used

382391A1

6

Not Used

CAV

7

Secondary Steer ACC Fused Pwr

1

19M-C

8

35X-D

Secondary Steer Low Press Sig

9

51P-A

Secondary Steer High Press

10

Not Used

11

0-CA

Secondary Steer Signal Grnd

12

0-CB

Secondary Steer Signal Grnd

CONNECTOR STA - TRANSMISSION AUTO SWITCH

WIRE IDENT

CIRCUIT Not Used

2

19A-D

Trans Enable Sw Fused Power

3

26E

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

Trans Enable Sw Fused Pwr

382391A1

CAV

WIRE IDENT

1

CIRCUIT Not Used

2

19A-Q

Trans Auto Sw Fused Power

3

25H

Trans Auto Signal

4

Not Used

5

Not Used

6

Not Used

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-174 CONNECTOR SWL - WORK LIGHTS SWITCH

CAV

WIRE IDENT

CIRCUIT

8

CAN-LF

CAN Low

9

17P-A

Switch Pad Pwr From AIC Pwr

10

0-B28

Switch Pad Ground

CONNECTOR TCOT - TORQUE CONVERTER OUTPUT SENDER

382391A1

CAV

WIRE IDENT

1

CIRCUIT Not Used

2

42-A


3

42FS

Front Work Lights Switch Power

4

Not Used

5

42-B


6

42RS

Rear Work Lights Switch Power

7

0-B14

Back Light Ground

8

49-A

Back Light Power

9

Not Used

10

Not Used

291718A1

CAV

WIRE IDENT

CIRCUIT

A

36G

TCO Temperature Signal

B

36R-D

TCO Temperature Return

CONNECTOR TDM - TIME DELAY MODULE

CONNECTOR SW-PD - SWITCH PAD

225351C1

CAV

87552623

CAV

WIRE IDENT

CIRCUIT

WIRE IDENT

CIRCUIT

1

13D

Time Delay Relay Ctrl Power

2

1DN


3

0-DC


1

41H-D

High Beam Power

4

43S-D

Time Delay Mod Door Sw Reset

2

41T-D


5

13K-A


3

42C-E

Front Work Light Fused Pwr

6

4

31H-A

Hydraulic Filter Rest Sw Signal

5

31F-A

Air Filter Rest Switch Signal

6 7

Not Used

Not Used CAN-HF

Bur 5-2750

CAN High

Issued 8-06

Printed in U.S.A.

4002-175 CONNECTOR TECM - TRANSMISSION ELECTRONIC CONTROL MODULE

411398A1

CAV

WIRE IDENT

CIRCUIT

1

0-DP

Diag TECM Ground

2

0-DQ

Diag TECM Ground

3

0-DM

Speed Sensors Ground

4

0-DN

Out Speed Sensor Ground

5

32J-D

Trans Enable Indicator Lamp

7

35C


8

58H-A

Ride Control Sw Power VPS2

9

25P-A

Trans Sol Valve Y5

10

25L-A

Trans Sol Valve Y2

12

25S-B


13

25S-C


15

37D-A

Diagnostic Signal

17

32F-A


18

37E


19

25A-A

Engine Speed Signal

20

26F-B

FNR Forward Signal

Bur 5-2750

CAV

WIRE IDENT

CIRCUIT

21

52P-C


22

25Y-A


23

19T-A


25

CAN-HD

CAN High

26

CAN-LK

CAN Low

27

CAN-LJ

CAN Low

29

25H

Trans Auto Signal

30

26R-B

FNR Reverse Signal

31

26E

Trans Enable Signal

32

25M-A

Trans Sol Valve Y3

39

36T-A


41

25C-A

Turb Speed Signal

42

25B-A

Int Speed Signal

43

25F

Forward Signal

44

26N-B

FNR Neutral Signal

45

19A-K

TECM Fused Power

46

36R-E


49

36G-A

Torque Conv Out Temp Signal

51

25J-A

Trans Sol Valve Y6

55

25N-A

Trans Sol Valve Y4

56

25K-A

Trans Sol Valve Y1

57

58L


62

25D-A

Output Speed Signal

63

25Z

1st and 4th Gear Signal

64

25R-

Reverse Signal

65

25W

3rd and 4th Gear Signal

66

25G-C


67

25T-C

Neutral Signal

Issued 8-06

Printed in U.S.A.

4002-176 CONNECTOR TR-SS - SEC-STR-MOD-OPT

CONNECTOR TRANS - CAB TO TRANSMISSION

380838A1

CAV

245488C1

CAV

WIRE IDENT

CIRCUIT

A

19M-A


B

19R-A


C

35X-B


D

0-HP


E

19S1-E

Sec. Steering Fused Power

F

Not Used

CONNECTOR TRAN-E - TRANS TO ENG

239451A1

CAV

WIRE IDENT

CIRCUIT

WIRE IDENT

CIRCUIT

1

33R-A

Redundant Brake Switch Signal

2

31D-B

Coolant Level Sender Eng Trans

2

31D


3

19M-A


4

19R-A


5

36T


6

35X-B


7

25A

Engine Speed Signal

8

25C

Turb Speed Signal

9

25B

Intermediate Speed Signal

10

25D

Output Speed Signal

11

0-HD

Speed Sensor Ground

12

36R-A


13

36G

Torque Conv Output Temp Sig

14

Not Used

15

Not Used

16

25K


16

25K-9


17

25L-9


17

25L


18

25M


19

25N


1

0-HP


20

25P


2

0-HC


21

25J


3

31D-B

Coolant Level Sender Eng Trans

22

25S


23

31H

Hyd Filter Restriction Sw Signal

4

Not Used

24

Not Used

25

Not Used

26

19S1-E

27

Bur 5-2750

Sec. Steering Fused Power Not Used

28

0-HE


29

19A

Output Speed Sensor Fused Pwr

30

36H

Hydraulic Oil Temperature Sign

31

32F


Issued 8-06

Printed in U.S.A.

4002-177 CONNECTOR TRC - TRANSMISSION CONTROL

CONNECTOR TS1 - TRANSMISSION SHIFTER

245486C1 371566A1

CAV

WIRE IDENT

CIRCUIT

CAV

WIRE IDENT

CIRCUIT

A

19A-H

Trans Shifter Fused Power

1

25K


B

25F

Forward Signal

1

25L-9


C

25R

Reverse Signal

2

25K-9


D

25T-B

Neutral Signal

2

25L


3

25M


4

25N


5

25P


6

25J


7

25S


8

36T


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

Bur 5-2750

CONNECTOR TS2 - TRANSMISSION SHIFTER

245487C1

CAV

WIRE IDENT

A

CIRCUIT Not Used

B

25W

3rd and 4th Gear Signal

C

25Z

1st and 4th Gear Signal

D

25Y

Transmission Kick Down Signal

Issued 8-06

Printed in U.S.A.

4002-178 CONNECTOR TSS - TURBINE SPEED SENSOR

CONNECTOR YCS - COMFOR STEERING SOLENOID

245482C1 291718A1

CAV

WIRE IDENT

CIRCUIT

1

25C

Turbine Speed Signal

2

0-HH

Turbine Speed Ground

CAV

WIRE IDENT

CIRCUIT

A

51B-D


B

0-AQ

Comfort Steering Solenoid Gnd

CONNECTOR YFN - FNA PWM SOLENOID CONNECTOR WF - WATER IN FUEL SENSOR

8602416

CAV

WIRE IDENT

CIRCUIT

256340A1

1

35W

Water Indicator

CAV

2

0-BP

Sensor Ground

A

56-A

Fan Control PWM

3

18J-H

Sensor Fused Power

B

0-BQ

Fan Speed PWM Solenoid Gnd

CONNECTOR WSH - WATER SEPARATOR HEATER

WIRE IDENT

CIRCUIT

CONNECTOR YFR - FAN REVERSING SOLENOID

225316C1

CAV 182069A1

CAV

WIRE IDENT

CIRCUIT

A

0-BW

Water Separator Heater Ground

B

1-GC

Water Separator Heater Power

Bur 5-2750

WIRE IDENT

CIRCUIT

1

52A-B

Fan Reversing Relay Out

2

0-BB

Fan Reversing Solenoid Ground

Issued 8-06

Printed in U.S.A.

4002-179 CONNECTOR YPB - PARKING BRAKE SOLENOID

CONNECTOR YRC - RIDE CONTROL OPT

291718A1

CAV

WIRE IDENT

CIRCUIT

291718A1

CAV

WIRE IDENT

CIRCUIT

1

52P

Parking Brake Relay Out

1

58


2

0-AN

Park Brake Solenoid Ground

1

58S-E

Ride Control Sol To Front Cab

2

0-AD

Ride Control Ground

CONNECTOR YPE - PIN ENGAGE OPT CONNECTOR YSS - SECONDARY STEERING SOLENOID

245482C1

CAV

WIRE IDENT

CIRCUIT

A

57

Pin Engage Solenoid Power

B

0-AE

Pin Engage Ground

225316C1

CAV

CONNECTOR YPP - PILOT PRESSURE SOLENOID

WIRE IDENT

CIRCUIT

1

51-C

Sec. Steering Solenoid Control

2

0-CF

Sec. Steering Solenoid Ground

245482C1

CAV

WIRE IDENT

CIRCUIT

A

5P-A


B

0-DU

Pilot Pressure Solenoid Gnd

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-180

NOTES

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-181

Symbols 12 Volt Radio .......................................................112

A A/C High/Low Pressure Switch ............................115 Air Filter Restriction Switch ....................................67 Air Seat Compressor and Switch .........................114 Alarm Back-up (Europe Only) ......................................96 Back-up (North America Only) ..........................96 Back-up, Disable Switch ...................................76 Back-up, Relay ..................................................76 Alternator ...............................................................40

B Back-up Alarm (Europe Only) ................................96 Back-up Alarm (North America Only) ....................96 Back-up Alarm Disable Switch ..............................76 Back-up Alarm Relay .............................................76 Batteries ................................................................41 Beacon Switch .......................................................79 Beacon, Rotating (Option) .....................................78 Brake Lamp Pressure Switch ................................83 Brake Lamps Relay ...............................................83 Brake Warning Pressure Switch ............................68 Buzzer ...................................................................66

C CAN Communication Diagnostics Connector ......109 Cigar Lighter ........................................................114 Circuit Breaker Cab B+ ..........................................47 Climate Control, Automatic 24 to 12 Volt Converter ...................................118 Blower Motor Resistor .....................................117 Blower Motors .................................................117 Compressor Relay ..........................................118 Electronic Panel ..............................................117 Electronic Water Valve ....................................118 External Air Temperature Sensor ....................117 Internal Air Temperature Sensor .....................117 Mixed Air Sensor .............................................117 Recycling Motor ..............................................118 Sun Sensor .....................................................117 Thermocouple Sensor .....................................117 Climate Control, Standard Air Conditioning Switch ...................................121 Air Recirculation Motor ....................................120 Air Recirculation Switch ..................................122 Blower Motor ...................................................120 Blower Motor Speed Resistors with Thermal Fuse 120 Blower Switch ..................................................121 Control Panel Lights ........................................121 Driver ...............................................................120 Electronic Water Valve ....................................120 Thermostat ......................................................121 Water Valve Potentiometer .............................121 Bur 5-2750

Cluster, Instrument Connector 1 ...........................65 Cluster, Instrument Connector 2 ...........................71 Compressor Clutch ..............................................115 Compressor Clutch Relay ...................................114 Compressor, Seat ...............................................114 Connector 108F ...................................................126 Connector 140M ..................................................126 Connector 197F ...................................................126 Connector 197M ..................................................126 Connector 202M ..................................................127 Connector 209F ...................................................127 Connector 209M ..................................................127 Connector 20M ....................................................127 Connector 215F ...................................................127 Connector 216F ...................................................127 Connector 64F .....................................................128 Connector 64M ....................................................128 Connector 69 .......................................................161 Connector ACT ....................................................128 Connector AIC1 ...................................................128 Connector AIC2 ...................................................129 Connector CAB_E ...............................................130 Connector CAB_F ...............................................131 Connector CAB_RF .............................................131 Connector CAB_T ...............................................132 Connector CAN ...................................................132 Connector CAN2 .................................................132 Connector CL ......................................................133 Connector CLS ....................................................133 Connector CNV ...................................................133 Connector D_OR .................................................133 Connector DIA .....................................................133 Connector DISC ..................................................133 Connector DM .....................................................134 Connector DNS-AC-SWITCH ..............................134 Connector DNS-ACTUATOR ..............................134 Connector DNS-BLUE .........................................134 Connector DNS-COMPRESSOR-RELAY ...........134 Connector DNS-CTRL-PANEL-LIGHT ................137 Connector DNS-DRIVER ....................................137 Connector DNS-ELECTRIC-FAN ........................137 Connector DNS-ELECT-WATER-VALVE ...........136 Connector DNS-ELECT-WATER-VALVE-S ........137 Connector DNS-EXTERNAL-AIR-TEMP-SNS ....134 Connector DNS-HVAC1 ......................................135 Connector DNS-HVAC1-S ..................................138 Connector DNS-HVAC2 ......................................135 Connector DNS-HVAC2-S ..................................138 Connector DNS-HVAC-CAN1 .............................134 Connector DNS-INTERNAL-AIR-TEMP-SNS .....135 Connector DNS-MISED-SIR-SENSOR ...............136 Connector DNS-NOT-USED ...............................135 Connector DNS-PWM-BLOWER ........................136 Connector DNS-PWM-BLOWER-PIN2 ...............136 Connector DNS-PWM-BLOWER-PIN4 ...............136 Connector DNS-RECIRCULATING-SWITCH .....137 Connector DNS-RECYCLING-MOTOR ..............136 Issued 8-06

Printed in U.S.A.

4002-182 Connector DNS-RESISTOR ................................137 Connector DNS-SPEED-SELECTOR .................136 Connector DNS-THERMOCOUPLE-SENSO ......136 Connector DNS-THERMOSTAT-1 ......................137 Connector DNS-THERMOSTAT-2 ......................137 Connector DNS-VOLTAGE-CONVERTER .........136 Connector DNS-WATER-VALVE-POT ................137 Connector DNS-YELLOW ...................................135 Connector DS ......................................................138 Connector E_HD .................................................138 Connector ECA ....................................................139 Connector ECB ....................................................140 Connector ECC ...................................................141 Connector ECD ...................................................142 Connector EDC7 .................................................143 Connector EM ......................................................143 Connector ENG ...................................................144 Connector ENG_D ...............................................144 Connector ENG_H ...............................................145 Connector ENG_T ...............................................145 Connector ESS ....................................................145 Connector FFH ....................................................145 Connector FLSHR ...............................................146 Connector FM ......................................................146 Connector FRONT ...............................................146 Connector FWM ..................................................147 Connector FWMG ................................................147 Connector FWW ..................................................147 Connector GHC ...................................................147 Connector GND_CAB_SPL .................................148 Connector GND_CAB_SPL2 ...............................148 Connector HD ......................................................148 Connector HD_E .................................................148 Connector HD_N .................................................149 Connector HDM ...................................................149 Connector HOT ...................................................149 Connector HVAC_CAN1 .....................................150 Connector HVAC1 ...............................................149 Connector HVAC2 ...............................................149 Connector ISS .....................................................150 Connector K_WCO ..............................................150 Connector LBEE ..................................................150 Connector LLF .....................................................151 Connector LLFW .................................................151 Connector LLR_E ................................................151 Connector LLR_N ................................................151 Connector LLRW .................................................152 Connector LPL .....................................................152 Connector LRF ....................................................152 Connector LRFW .................................................152 Connector LRR_E ...............................................153 Connector LRR_N ...............................................153 Connector LRRW ................................................153 Connector LSPK ..................................................153 Connector OSS ...................................................153 Connector PAF ....................................................154 Connector PBD ....................................................154 Bur 5-2750

Connector PBL ....................................................154 Connector PBW ...................................................154 Connector PO1 ....................................................155 Connector PO2 ....................................................155 Connector PR ......................................................155 Connector PRB1 .................................................155 Connector PRB2 .................................................155 Connector PRBF .................................................156 Connector PRM_A1 ............................................156 Connector PRM_B1 ............................................156 Connector PRM_B2 ............................................156 Connector PRM_C1 ............................................156 Connector PRM_C2 ............................................157 Connector PRM_D1 ............................................157 Connector PRM_E1 ............................................157 Connector PRM_E2 ............................................157 Connector PSS ....................................................157 Connector PXF ....................................................158 Connector PXH ...................................................158 Connector PXM ...................................................158 Connector PXT ....................................................158 Connector RAD ...................................................158 Connector RAD_J1 .............................................159 Connector RAD_J2 .............................................159 Connector RAD_J3 .............................................159 Connector RECT .................................................159 Connector ROOF ................................................160 Connector RSPK .................................................160 Connector RTHP .................................................160 Connector RWM ..................................................160 Connector RWMG ...............................................161 Connector RWW .................................................161 Connector S_KEY ...............................................161 Connector SBE ....................................................161 Connector SBU ...................................................162 Connector SC ......................................................162 Connector SCS ...................................................162 Connector SDC ...................................................162 Connector SDR ...................................................163 Connector SETHR ...............................................163 Connector SFC ....................................................163 Connector SFL ....................................................163 Connector SFNR .................................................164 Connector SFWW ...............................................164 Connector SHC ...................................................164 Connector SHZ ....................................................164 Connector SPB ....................................................165 Connector SPC ...................................................165 Connector SPE ....................................................165 Connector SPK ....................................................165 Connector SPL_BCK_LGT ..................................166 Connector SPL_BCK_LGT2 ................................166 Connector SPL_BCK_LT_GD .............................166 Connector SPL_BCK_LT_GD2 ...........................167 Connector SPL_ENG_GND ................................167 Connector SPL_HOOD_GND .............................167 Connector SPL_PED_BL ....................................168 Issued 8-06

Printed in U.S.A.

4002-183 Connector SPL_PED_BL_GD .............................168 Connector SPL_PIN ............................................168 Connector SPL_PK1 ...........................................169 Connector SPL_PK2 ...........................................169 Connector SPL_PK3 ...........................................170 Connector SPL_ROOF ........................................170 Connector SPL_SEC_STR ..................................170 Connector SPL_TRN_GRD .................................171 Connector SPL_TRNS_PWR ..............................171 Connector SRC ...................................................171 Connector SRC_1 ...............................................171 Connector SRHSTLK ..........................................172 Connector SRTD .................................................172 Connector SRWP ................................................172 Connector SS_TR ...............................................172 Connector SSM ...................................................173 Connector STA ....................................................173 Connector STE ....................................................173 Connector SW_PD ..............................................174 Connector SWL ...................................................174 Connector TCOT .................................................174 Connector TDM ...................................................174 Connector TECM .................................................175 Connector TR_SS ...............................................176 Connector TRAN_E .............................................176 Connector TRANS ...............................................176 Connector TRC ....................................................177 Connector TS1 ....................................................177 Connector TS2 ....................................................177 Connector TSS ....................................................178 Connector WF .....................................................178 Connector WSH ...................................................178 Connector YCS ....................................................178 Connector YFN ....................................................178 Connector YFR ....................................................178 Connector YPB ....................................................179 Connector YPE ....................................................179 Connector YPP ....................................................179 Connector YRC ...................................................179 Connector YSS ....................................................179 Connector, Diagnostic ...........................................63 Coolant Level Sender ............................................74 Crank Control Relay ..............................................41 Crank Request Relay ............................................41

D Declutch Brake Switch ...........................................63 Declutch Switch .....................................................63 Diagnostic Connector ............................................63 Diodes Lights .................................................................81 Secondary Steering .........................................105 Wipers .............................................................103 Dome Lamp ...........................................................79 Door Switch ...........................................................78 Driving Lamp Switch ..............................................86

Bur 5-2750

E Electrical Wire Identification ....................................8 Electromagnetic Detents .......................................54 Electronic Diesel Control .......................................51 Engine Speed Sensor ...........................................63

F Fan PWM Solenoid ...............................................61 Fan Reverse Relay ................................................59 Fan Reversing Solenoid ........................................61 Fan Reversing Switch ...........................................59 Filter Maintenance Switch .....................................63 Flasher Module ......................................................84 FNR Switch for Joystick Controls ..........................63 FNR Switch for Single Axis Controls .....................63 Front Left Hand Work Lamp .......................................79 Right Hand Work Lamp .....................................80 Front Left Hand Combination Lamp ......................88 Front Right Hand Combination Lamp ....................89 Front Washer Pump Motor ..................................102 Front Wiper and Washer Switch ..........................100 Front Wiper Cut Out Relay ....................................98 Front Wiper High Speed Relay ..............................98 Front Wiper Low Speed Relay ..............................99 Front Wiper Motor ...............................................101 Fuel Filter Heater ...................................................48 Fuel Filter Heater Relay ........................................46 Fuel Level Sender .................................................67

G Grid Heater ............................................................47 Grid Heater Relay ..................................................47

H Hazard Switch .......................................................85 Heater Fuel Filter ..........................................................48 Grid ...................................................................47 Water Separator ................................................47 Height Control Switch ............................................53 Height Control/Return-To-Travel Proximity Switch 55 High-Low Beam Switch .........................................85 Hood Down Relay .....................................................124 Motor ...............................................................125 Switch .............................................................124 Up Relay .........................................................124 Horn .......................................................................90 Horn Relay ............................................................90 Horn Switch ...........................................................85 Hydraulic Filter Restriction Switch .........................72 Hydraulic Oil Temperature Sender ........................72

I Ignition Switch .......................................................43 Instrument Cluster Connector 1 ............................65 Issued 8-06

Printed in U.S.A.

4002-184 Instrument Cluster Connector 2 .............................71 Intermediate Speed Sensor ...................................63

L Lamp Dome .................................................................79 High Beam ..................................................88, 89 Left Hand Front Combination ............................88 Left Hand Front Work ........................................79 Left Hand Rear Combination (Europe Only) .....95 Left Hand Rear Combination (North America Only) ............................................................94 Left Hand Rear Work ........................................80 License Plate (Europe Only) .............................96 License Plate (North America Only) ..................95 Low Beam ...................................................88, 89 Position .......................................................88, 89 Right Hand Front Combination ..........................89 Right Hand Front Work .....................................80 Right Hand Rear Combination (Europe Only) ...93 Right Hand Rear Combination (North America Only) ...................................................92 Right Hand Rear Work ......................................80 Switch, Driving ..................................................86 Turn .............................................................88, 89 Left Hand Front Combination Lamp ......................88 Left Hand Front Work Lamp ..................................79 Left Hand Rear Combination Lamp (Europe Only) 95 Left Hand Rear Combination Lamp (North America Only) .........................................................94 Left Hand Rear Work Lamp ...................................80 Left Speaker ........................................................112 License Plate Lamp .........................................95, 96 License Plate Lamp (Europe Only) ........................96 License Plate Lamp (North America Only) ............95 Lights Diodes .........................................................81 Locating Components on the Schematic Posters ..38

M Magnetic Detents ...................................................54 Master Disconnect Switch .....................................42 Module Flasher ..............................................................84 Secondary Steering .........................................106 Time Delay ........................................................42 Transmission Electronic Control .......................63 Motor Hood ................................................................125 Starter ...............................................................43

N Neutral Start Relay ................................................44

O Outlet, Power .......................................................111 Output Speed Sensor ............................................63 Bur 5-2750

P Parking Brake Relay .............................................. 66 Parking Brake Solenoid ......................................... 67 Parking Brake Switch ............................................ 73 Pilot Control Relay ................................................. 55 Pilot Control Switch ............................................... 60 Pilot Pressure Solenoid ......................................... 56 Pin Engage Solenoid ............................................. 56 Pin Engage Switch ................................................ 56 Potentiometer Throttle .............................................................. 50 Power Converter (24 volts to 12 volts) ................111 Power Outlet ........................................................111 Power Relay Module A Ignition Power ................................................ 46 B Ignition Power ................................................ 46 C Fuel Filter Heater ........................................... 46 D Accessory Power ........................................... 48 E Power Converter 24V to 12V .......................111 Proximity Switch Height Control/Return-To-Travel .......................55 Return-To-Dig ................................................... 54

R Radiator Coolant Temperature Sender ................. 68 Radio 12 Volt .............................................................112 Rear Left Hand Combination Lamp (Europe Only) .... 95 Left Hand Combination Lamp (North America Only) .................................................. 94 Left Hand Work Lamp ....................................... 80 Right Hand Combination Lamp (Europe Only) . 93 Right Hand Combination Lamp (North America Only) .................................................. 92 Right Hand Work Lamp ..................................... 80 Rear Washer Pump Motor ...................................102 Rear Wiper and Washer Switch ............................ 99 Rear Wiper Motor ................................................102 Redundant Brake Pressure Switch 1 .................... 73 Redundant Brake Pressure Switch 2 .................... 73 Relay Backup Alarm ....................................................76 Brake Lamps ..................................................... 83 Compressor Clutch .........................................114 Crank Control ....................................................41 Crank Request .................................................. 41 Fan Reverse ..................................................... 59 Front Wiper Cut Out .......................................... 98 Front Wiper High Speed ................................... 98 Front Wiper Low Speed .................................... 99 Fuel Filter Heater .............................................. 46 Grid Heater ....................................................... 47 Hood Down .....................................................124 Hood Up ..........................................................124 Horn .................................................................. 90 Neutral Start ...................................................... 44 Issued 8-06

Printed in U.S.A.

4002-185 Parking Brake ....................................................66 Pilot Control .......................................................55 Power Relay Module A Ignition Power ..............46 Power Relay Module B Ignition Power ..............46 Power Relay Module C Water Separator Htr ....46 Power Relay Module D Accessory Power .........48 Power Relay Module E Power Converter ........111 Ride Control ......................................................58 Starting ..............................................................40 Voltmeter ...........................................................44 Resistor Alternator ...........................................................40 Return to Dig Switch Switch ..................................55 Return-To-Dig Proximity Switch ............................54 Return-To-Travel/Float Switch ...............................53 Ride Control Relay ................................................58 Ride Control Solenoid ............................................60 Ride Control Switch ...............................................58 Right Hand Front Combination Lamp ....................89 Right Hand Front Work Lamp ................................80 Right Hand Rear Combination Lamp (Europe Only) . 93 Right Hand Rear Combination Lamp (North America Only) .........................................................92 Right Hand Rear Work Lamp ................................80 Right Speaker ......................................................112 Rollback Jumper ....................................................61 Rollback Pressure Switch ......................................60 Rotating Beacon (Option) ......................................78

S Seat Compressor and Switch ..............................114 Secondary Steering Module ............................................................106 Motor ...............................................................107 Pressure Switch ..............................................107 Solenoid ..........................................................105 Secondary Steering Diodes .................................105 Sender Coolant Level ....................................................74 Fuel Level ..........................................................67 Hydraulic Oil Temperature ................................72 Radiator Coolant Temperature ..........................68 Torque Converter Output Temperature .............63 Sensor Engine Speed ....................................................63 Intermediate Speed ...........................................63 Output Speed ....................................................63 Transmission Solenoid Valve and Temperature ... 63 Turbine Speed ...................................................63 Water In Fuel .....................................................50 Shifter, Transmission .............................................63 Solenoid Fan PWM ..........................................................61 Fan Reversing ...................................................61 Parking Brake ....................................................67 Bur 5-2750

Pilot Pressure ....................................................56 Pin Engage .......................................................56 Ride Control ......................................................60 Secondary Steering .........................................105 Speaker Left ..................................................................112 Right ................................................................112 Specifications ..........................................................7 Speed Resistors Blower Motor ...................................................120 Starter Motor .........................................................43 Starting Relay ........................................................40 Steering Secondary, Module .........................................106 Secondary, Motor ............................................107 Secondary, Pressure Switch ...........................107 Secondary, Solenoid .......................................105 Switch A/C High/Low Pressure ...................................115 Air Filter Restriction ...........................................67 Back-up Alarm Disable ......................................76 Beacon ..............................................................79 Blower .............................................................121 Brake Lamp Pressure .......................................83 Brake Warning Pressure ...................................68 Declutch ............................................................63 Declutch Brake ..................................................63 Door ..................................................................78 Driving Lamp .....................................................86 Fan Reversing ...................................................59 Filter Maintenance .............................................63 FNR for Joystick Controls .................................63 FNR for Single Axis Controls ............................63 Front Wiper and Washer .................................100 Hazard ..............................................................85 Height Control ...................................................53 High-Low Beam .................................................85 Hood ...............................................................124 Horn ..................................................................85 Hydraulic Filter Restriction ................................72 Ignition ..............................................................43 Master Disconnect ............................................42 Pad ....................................................................70 Parking Brake ....................................................73 Pilot Control Switch ...........................................60 Pin Engage .......................................................56 Proximity, Height Control/Return-To-Travel ......55 Proximity, Return-To-Dig ...................................54 Rear Wiper and Washer ....................................99 Redundant Brake Pressure 1 ............................73 Redundant Brake Pressure 2 ............................73 Return to Dig .....................................................55 Return-To-Travel/Float ......................................53 Ride Control ......................................................58 Rollback Pressure .............................................60 Seat Compressor ............................................114 Secondary Steering Pressure .........................107 Issued 8-06

Printed in U.S.A.

4002-186 Transmission Auto ............................................63 Transmission Enable .........................................63 Transmission Kick-down ...................................63 Turn Signal ........................................................85 Work Lamps ......................................................78 Switch Pad .............................................................70

T Thermal Fuse Blower Motor ...................................................120 Throttle Potentiometer ...........................................50 Time Delay Module ................................................42 Torque Converter Output Temperature Sender ....63 Transmission Auto Switch .....................................63 Transmission Electronic Control Module ...............63 Transmission Enable Switch .................................63 Transmission Kick-down Switch ............................63 Transmission Shifter ..............................................63 Transmission Solenoid Valve and Temperature Sensors ...........................................................63 Turbine Speed Sensor ...........................................63 Turn Signal Switch .................................................85

U Understanding the Troubleshooting Tables ...........38

V Voltmeter Relay .....................................................44

W Warning Buzzer .....................................................66 Water In Fuel Sensor .............................................50 Water Separator Heater ...............................................................47 Heater Relay .....................................................46 Wiper Front Cut Out Relay ..........................................98 Front Motor ......................................................101 Front Switch ....................................................100 Front Washer Pump Motor ..............................102 Front Washer Switch .......................................100 Front Wiper High Speed Relay .........................98 Front Wiper Low Speed Relay ..........................99 Rear Motor ......................................................102 Rear Switch .......................................................99 Rear Washer Pump Motor ..............................102 Rear Washer Switch .........................................99 Wiper Diodes .......................................................103 Wire Identification ....................................................8 Work Lamp Switch .................................................78

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4003

Section 4003 BATTERIES


Bur 6-42330


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

Bur 6-42330

Issued 4-03

3 3 4 4 4 5 5 5 6 7 7 8 8

Printed in U.S.A.

4003-3

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

WARNING: Never cause sparks to occur or smoke near batteries that are charging or have been recently charged. 13-8A

WARNING: Disconnect the ground cable first when the battery cables are disconnected from the battery. Connect the ground cable last when the battery cables are connected to the battery. 47-55A

WARNING: Some batteries have a ventilation tube. If there is battery acid in the ventilation tube, this battery acid can be released when the battery is turned upside down. If you turn the battery upside down, make sure that the end of the ventilation tube is away from you and away from any other people in the area. Battery acid can cause severe burns.

WARNING: Battery acid causes severe burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes, or clothing. Antidote: EXTERNAL-Flush with water. INTERNAL-Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician immediately. Eyes: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases. Keep sparks, flame, and cigarettes away. Ventilate when charging or using in enclosed area. Always shield eyes when working near batteries. Keep out of reach of children. 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.

Bur 6-42330

Issued 4-03

Printed in U.S.A.

4003-4

MAINTENANCE Electrolyte Level

Inspecting and Cleaning a Battery

If the battery is a maintenance free battery, check the level of the electrolyte every 1000 hours of operation or six months, whichever occurs first. For all other batteries, check the level of the electrolyte every 250 hours of operation.

If damage causes an electrolyte leak, replace the battery.

NOTE: A maintenance free battery will have the words Maintenance Free on the decal on the top of the battery. If the center part of the decal has been removed for access to the battery caps, it is possible that the words Maintenance Free have been removed from the decal. Check the level of the electrolyte more often during hot weather. The use of a large amount of water by the batter y can be caused by high batter y temperature or a voltage regulator setting that is too high. Keep the electrolyte level above the top of the plates in the battery at all times to prevent damage to the battery. NOTE: On maintenance free batteries it is necessary to remove the center part of the decal for access to the battery caps. Do not discard the center part of the decal. Install the center part of the decal after the battery caps have been installed.

Inspect the battery at regular intervals for dir t, corrosion, and damage. Electrolyte and dirt on the top of the battery can cause the battery to discharge by making a passage for the current to flow. If the battery must be cleaned, remove the battery from the battery carrier and clean the battery, cable terminals, and the battery carrier. When available, use Case Battery Saver and Cleaner according to the instructions on the container. Case Battery Saver and Cleaner also helps prevent corrosion. If Case 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 Case 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 n e e d e d . To o m u c h w a t e r c a n c a u s e b a d performance, a short service life, and corrosion around the battery. NOTE: Add water only. DO NOT add electrolyte.

Bur 6-42330

Issued 4-03

Printed in U.S.A.

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.

Bur 6-42330

Issued 4-03

Printed in U.S.A.

4003-6

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

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 vo l t a g e s h o w n , t h e b a t t e r y i s i n g o o d condition. B. If the test result is less than the voltage shown, discard the battery.

B790499

1. LOAD CONTROL KNOB

Bur 6-42330

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

Issued 4-03

Printed in U.S.A.

4003-7

CHARGING A BATTERY The charging rate must be decreased if: WARNING: Never try to charge the battery if the electrolyte in the battery is frozen. 47-83

1. Too much gas causes the electrolyte to flow from the cells.

Before you charge the battery, check the level of the electrolyte.

2. The temperature of the electrolyte rises above 52°C (125°F).

It is difficult to give an exact charging rate because of the following variable conditions: (1) temperature of the electrolyte, (2) level of charge, and (3) condition of the battery. Use the charging guide for the correct charging rate and time.

NOTE: For the best charge, use the slow charging rates. The battery is fully charged when, over a three hour period at a low charging rate, no cell is giving too much gas, and the specific gravity does not change.

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

Charging Guide For Maintenance Free Batteries Recommended Rate* and Time for Fully Discharged Battery Battery Capacity - See Reserve Capacity under Specifications

Slow Charge

Fast Charge

10 Hours at 5 Amperes 5 Hours at 10 Amperes

2.5 Hours at 20 Amperes 1.5 Hours at 30 Amperes

Above 80 to 125 Minutes

15 Hours at 5 Amperes 7.5 Hours at 10 Amperes

3.75 Hours at 20 Amperes 1 .5 Hours at 50 Amperes






7.5 Hours at 20 Amperes 3 Hours at 50 Amperes

80 Minutes or Less

*lnitial rate for standard taper charger.

NOTE: A maintenance free battery will have the words Maintenance Free on the decal on the top of the battery. If the center part of the decal has been removed to get access to the battery caps, it is possible the words Maintenance Free will have been removed from the decal. Continued on next page

Bur 6-42330

Issued 4-03

Printed in U.S.A.

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


2.5 Hours at 20 Amperes 1.5 Hours at 30 Amperes


15 Hours at 5 Amperes 7.5 Hours at 10 Amperes

3.75 Hours at 20 Amperes 1 .5 Hours at 50 Amperes






7.5 Hours at 20 Amperes 3 Hours at 50 Amperes

Above 250 Minutes

24 Hours at 10 Amperes


80 Minutes or Less

*lnitial rate for standard taper charger.

PREPARING A DRY CHARGED BATTERY FOR USE 1. Remove the caps from the battery. 2. Fill each cell to the top of the separators with electrolyte. This will per mit 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 spe cific gravity is 1 .25 0 or m ore a nd 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.

Bur 6-42330

Issued 4-03

Printed in U.S.A.

Section 4005

4005

INSTRUMENT CLUSTER


Bur 5-2760


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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hardware Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Software Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Selecting Power Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Language Screen, Measurement Units, and Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Options Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Display Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MPH/KPH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RETRIEVING FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Fault Code Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fault Code Grouping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VEHICLE FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTRUMENT CLUSTER FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 5-2760

Issued 8-06

3 4 4 5 6 9 10 10 10 10 11 13 13 13 13 13 14 14 14 15 17 27 32

Printed in U.S.A.

4005-3

INSTRUMENT CLUSTER

1

2

3

4

5

6

7

8

9

10

11

15 14

12

13

BD06H039

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:

Bur 5-2760

Issued 8-06

Printed in U.S.A.

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/r eplace 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:

Bur 5-2760

Issued 8-06

Printed in U.S.A.

4005-5

LCD Multi-function Display

2. This example, shows that the Transmission Control Lever is in Neutral. The display will show Forward, Neutral, or Reverse, depending on where the Directional Control Lever is positioned. NOTE: Forward and Reverse will blink if the transmission clutches are disconnected. 3. This example shows the maximum gear allowed when in Automatic mode. If display is blank the Manual mode has been selected. 4. This example shows the current transmission mode that has been selected. A. If the Transmission is operating normally it will display either BD06J132

The LCD Multi-Function Display is located at the center of the modular dashboard. On start up the cluster will flash the instructional lamps and the LCD Multi-Display will display, CASE, with the machine model and current hour reading.

2

1 3

5

4

●

A - Automatic

●

M - Manual operation.

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

C - Substitute Clutch.

●

L - Limp Home.

●

S - Transmission Shutdown.

●

U - TCU Shutdown.

5. This example (not displayed) will show the transmission clutches disengaged, if the Park Brake is OFF. 6. This example shows the Power Boost Status.

6

7 BD06F185

●

MAX - Maximum Power.

●

STD - Normal/Standard mode of Operation.

●

AUTO - Switches automatically Maximum and Standard Power.

●

ECO - Limited Power for fuel efficiency.

between

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

LCD MULTI-FUNCTION DISPLAY

Information will be displayed in different zones on the LCD, as directed by the operator or machine. In most situations the operator or technician will be given specific information to follow if conditions are not correct. 1. In the example, above, the machine hours are d i s p laye d . M a c h i n e h o u r s w i l l a l way s b e displayed briefly, on start up. After, the machine is started, the display will show engine rpm’s. After, beginning travel, the machine will display travel speed, if default settings were not changed by the operator.

Bur 5-2760

Issued 8-06

Printed in U.S.A.

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. BD06F183

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 voltage level.

Bur 5-2760

Issued 8-06

Printed in U.S.A.

4005-7

BD06F169

BD06F027

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

Press the down button again and the Trip 1 screen will display. The LCD provides two trip computers. These will display since last reset the total time in h o u r s , t h e t o t a l f u e l , a n d t h e a ve r a g e f u e l consumption per hour.

BD06F170 BD06F184

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

Bur 5-2760

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.

Issued 8-06

Printed in U.S.A.

4005-8

Reset The Trip Information

BD06F172 BD06F170

Highlight the trip screen you wish to set.

The trip screen will indicate a reset message. At this screen, press confirm to clear the numbers and reset the trip information. The current date and time will display automatically. The hours, fuel consumption, and fuel used per hour will reset and revert to zero.

BD06F187

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

Bur 5-2760

Issued 8-06

Printed in U.S.A.

4005-9

Entering The Service Screens After the machine has been started or the key switch has been turned to on the operator or service technican may use this service menu to adjust machine configurations to working conditions, test components, view faults that may have occurred, or select preferences. NOTE: When all the selections have been made they will be stored in memory. If there is an abrupt battery disconnect you may loose all of your selections and need to reprogram the LCD Multi-function display.

BD06H038 / 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. Power Mode Menu

●

Month

●

Year

●

Max - Maximum power possible

●

Standard - Standard operation

●

Part Number

●

Auto - Will cycle between Max and Standard

●

Serial Number

●

Eco - Limited power for economy

●

ID

●

Version

2. Preferences Menu

6. Cluster H/W

●

Language - English, Italian, French, Spanish, Portuguese, German

●

Part Number

●

Units - Metric, English or Imperial

●

Loader Version

●

Clock - 24 or 12 hour

●

ID

●

Version

3. Options Menu

7. Cluster S/W

●

Fan Auto - manual or automatic

●

Idle Auto - manual or automatic

●

Change Model *

●

Show RPM

●

Select Tires (Select tire sizes)

●

Show MPH/KPH

●

Clutch Calibration (calibrate gear box)*

4. Display Menu

8. Config Menu

●

Gear Limits (choose maximum gear)

●

Day Display

●

Park Brake (Park brake test)

●

Day LED

●

Cold Start (choose cold start system)

●

Night Display

●

FAN Test (sound level)

●

Night LED

●

Special

5. Clock Menu ●

Hour

●

Minute

●

Day

Bur 5-2760

- Reset Error - Factory Set

Issued 8-06

Printed in U.S.A.

4005-10 * The tests in the configuration menu should be performed only by a qualified operator or technician, as some tests require the engine to be running at high RPM’s.

Software Screen

Select Screen The select screen will allow you to make time s e t t i n g s a s w e l l a s g i ve a c c e s s t o m a c h i n e information. Navigate this screen also by highlighting your selection and pressing confirm. This will allow you to change clock settings or view the hardware and software screens. No operator changes can be made to the hardware or software screens. BD06H028

The cluster software selection will display the CNH part number, serial number, ID number and software version of the Instrument cluster. This display is a convenient source of information when ordering parts or accessories. Press escape to exit from this field and return to the selection menu or use the up or down arrow key to toggle to the software information screen.

Selecting Power Modes BS06F177

Hardware Screen Scroll to the hardware selection and press confirm to display machine information.

The power mode allows the operator to choose the most effective machine power for the current job conditions. Most commonly auto is chosen, as the power will automatically increase or decrease between maximum power and standard power while the machine is working. This allows for maximum power if necessary, but will switch to standard mode for economy. Maximum power can be chosen for more severe work conditions. Economy can be chosen for limited power and fuel efficiency. Press and hold the confirmation button for two seconds to arrive at the service screen.

BD106F193

The cluster hardware selection will display the CNH part number, serial number, ID number and version of the Instrument cluster. This display is a convenient source of infor mation when ordering par ts or accessories. Press escape to exit from this field and return to the selection menu or use the up or down arrow key to toggle to the software information screen.

Bur 5-2760

BD06H038

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

Issued 8-06

Printed in U.S.A.

4005-11

Preferences

BD06F178

At the Power Mode Menu press the confirmation bu t t o n a g a i n t o a c t i va t e t h e s e l e c t i o n s. T h e highlighted section will flash to indicate a new selection can be made. Press the up or down button to select the Power Mode, and then press the confirmation button again. This changes the mode and locks it into memory. The selected mode will display in zone 3 (bottom) of the Multi-Function Display when power mode is correctly selected. NOTE: Selecting options and navigating through the screen menus are the same for all functions. The display will tell the operator if errors have occurred.

BD06F179

Language Screen, Measurement Units, and Clock The LCD screen can be set with language, units, and clock preferences. Use the arrow keys to scroll to the preferences menu. Press confirm. Choose the preferences desired, language in (English, Italian, Spanish, Portuguese, German, French, measurement units in English, Metric, or Imperial and clock units in either 12 or 24 hour). Highlight the preference you wish to change and press the confirm key. The preference will flash and allow you to scroll through the choices. When the correct preference is chosen, use the confirm key to lock in the preference for the display. The escape key will allow you to leave this application.

BD06F176

S h o u l d a n e r r o r m e s s a g e d i s p l ay, p r e s s t h e confirmation button to acknowledge and begin again.

Bur 5-2760

Issued 8-06

Printed in U.S.A.

4005-12

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 Config.

BD06F196

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

BD06F202

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. BD06F195

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

Bur 5-2760

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

Issued 8-06

Printed in U.S.A.

4005-13

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

Display Menu

BD06F174

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

Fan Auto The fan can be set to run at automatic or the fan will run at maximum speed. Automatic is the more common or preferred setting. It will switch between high speed, low speed, or reverse as conditions require depending on actual temperature of the coolant, turbocharger air, transmission oil, and hydraulic oil.

The display menu can be used to change the background and brightness of the screen. Use the arrow keys to make your selection from the display menu and press the confirm key to lock the selection into memory. The screen display can be changed to suit working conditions for day and night separately.

RPM Engine speed in RPM will show on the display if the engine speed is running up to 550 RPM’s, and will disappear if the engine speed is lower than 300 RPM.

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

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.

Bur 5-2760

Issued 8-06

Printed in U.S.A.

4005-14

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

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

A

5. 5000 to 5999 eltro-hydraulic system errors.

C

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

B

D BD06F186

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

will

be

continuous,

A. Operator can acknowledge it by pressing the enter key. B. Buzzer will change to a less stressing sound, but will remain. C. Message will remain on display with indication of URGENT STOP.

Bur 5-2760

Issued 8-06

Printed in U.S.A.

4005-15

VEHICLE FAULT CODES CODE

DEFINITION

POSSIBLE STEPS FOR REPAIR

1310

Hydraulic filter blocked

Change filter

1311

Engine air filter blocked

Change filter

1312

Hydraulic oil temperature above normal

1313

Hydraulic oil temperature to high

1314

Transmission oil temperature above normal

1315

Transmission oil temperature to high

1. 2. 3. 4.

Stop machine operations Run engine at 1500 rpm Check fan operation Check cooling core for clogs

Brake pressure too low

1. 2. 3. 4.

Stop machine operations Run engine at 1500 rpm Check brake system pressure Check brake system for leaks

1317

Steering pressure too low

1. 2. 3. 4.

Stop machine operations Run engine at 1500 rpm Check steering system for operation Check steering system for leaks

1318

Engine coolant temperature above normal

1319

Engine coolant temperature high - critical

1. 2. 3. 4.

Stop machine operations Run engine at 1500 rpm Check fan operation Check radiator core for clogs

1320

Engine oil pressure too low

1321

Engine oil pressure below normal

1. Stop machine operations 2. Check engine oil level 3. Check pressure sender unit

1322

Engine oil pressure above normal

1. Check engine oil for proper type 2. Check pressure sender unit

1323

Battery voltage low

1324

Battery voltage high

1325

Oil temperature too high

1326

Coolant level low

Fill radiator level

1327

Moved during accelerated idle

No information available at time of print.

1328

Moving when shifting to low idle


1331

Electrical charging system voltage low critical level

1332

Water detected in fuel

Drain fuel filter

1333

Engine overspeed

Check engine speeds

1334

Intake manifold temperature high - critical

Check for defective or clogged after cooler

1316

1335

Bur 5-2760

Check charging system

Brake pressure too low

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

1. Stop machine operations 2. Check charging system

1. 2. 3. 4.

Stop machine operations Run engine at 1500 rpm Check brake system pressure Check brake system for leaks

Issued 8-06

Printed in U.S.A.

4005-16 CODE 1336

DEFINITION Transmission oil filter blocked

POSSIBLE STEPS FOR REPAIR Replace filter

NOTE: The following fault codes are for optional climate controlled heating and air conditioning system. CODE 1909

1910

1919

1920

1921

Bur 5-2760

DEFINITION Open circuit evaporator temperature sensor

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR AC relay compressor is disabled.

Short circuit evaporator temperature sensor

1. Check sensor for short circuit to ground or open circuit. 2. Check harness between control module and relay.

Water valve motor output failure, does not work correctly

1. Verify if the system controls are functioning properly when requesting heat or AC. 2. The motor is working in a degraded mode, replace valve.

Recirculation actuator DC motor output failure, does not work correctly

1. Turn system on with fan speed on low, verify position of flap. 2. Place the fan speed on high, check position of flap. 3. Check harness between controller and flap motor.

AC relay output failure, does not work.

1. Check for proper connection of relay. 2. Replace relay with known good relay and retest system. 3. Verify system activation when AC button is pressed. 4. Check charge level of AC system.

Issued 8-06

Printed in U.S.A.

4005-17

ENGINE FAULT CODES CODE

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

3001

Foot throttle sensor signal not plausible

Idle switch defect or wiring of idle switch broken or accelerator pedal defect. Check wiring, replace idle switch or replace accelerator pedal.

3002

Foot throttle sensor signal above range max.

Short circuit in wiring or in accelerator pedal. Check wiring or replace accelerator pedal.

3003

Foot throttle sensor signal below range min.

Short circuit in wiring or in accelerator pedal. Check wiring or replace accelerator pedal.

3004

Foot throttle sensor - no signal

Check wiring or replace accelerator pedal

3006

Coolant temperature sensor signal not plausible

See OTS (Oil Temperature Sensor) plausibility check (Fault 3033)

3007

Coolant temperature sensor signal above range max.

Sensor defective or short circuit to external source. Check wiring or replace sensor.

3008

Coolant temperature sensor signal below range min.

Sensor defective or short circuit to ground. Check wiring or replace sensor.

3009

Coolant temperature sensor null (via CAN)

No CAN plausibility check performed, restart system, if problem reoccurs. Check wiring or replace sensor.

3015

Fuel temperature signal above range max.


3016

Fuel temperature signal below range min.


3019

Boost pressure sensor signal above range max.


3021

Boost pressure sensor null (via CAN)


3022

Boost pressure sensor signal not plausible

Difference of ambient and boost pressure is out of range. Check wiring or replace sensor.

3023

Atmospheric pressure sensor signal not plausible

3024

Atmospheric pressure sensor signal above range max.

3025

Atmospheric pressure sensor signal below range min.

Bur 5-2760

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

Issued 8-06

Printed in U.S.A.

4005-18 CODE

DEFINITION


3028

Oil pressure sensor pressure too low

Inaccurate oil pressure sensor or defect (e.g. too low oil level, leakage...) in the oil system. Check oil pressure sensor for accuracy and check oil system.

3029

Oil pressure sensor short-circuit to battery


3030

Oil pressure sensor short-circuit to ground


3031

Oil pressure sensor ADC conversion error


Oil pressure sensor pressure too high

Inaccurate oil pressure sensor or defect (e.g. blocked piping) in the oil system. Check oil pressure sensor for accuracy and check oil system.

3033

Oil temperature sensor signal not plausible

Inaccurate oil or coolant temperature sensors or insufficient oil or coolant recirculation (low coolant level etc.). Check oil and coolant temperature sensor for accuracy and check oil and coolant system for proper functioning.

3034

Oil temperature sensor signal above range max.


3035

Oil temperature sensor signal below range min.


3036

Oil temperature sensor signal CAN transmission disturbed


3037

Boost pressure sensor signal low


3043

Vehicle speed sensing hardware conversion error


3046

Vehicle speed sensing signal not plausible


3051

Battery voltage to ECM too high

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

Battery voltage to ECM too low

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

Cylinder 1 unclassified error in injector

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

3032

3052

3060

Bur 5-2760

Issued 8-06

Printed in U.S.A.

4005-19 DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

CODE

DEFINITION

3061

Cylinder 1 injector cable short-circuit low side to battery

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

3062

Cylinder 1 signal low

Check the wiring and the injection signals, replace ECU

3063

Cylinder 1 short-circuit high side to ground

Defective coil of injector. Check the wiring and replace injector

3064



3065



3066


Check the wiring and the injection signals, replace ECU.

3067



3068



3069



3070



3071



3072



3073



3074



3075





3076

Bur 5-2760

Issued 8-06

Printed in U.S.A.

4005-20 DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

CODE

DEFINITION

3077



3078



3079



3080



3081



3082



3083



3088

Crankshaft sensor lost synchronization

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

3089

Crankshaft sensor defective

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

3090

Camshaft sensor lost phase

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

3091

Camshaft sensor phase synchronization failure

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

3093

Offset between camshaft and crankshaft outside boundaries

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

3095

Operating with camshaft sensor only

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

3102

Rail pressure sensor CP3 signal below range min.

Short circuit of wiring to ground or defective pressure sensor. Check wiring and proper functioning of rail pressure sensor

Bur 5-2760

Issued 8-06

Printed in U.S.A.

4005-21 CODE

DEFINITION


Rail pressure relief valve open

Defective rail pressure sensor, defect in other injection relevant component. Check rail pressure sensor for plausible values, ensure proper functioning of the injection components

3105

Rail pressure relief valve pressure shock requested

PRV does not open once the pressure limit is reached: Mechanical defect or wrong application parameter. Check application value of maximum rail pressure, check functioning of the PRV

3106

Rail pressure relief valve did not open after pressure shock

PRV does not open even after pressure shock: Stuck PRV or wrong application parameter. Check application value of maximum rail pressure, check functioning of the PRV

3107

Metering unit output short-circuit to battery on low side

Short circuit of wiring to external source or inside relay. Check wiring or replace relay

3110

Rail pressure sensor offset monitoring signal above range max.

3111

Rail pressure sensor offset monitoring signal below range min.

3104

Rail pressure sensor inaccurate. Ensure correct wiring and proper functioning of rail pressure sensor, replace sensor

3112

Rail pressure sensor CP3 signal above range max.

Short circuit of wiring to external source or defective pressure sensor, rail pressure overshoot. Check wiring and proper functioning of rail pressure sensor

3113

Grid heater battery switch relay short-circuit to battery

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

3114

Grid heater battery switch relay short-circuit to ground

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

3118

ECM 12V sensor supply voltage high

3119

ECM 12V sensor supply voltage low

3131

Grid heater always switched on

Short circuit to ground of grid heater. Check grid heater switch and replace it

3137

Metering unit open load

Broken or disconnected wiring or defective relay. Check of wiring or replace relay

Metering unit signal not plausible

Defective wiring, ECU, power stage or metering unit. Check wiring, ECU, power stage and metering unit

3138

Bur 5-2760

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

Issued 8-06

Printed in U.S.A.

4005-22 CODE

DEFINITION


3141

Set point of fuel volume flow through metering unit is lower than calculated limit

High pressure system: Rail pressure sensor inaccurate, high pressure pump defective. Low pressure system: Metering unit reflux too low. Check for defects according to failure list.

3147

Oil temperature sensor signal above normal range

Check oil temperature sensor for accuracy and check oil system.

3154

Grid heater relay short-circuit to battery


3155

Grid heater relay short-circuit to ground

Short circuit of wiring to ground or inside relay. Check wiring or replace relay

3156

Grid heater relay no load

Broken or disconnected wiring or defective relay. Check wiring or replace relay

3161

Fan actuator signal low


Fuel rail/system pressure - too low

High pressure side: Leakage in high pressure section, injection nozzle stuck in open position, worn high pressure pump, worn injector, leaking pressure relieve valve Low pressure side: Pressure before gear pump too low, gear pump output too low (fuel filter clogged, leakage in low pressure side).

3172

Fuel rail/system pressure - too high

Metering unit stuck in open position, zero-delivery throttle clogged, metering unit without power due to electrical error. Low pressure side: Pressure before gear pump too high (e.g. by pressure relieve valve), pressure after zero-delivery throttle too high.

3173

Fuel rail/system pressure - too low

See fault 3171

3174

Fuel rail/system pressure - too high

See fault 3172

Fuel system leak detected – large leak

Leakage in the high pressure section, injection nozzle stuck in open position, worn high pressure pump, worn injector, leaking pressure relieve valve, injector reflux too high.

Fuel delivery exceeded threshold for pressure in overrun mode

High pressure system: Leakage in the high pressure section, injection nozzle stuck in open position, worn or defective high pressure pump, worn injector, leaking pressure relieve valve. Low pressure system: 'Zero delivery' is not active in metering unit (excessive leakage in metering unit). Check for defects according to failure list.

3171

3175

3176

Bur 5-2760

Issued 8-06

Printed in U.S.A.

4005-23 CODE

DEFINITION

3178

Time-out of CAN message BC2EDC1

3179

Time-out of CAN message BC2EDC2

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR Defective CAN controller of Body Computer, undervoltage of BC, missing BC, CAN cable connecting the BC is disconnected or broken. Short circuit in wiring. Check presence and correct connection of the BC to the network, Check correct functioning of the BC CAN controller and its voltage supply. Check wiring. Defective CAN controller of Vehicle Control Module, undervoltage of VCM, missing VCM, CAN cable connecting the VCM is disconnected or broken. Short circuit in wiring. Check presence and correct connection of the VCM to the network, Check correct functioning of the VCM CAN controller and its voltage supply. Check wiring.

3180

Time-out of CAN message VCM2EDC

3188

Cylinder 1 open load

3192


3196


3200


3204


3208


3210

Bank 1 general short-circuit on injection cable

Short circuit of high-side to battery or ground. Check the wiring or replace injector.

3211

Bank 1 injection cable short-circuit low side to ground

Short circuit of low-side to ground in injector cable. Check the wiring or replace injector.

3212

Bank 1 no signal


3213

Bank 1 unclassified error

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

3218

Bank 2 general short-circuit on injection cable

Short circuit of high-side to battery or ground. Check the wiring or replace injector.

3219

Bank 2 injection cable short-circuit low side to ground

Short circuit of low-side to ground in injector cable. Check the wiring or replace injector.

3220

Bank 2 no signal


Bank 2 unclassified error

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

3221

Bur 5-2760

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

Issued 8-06

Printed in U.S.A.

4005-24 CODE

DEFINITION


3227

Injection processor error - stop engine

Clock error or interruption of the power supply voltage. Check the power supply or replace ECU if problem reoccurs.

3228


Defective ECU, reset ECU. If no recovery, replace ECU.


Internal failure of ECU or 'TESTMODE' takes too long. Check 'TESTMODE' parameters or replace ECU if problem reoccurs

3230


Defective SPI-bus participant, timing problem due to software bug. Replace ECU if problem reoccurs (Send in ECU for investigation)

3231


3232


3233


3234


3238

Communication error of CJ940 processor

3242

Recovery which is locked

3243

Recovery which is suppressed

3244

Recovery which is visible

3229

Defective ECU. Replace ECU if problem reoccurs

Electric disturbances, internal defect of the ECU leading to a SPI bus communication error. Replace ECU if failure remains present Electronic disturbances, various hardware defects (ECU internal) or configuration problems. Analyze what error triggered the recovery (Read out label HWEMon_numRecovery and compare the value with the according table). If error occurs repeatedly, reprogram EDC. If error remains, replace EDC.

3245

Communication supervision watchdog control flag

Defective monitoring module or CPU (e.g. impaired functioning of the CPU clock) of the EDC. Disturbed SPI-Bus. If error exists only temporary (i.e. injection reoccurs) error can be ignored and error deleted in the fault memory. In case of a permanent error the injection remains blocked and the ECU has to be replaced

3246

Redundant shutoff paths during initial

Watch dog switch off path defect. If failure remains after ECU initialization: replace ECU

3247


3248


Bur 5-2760

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

Issued 8-06

Printed in U.S.A.

4005-25 CODE

DEFINITION


3253

Error status ADC monitoring

3254


3255


3256


3258

Short-circuit to battery at high side power stage


3259

Short-circuit to ground at high side power stage

Short circuit of wiring to ground or inside relay. Check of wiring or replace relay

3260

Open load at low side power stage

Broken or disconnected wiring or defective relay. Check wiring or replace relay

3261

Short-circuit to battery or excessive temperature at low side power stage


3262

Short-circuit to ground at low side power stage

Short circuit of wiring to ground or inside relay. Check wiring or replace relay

3265

Energizing time exceeds limit of over run monitoring

Electronic disturbances, requested torque increase via tester, wrong application of injection relevant parameters, defective ECU. Check injection relevant application, if failure persists replace ECU

3266

Plausibility error in engine speed check

Electronic disturbances, internal ECU problem. If failure persists after reinstallation replace ECU

Supply voltage CJ940 upper limit

Excessive voltage supply of a CJ940 component: High battery voltage, defective wiring, internal defect of the EDC. Check the battery for correct voltage supply, check wiring. If defect remains replace EDC (internal defect)

Supply voltage CJ940 lower limit

Insufficient voltage supply of a CJ940 component: Low battery voltage, defective wiring, internal defect of the EDC. Check the battery for sufficient voltage supply, check wiring. If defect remains replace EDC (internal defect)

Sensor supply voltage 1 high

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

3278

3279

3280

Bur 5-2760

Buffer overrun No additional information available at time of print

Issued 8-06

Printed in U.S.A.

4005-26 CODE

DEFINITION


Sensor supply voltage 1 low

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







3286



3290

Turbo compound monitoring signal not plausible


3281

3283

3284

3285

Bur 5-2760

Issued 8-06

Printed in U.S.A.

4005-27

TRANSMISSION FAULT CODES CODE

DEFINITION


Logical error at FNR switch

1. Check the cables from the TCU to the FNR switch. 2. Check the connectors from the TCU to the FNR switch. 3. Check the FNR switch.

4114

Logical error at direction select signal

1. Check the cables from the TCU to the FNR switch. 2. Check the connectors from the TCU to the FNR switch. 3. Check the FNR switch signal combinations.

4116

Logic error at park brake status

1. Check the cables from the TCU to the instrument cluster connector 2 pin 6. 2. Check park brake switch.

4117

Logic error at direction select signal 2

1. Check the cables from the TCU to the FNR switch. 2. Check the connectors from the TCU to the FNR switch. 3. Check the FNR switch signal combinations.

4119

Short circuit to ground at ride control

4120

Short circuit to battery voltage at ride control

4121

Open circuit at ride control

1. Check the cables from the TCU to the ride control relay. 2. Check the connectors from the TCU to the ride control relay. 3. Check the ride control relay.

4133

Short circuit to battery voltage or open circuit at temperature sensor

1. Check the connectors. 2. Check the temperature sensor.

4134

Short circuit to ground at temperature sensor

4135

Short circuit to battery voltage or open circuit at converter output temperature sensor

4136

Short circuit to ground at converter output temperature sensor

4137

Short circuit to battery voltage or open circuit at parking brake sensor input

4145

Short circuit to battery voltage or open circuit at engine speed sensor

4146

Short circuit to ground at engine speed sensor

4113

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

1. Check the cables from TCU to the sensor. 2. Check the connectors. 3. Check the parking brake sensor. 1. Check the parking brake fuse. 2. Check the parking brake relay. 3. Check the parking brake solenoid. 1. Check the cables from TCU to the sensor. 2. Check the connectors. 3. Check the speed sensor.

4147

Bur 5-2760

Logical error at engine speed sensor input

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

Issued 8-06

Printed in U.S.A.

4005-28 CODE

DEFINITION

4148

Short circuit to battery voltage or open circuit at turbine speed sensor input

4149

Short circuit to ground at turbine speed sensor input

4150

Logical error at turbine speed sensor input


1. Check the cables from TCU to the sensor. 2. Check the connectors. 3. Check the speed sensor. 1. Check the cables from TCU to the sensor. 2. Check the connectors. 3. Check the speed sensor. NOTE: This fault code is reset after power up of the TCU.

4151

Short circuit to battery voltage or open circuit at intermediate speed sensor input

4152

Short circuit to ground at intermediate speed input

4153

Logical error at intermediate speed sensor input

4154

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

4155

Short circuit to ground at output speed sensor

4156

Logical error at output speed sensor

1. Check the cables from TCU to the sensor. 2. Check the connectors. 3. Check the speed sensor. 1. Check the cables from TCU to the sensor. 2. Check the connectors. 3. Check the speed sensor. NOTE: This fault code is reset after power up of the TCU. 1. Check the cables from TCU to the sensor. 2. Check the connectors. 3. Check the speed sensor. 1. Check the cables from TCU to the sensor. 2. Check the connectors. 3. Check the speed sensor. NOTE: This fault code is reset after power up of the TCU.

4158

Output speed zero, does not match other speeds.

1. Check the sensor signal of the output speed sensor. 2. Check the connector connected to the output speed. 3. Check the cable from the TCU to the sensor. NOTE: This fault code is reset after power up of the TCU.

4160

Invalid gear range restriction (CAN)

4180

Vehicle controller time-out (CAN)

4185

Invalid test mode signal (CAN)

4186

Invalid park brake status (CAN)

Bur 5-2760

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

Issued 8-06

Printed in U.S.A.

4005-29 CODE

DEFINITION

4209

Short circuit to battery voltage at clutch K1

4210

Short circuit to ground at clutch K1

4211

Open circuit at clutch K1

4212


4213


4214


4215


4216


4217


4225


4226


4227


4228

Short circuit to battery voltage at clutch KV

4229

Short circuit to ground at clutch KV

4230

Open circuit at clutch KV

4231

Short circuit to battery voltage at clutch KR

4232

Short circuit to ground at clutch KR

4233

Open circuit at clutch KR

4241

Short circuit to ground at backup alarm relay

4242

Short circuit to battery voltage at backup alarm relay

4243

Open circuit at backup alarm relay

4273

4274

4275

Bur 5-2760


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

1. Check the cable from the TCU to the backup. alarm relay. 2. Check the connectors from the backup alarm relay to TCU. 3. Check the resistance of backup alarm relay circuit.

Slippage at clutch K1

1. 2. 3. 4. 5.

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


1. 2. 3. 4. 5.



1. 2. 3. 4. 5.


Issued 8-06

Printed in U.S.A.

4005-30 CODE

DEFINITION



1. 2. 3. 4. 5.


Slippage at clutch KV

1. 2. 3. 4. 5.

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

Slippage at clutch KR

1. 2. 3. 4. 5.

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

4279

Oil temperature at valve body is above limit

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

4281

Engine speed is measured above 5,000 rpm for 0.2 seconds

4276

4277

4278

Check engine speed sensor 1. Check oil filter. 2. Check wiring from TCU to filter maintenance switch. 3. Check filter maintenance switch (measure resistance).

4282

TCU sensed a voltage at oil filter maintenance switch out of the allowed range (dirty filter)

4284

Overspeed output


4288

Engine torque or engine power overload


4289

Transmission output torque overload


4290

Transmission input torque overload


4291

4292

Bur 5-2760

Oil temperature at converter output is above limit

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

Joystick status indicator short-circuit to ground

1. Check the cables from the TCU to the joystick. 2. Check the connectors from the TCU to the joystick. 3. Check the resistance of the joystick.

Issued 8-06

Printed in U.S.A.

4005-31 CODE

DEFINITION


Joystick status indicator short-circuit to battery voltage


4294

Joystick status indicator over current


4305

Power supply for sensors short-circuit to battery voltage

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

4306

Power supply for sensors short-circuit to ground

4307

Low voltage at battery

4308

High voltage at battery

4309

Error at VPS 1 for solenoid power supply

4310

Error at VPS 2 for solenoid power supply

4325

Vehicle ID #1 time out


4326

Undefined VIN request via CAN.


4337

General EEPROM fault

Replace the TCU.

4338

Configuration error

Reprogram the correct configuration for the vehicle.

4339

Application error (ZF internal)

Replace the TCU.

4341

Clutch calibration fault

4342

Clutch adjustment data lost

4293

Bur 5-2760

1. Check batteries. 2. Check B+ wires from batteries to TCU. 3. Check voltage at TCU connector pin 45. 1. 2. 3. 4.

Check fuse A2. Check cable from control valve to TCU. Check connectors from control valve to TCU. Replace TCU.

Do the transmission clutch calibration procedure.

Issued 8-06

Printed in U.S.A.

4005-32

INSTRUMENT CLUSTER FAULT CODES CODE

DEFINITION

9128

CAN timed out during operation

9129


9130


Bur 5-2760

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR If error is permanent or repeats often, check CAN wiring harness and connections on the CAN bus circuits.

Issued 8-06

Printed in U.S.A.

5001 Section 5001 REMOVAL AND INSTALLATION OF STEERING COMPONENTS


Bur 5-2780


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

Bur 5-2780

Issued 8-06

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

Printed in U.S.A.

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. BD06G245

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.

BD06G246

Remove the steering wheel from the shaft.

STEP 9

STEP 6

BD06G247 BD06G244

Remove the center cap from the steering wheel.

Bur 5-2780

Remove the six mounting screws from the instrument cover.

Issued 8-06

Printed in U.S.A.

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.

Bur 5-2780

BD06G260

Remove the two lower mounting screws from the front vent.

Issued 8-06

Printed in U.S.A.

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.

Bur 5-2780

Issued 8-06

Printed in U.S.A.

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.

Bur 5-2780

Issued 8-06

Printed in U.S.A.

5001-7

STEP 27

STEP 30

BD06G247

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 BD06G245

Install the skirts onto the cab or canopy.

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

STEP 34

STEP 29

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

BD06G244

Install the center cap on the steering wheel.

Bur 5-2780

Issued 8-06

Printed in U.S.A.

5001-8

AUXILIARY STEERING PRIORITY VALVE Removal

Installation

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

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

2. Put master disconnect switch in OFF position.

3. Tighten pressure tube fitting (5).

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

4. Tighten the nuts (6).

4. Remove hydraulic reservoir fill cap.

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

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

5. Connect a vacuum pump to hydraulic reservoir.

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

6. Start vacuum pump.

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

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

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

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

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

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

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

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

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

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

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

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

Bur 5-2780

Issued 8-06

Printed in U.S.A.

5001-9

1 2 3 6

10 4

9 8

6

7

5

BC05M084

1. 2. 3. 4. 5.

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

6. 7. 8. 9. 10.

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

AUXILIARY STEERING PRIORITY VALVE ILLUSTRATION

Bur 5-2780

Issued 8-06

Printed in U.S.A.

5001-10

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

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

6. Start vacuum pump.

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

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

5. Stop vacuum pump.

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

6. Disconnect reservoir.

vacuum

pump

from

hydraulic

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

Bur 5-2780

Issued 8-06

Printed in U.S.A.

5001-11

1

2

3 6

7

4

5

4

8

3

BC05M087

1. 2. 3. 4.

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

5. 6. 7. 8.

STEERING PUMP OUTPUT LINE O-RINGS STEERING PRIORITY VALVE BOLT

STEERING PRIORITY VALVE ILLUSTRATION

Bur 5-2780

Issued 8-06

Printed in U.S.A.

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 star t operating immediately. Check that auxiliary steering light on infor mation center is ON and auxiliar y 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. Bur 5-2780

Issued 8-06

Printed in U.S.A.

5001-13

2 1

3 8 7

4 5

6

BC05M085

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

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

Bur 5-2780

Issued 8-06

Printed in U.S.A.

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

Installation 1. Put steering cylinders (11) in position in machine. Make sure that washers (4) are installed between steering cylinder (11) and rear frame. See illustration on page 15. NOTE: Install a washer (4) on top and bottom of steering cylinders (11) if possible. If only one washer (4) can be installed, place washer (4) at bottom of steering cylinders (11). 2. Make sure washers (14) are installed between steer ing cylinders (11) and front frame of machine. 3. Install the pivot pin (5) to secure rear of steering cylinders (11) to machine frame. Install spacer (6), washer (7), and cap screw (8) to secure pivot pin (5). 4. Tighten cap screw (8). 5. Install pin (12) in front of steering cylinders (11). Make sure that washers (14) are installed in correct position. 6. Install cap screw (13) and new locknut (15) in steering cylinders (11) rod end and pin (12). Tighten locknut (15). NOTE: Cap screw (13) should turn freely in hole after tightening. 7. Connect hose assemblies (2, 3, 9, and 10) to steering cylinders (11). 8. Connect grease hoses (1 and 16) to steering cylinders (11). 9. Tighten hydraulic reservoir fill cap. 10. Start engine. 11. Turn steering wheel all the way to right and then to the left several times. 12. Stop the engine. Check fluid level in hydraulic reservoir. Add oil as required. See Section 1002 for specifications.

Bur 5-2780

Issued 8-06

Printed in U.S.A.

5001-15

9

10

8 7 6 5 4 3

11

2 12

1

1

13 14 15

11

16 BS03B141

1. 2. 3. 4.

GREASE HOSE HOSE ASSEMBLY HOSE ASSEMBLY WASHER

5. 6. 7. 8.

PIVOT PIN SPACER WASHER CAP SCREW

9. 10. 11. 12.

HOSE ASSEMBLY HOSE ASSEMBLY STEERING CYLINDER PIN

13. 14. 15. 16.

CAP SCREW WASHER LOCKNUT GREASE HOSE

STEERING CYLINDER ILLUSTRATION

Bur 5-2780

Issued 8-06

Printed in U.S.A.

5001-16

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

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

Bur 5-2780

Issued 8-06

Printed in U.S.A.

5001-17

1

2

3

4

5

6

7

BS06G529

1. 2. 3. 4.

STEERING CONTROL VALVE RETURN HOSE PRESSURE HOSE CONNECTOR M27 ORB

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

STEERING BACK PRESSURE VALVE ILLUSTRATION

Bur 5-2780

Issued 8-06

Printed in U.S.A.

5001-18

NOTES

Bur 5-2780

Issued 8-06

Printed in U.S.A.

5002

Section 5002 STEERING SPECIFICATIONS, PRESSURE CHECKS, AND TROUBLESHOOTING


Bur 5-2790


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

Bur 5-2790

Issued 8-06

3 3 4 4 4 5 5 5 5 6 6 7 8 9 10

Printed in U.S.A.

5002-3

SPECIAL TOOLS

B785789

OEM-1239 (CAS-10280) FLOWMETER

B009638

CAS-1804 PRESSURE TEST FITTING KIT

B797157

CAS-1808 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.

Bur 5-2790

Issued 8-06

Printed in U.S.A.

5002-4

AUXILIARY STEERING SYSTEM PUMP TEST Equipment Required

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

1. CAS- 10280 Flowmeter 2. CAS-1808 Flowmeter fitting kit

Test Procedure 1. Install articulation lock.

1

BB830300

1. AMMETER CLAMP

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

1 BD03A040

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 Auxiliar y 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.

Bur 5-2790

Issued 8-06

Printed in U.S.A.

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.

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

2. A remote starter switch.

7

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

8

Test Procedure 1. Remove the connector that is between the ter minals 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.

B795328

6. AMMETER 7. VOLTMETER 8. LOAD CONTROL

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

2

1

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

4

3

5

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

B790852

1. 2. 3. 4. 5.

Bur 5-2790

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

Issued 8-06

Printed in U.S.A.

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

1 BD03A040


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

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

2 1 BD06F148

1. G1 TEST PORT 2. G2 TEST PORT

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

Bur 5-2790

Issued 8-06

Printed in U.S.A.

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.

2

4. Stop the engine before removing the pressure gauge. BD06F147

1. STEERING PRIORITY VALVE 2. LIMIT VALVE

Bur 5-2790

Issued 8-06

Printed in U.S.A.

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.

Bur 5-2790

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 8-06

Printed in U.S.A.

5002-9

STEERING BACK PRESSURE VALVE 1

2

3

4

5

6

7

BS06G529

1. 2. 3. 4.

Bur 5-2790

STEERING CONTROL VALVE RETURN HOSE PRESSURE HOSE CONNECTOR M27 ORB

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

Issued 8-06

Printed in U.S.A.

5002-10

Pressure Test 1. Disconnect the return hose (2) from the connector (4). 2. Install a “T” 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.

Bur 5-2790

Issued 8-06

Printed in U.S.A.

Section 5005

5005

STEERING CYLINDERS


Bur 5-3160


5005-2

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

Bur 5-3160

Issued 8-06

3 3 3 3 5

Printed in U.S.A.

5005-3

SPECIFICATIONS Torque for piston cap screw........................................................................ 810 to 925 Nm (597.5 to 682 pound feet) Torque for gland............................................................................................. 339 to 475 Nm (250 to 350 pound feet)

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

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

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

Bur 5-3160

Issued 8-06

Printed in U.S.A.

5005-4

15

16

17 16

18 8 9

19 13 12 11 10

7

3

4

5

6

1

14

2

BC05M089

1. 2. 3. 4. 5.

GLAND ROD WIPER ROD SEAL BUFFER SEAL BEARING

6. 7. 8. 9. 10.

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

11. 12. 13. 14.

WEAR RING RING LOADER SEAL PISTON ROD

15. 16. 17. 18.

GREASE FITTING RETAINING RING BUSHING TUBE

STEERING CYLINDER ILLUSTRATION

Bur 5-3160

Issued 8-06

Printed in U.S.A.

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. 6. Install O-ring (7) on gland (1). 7. 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). 8. Fasten piston rod (14) yoke in vise.

17. Install bolt and hardened washer (8) in piston (9). 18. Install piston (9) on piston rod (14) and start bolt (8) into piston rod. 19. Tighten bolt (8) to a torque of 810 to 925 Nm (597.5 to 682 pound feet). 20. Fasten tube (18) in vise. Be careful not to damage tube. 21. Apply petroleum jelly to O-rings (7) and backup ring (6) on gland (1) and to sealing surface in tube (18). 22. Lubricate piston (9) and inside of tube (18) with clean hydraulic oil. 23. 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). 24. When piston (9) is in smooth part of tube (18), start gland (1) into tube (18). 25. If the original parts are being assembled:

9. Lubricate piston rod (15) and bore in gland (1) with clean hydraulic oil.

A. Tighten gland to a torque of 339 to 475 Nm (250 to 350 pound-feet).

NOTE: If a new gland (1) is being installed, write part number of cylinder on gland.

B. Install and tighten self-tapping screw (19) to a torque of 2.3 Nm (20 inch-pounds).

10. Push gland (1) onto piston rod (14) large end first. If necessary, use a soft hammer to drive the gland onto piston rod.

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 26.

11. 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.

26. If a new gland (1) or a new tube (18) are being assembled:

12. Install new cast iron ring (10) on piston (9). 13. Install new wear ring (11) on piston (9). 14. Install a new loader ring (12) on piston (9). 15. Install a new seal (13) over loader ring (12). 16. 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.

Bur 5-3160

A. Tighten gland (1) to a torque of 339 to 475 Nm (250 to 350 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). 27. If hoses were removed with cylinder, install new O-rings, if equipped, on hose fittings. Lubricate O-rings with clean oil. Install hoses.

Issued 8-06

Printed in U.S.A.

5005-6

NOTES

Bur 5-3160

Issued 8-06

Printed in U.S.A.

Section 5006

5006

CENTER PIVOT


Bur 5-3170


5006-2

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

Bur 5-3170

Issued 8-06

3 3 4 4 6 9

Printed in U.S.A.

5006-3

SPECIFICATIONS SPECIAL TORQUES M16 bolt for upper pivot pin .......................................................................220 to 250 Nm (162 to 184 pound-feet) M12 bolts for bearing retainers and lower pivot pin...........................................................124 Nm (91 pound-feet) M12 bolts for lower pin plate .......................................................................128 to 136 Nm (94 to 100 pound-feet) Ferry head screws for the drive shaft ................................................................61 to 81 Nm (45 to 60 pound-feet) LUBRICANT Pivot bearings and seals ............................................................................... Case AKCELA molydisulfide grease Steering cylinder rod eyes............................................................................. Case AKCELA molydisulfide grease

SPECIAL TOOLS CAS10219 ....................................................................................................................... Hand pump (hydraulic ram) CAS10512 ....................................................................................................................................... 10 ton ram (long) CAS10592 ........................................................................................................... Puller set, includes 24827 leg ends CAS10600 ................................................................................ Bearing cup and seal puller, includes 24850 adapter CAS10193 .............................................................................................................................. Vacuum pump (12 volt) CAS2029 ................................................................................... *Top bearing driver, bottom bearing driver and plate * (Requires screw, two nuts, and two washers from CAS10592)

BC06A174

CAS2029 DRIVER SET

Bur 5-3170

Issued 8-06

Printed in U.S.A.

5006-4

CENTER PIVOT Disassembly

19. Disconnect the supply hose.

1. Remove all dirt and grease from the area of the center pivot. Park the machine on a level surface.

20. Install a cap on the hose and a plug in the fitting.

2. Lower the bucket until the bucket is flat on the floor. 3. Stop the engine and apply the parking brake.

22. Loosen and remove the self-locking nut and bolt that hold the pivot pin for the steering cylinder rod eye.

4. Remove the covers from both sides of the machine.

23. Remove the pivot pin from the rear frame and the steering cylinder rod eye.

5. Disconnect the front wiring harness from the cab floor.

24. Remove the washer from the rear frame. Move the steering cylinder out of the way.

6. Remove any tie straps that fasten the front wiring harness to the chassis near the center pivot.

25. Repeat steps 22, 23 and 24 for the other steering cylinder.

7. Loosen and remove the nut and washer that fasten the chassis ground wire and cab ground wire to the studs.

26. Loosen and remove the Ferry head screws and retainers that fasten the drive shaft to the front yoke. Move the drive shaft out of the way.

8. Loosen and remove the bolt, lock washer, and nut that fasten the clamp on the front wiring harness to the bracket on the rear frame. Move the front wiring harness out of the way.

27. Place two stands below and in contact with the front frame.

9. Loosen and remove the fill cap for the hydraulic reservoir. 10. Connect a vacuum pump to the hydraulic reservoir. Start the vacuum pump. 11. Disconnect the brake hose from the backside of front brake line bracket.

21. Stop the vacuum pump.

28. Install blocks between the rear axle and the rear frame on both sides of the machine to prevent the rear frame from tipping. 29. Put a jack in contact with both sides of the rear frame near the center pivot area. Use another jack at the rear of the machine to prevent the rear frame from tipping.

12. Install a plug in the tube and a cap on the fitting.

30. Loosen and remove the bolt (1), washer (2), and spacer (3) that fasten the upper pivot pin (4) to the rear chassis (5).

13. Disconnect the hoses for the steering cylinder.

31. Use a prybar to remove the upper pivot pin (4).

14. Install caps on the fittings and plugs in the hoses.

32. Loosen and remove the bolts (1) and washers (2) that fasten the lower pin plate (15) to the lower pivot pin (10).

15. Loosen and remove the bolts, lock washers, and self-locking nuts that fasten the mounting bracket for the hoses to the bracket on the front frame. 16. Loosen and remove the bolts, flat washers, and self-locking nuts that fasten the bracket for the hoses to the rear frame.

33. Loosen and remove the bolts (1) and washers (2) that fasten the lower pin plate (15) to the bottom of the rear chassis (5).

17. Disconnect the return hose.

34. Use the ram and hand pump to remove the lower pivot pin (10).

18. Install the cap on the hose and a plug in the fitting.

35. Install the puller on the bottom spacer (14), see Special Tools in this section.

Bur 5-3170

Issued 8-06

Printed in U.S.A.

5006-5

1

2 3

4

5

1

6

2

7 5 8

10 6

9 5

12

16

11 6

8 13 6 2

14

1 5

8 15

2

2

1

1

BS03B152

1. 2. 3. 4.

BOLT WASHER SPACER UPPER PIVOT PIN

5. 6. 7. 8.

REAR CHASSIS SEAL BEARING RETAINER SHIM

9. 10. 11. 12.

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

13. 14. 15. 16.

BEARING RETAINER BOTTOM SPACER LOWER PIN PLATE FRONT CHASSIS

CENTER PIVOT ASSEMBLY

Bur 5-3170

Issued 8-06

Printed in U.S.A.

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).


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.

20

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.

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).

17 23

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

Bur 5-3170

25. BEARING CONE 26. BEARING CUP

Issued 8-06

Printed in U.S.A.

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).

Bur 5-3170

Issued 8-06

Printed in U.S.A.

5006-8

21

18

25

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

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

13 BC06A125

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

43. Apply grease to the lower pivot pin (10). 44. Install the lower pivot pin (10) in the bottom pivot. 45. Hold the bottom spacer (14) in place and lubricate the bottom pivot until grease is forced out of the seal (6). 46. Rotate the lower pivot pin (10) to check the bearing assembly. The lower pivot pin (10) must rotate smoothly, but not easily. 47. Remove the lower pivot pin (10) and the upper pivot pin (4). 48. Remove the bottom spacer (14).

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

Bur 5-3170

Issued 8-06

Printed in U.S.A.

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


29. Start the vacuum pump.

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

30. Connect the return hose.

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

31. Connect the supply hose.

7. Tighten the bolt (1) to 220 to 250 Nm (162 to 184 pound-feet). 8. Apply grease to the lower pivot pin (10). 9. Install the lower pivot pin (10) in the frames. Be careful not to damage the seal (6). 10. Use the ram and hand pump to install the bottom spacer (14). See Special Tools in this section.

32. Put the bracket for the hoses in position on the rear frame. Install the bolts, flat washers, and self-locking nuts that fasten the bracket to the rear frame. 33. Put the bracket for the hoses in position on the front frame. 34. Install the bolts, flat washers, and self-locking nuts that fasten the bracket to the front frame. 35. Connect the hoses for the steering cylinders.

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).

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

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

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

13. Measure the gap between the lower pin plate (15) and the bottom pivot. Make a record of the measurement. Subtract 0.0762 to 0.1016 mm (0.003 to 0.004 inch) from the measurement. Select shims equal to that value. 14. Loosen the bolts (1) that fasten the lower pin plate (15) to the lower pivot pin (10). 15. Start the six outer bolts (1) into the lower pin plate (15) and the bottom pivot.

37. Stop the vacuum pump.

39. Put the clamp on the wiring harness in position on the bracket. Install the bolt, lock washer, and nut that fasten the clamp on the wiring harness to the bracket. 40. Put the ground wire in position on the stud. Install the washer and nut that fasten the ground wire to the stud.

16. Install the shims (8).

41. Install a tie strap to fasten the wiring harness to the tube.

17. Tighten the six outer bolts (1) to 128 to 136 Nm (94 to 100 pound-feet).

42. Disconnect the vacuum pump from the hydraulic reservoir.

18. Tighten the three inner bolts (1) to 124 Nm (91 pound-feet).

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

19. Remove the jacks from the rear frame.

44. Install the fill cap in the hydraulic reservoir.

20. Remove the blocks from the rear axle.

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

21. Remove the stands from the front frame. 22. Put the drive shaft in position on the front yoke. 23. Install new Ferry head screws that fasten the drive shaft to the front yoke. 24. Tighten the Ferry head screws to 61 to 81 Nm (45 to 60 pound-feet).

46. Lubricate the pivot pins for the steering cylinder rod eyes. 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. Bur 5-3170

Issued 8-06

Printed in U.S.A.

5006-10

NOTES

Bur 5-3170

Issued 8-06

Printed in U.S.A.

Section 5008

5008

AUXILIARY STEERING MOTOR AND PUMP


Bur 6-42430


5008-2

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

Bur 6-42430

Issued 4-03

3 4 4 4 4

Printed in U.S.A.

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)

Bur 6-42430

Issued 4-03

Printed in U.S.A.

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. Bur 6-42430

Issued 4-03

Printed in U.S.A.

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

Bur 6-42430

Issued 4-03

Printed in U.S.A.

5008-6

NOTES

Bur 6-42430

Issued 4-03

Printed in U.S.A.

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


Bur 5-3180


6001 Section 6001 REMOVAL AND INSTALLATION OF POWER TRAIN COMPONENTS


Bur 5-4010

Copyright © 2006 CNH America LLC. All rights reserved. Printed in U.S.A. Issued August, 2006

6001-2

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

Bur 5-4010

Issued 8-06

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

Printed in U.S.A.

6001-3

TRANSMISSION Removal

STEP 7

STEP 1 Park the machine on a level surface and lower the bucket to the floor. Stop the engine and apply the parking brake.

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

STEP 3 Refer to Section 9007 and remove ROPS cab or ROPS canopy.

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

BD01D315

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

STEP 8

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

STEP 6

BD01D317

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

STEP 9 BD01D306

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

BD01D310

Remove two socket head bolts securing transmission wiring harness clamps. Bur 5-4010

Issued 8-06

Printed in U.S.A.

6001-4

STEP 10

STEP 13

BD01D312

BD01F281

Identify, tag, and disconnect transmission wiring harness connectors from engine speed sensor, intermediate speed sensor, and turbine speed sensor. Move transmission wiring harness away from transmission.

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

STEP 14

STEP 11

BD03A165

BD01D316

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

STEP 12

Identify, tag, and disconnect parking brake hose from parking brake. Plug hose and cap fitting to prevent entry of foreign matter into hydraulic system. Move hose away from transmission. Remove four bolts and two straps securing center drive shaft to transmission output flange. Disconnect center drive shaft from transmission.

BD01D314

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

Bur 5-4010

Issued 8-06

Printed in U.S.A.

6001-5

STEP 15

STEP 18

BD03A161

BD01D339

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

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

STEP 19 STEP 16

BD01D340 BD03A160

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

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

STEP 20

STEP 17

BD01D343

BD01D318

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

Identify, tag, and disconnect cooler hose from fitting installed in LH side of transmission. Install a plug in hose. Remove and discard O-ring face seal from fitting.

Bur 5-4010

Issued 8-06

Printed in U.S.A.

6001-6

STEP 21

STEP 23

BD01D342

BD03A164

In area between the transmission and the engine, remove four bolts and two straps. Use pry bar to disconnect engine drive shaft from transmission. Using 3/4 inch drive socket, extensions, and impact wrench, remove four bolts and washers securing transmission to top mounting bracket.

Raise transmission just enough to enable removal of RH and LH mounting brackets. Remove two bolts and washers securing RH and LH mounting brackets to transmission. Remove RH and LH mounting brackets.

STEP 24 STEP 22

BD01D345 BD03A163

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

Slowly and carefully raise transmission from loader while checking that all hoses, electrical connectors, and wires have been disconnected and nothing interferes with transmission removal. Remove transmission from loader.

STEP 25

BD01D361

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

Bur 5-4010

Issued 8-06

Printed in U.S.A.

6001-7

Transmission Mounting 4

3

2 1

C B 1 3

4

2 2

2

1

1

5

5 7

6

1 5

5

1

2

2 A

BS03B153

1. 2. 3. 4. 5.

Bur 5-4010

ISOLATOR BOLT WASHER BOLT BOLT BOLT

6. 7. A. B. C.

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

Issued 8-06

Printed in U.S.A.

6001-8

Installation

STEP 29

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

STEP 27

BD03A164

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

STEP 30

BD01D361

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

STEP 28

BD03A163

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

BD01D345

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

Bur 5-4010

Issued 8-06

Printed in U.S.A.

6001-9

STEP 31

STEP 33

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

BD01D343

Disconnect lifting equipment from transmission lifting eyes. BD01D342

STEP 34

Using 3/4 inch drive socket, extensions, and impact wrench, install four washers and bolts to secure top mounting bracket to transmission. Then tighten bolts to a torque of 251 to 319 Nm (185 to 235 pound feet). If bracket had been removed, tighten bolt to a torque of 890 to 1000 Nm (655 to 735 pound feet). Connect engine drive shaft to transmission. Install two new straps and four new bolts. Tighten bolts to a torque of 61 to 81 Nm (45 to 60 pound feet).

STEP 32 BD01D340

Install new O-ring on fitting and install fitting in transmission. Install new O-ring face seal in fitting then connect cooler hose to fitting following tag installed during removal. Remove and discard tag.

STEP 35

BD03A163

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

BD01D318

Install new O-ring on fitting and install fitting in transmission. Install new O-ring face seal in fitting then connect cooler hose to fitting following tag installed during removal. Remove and discard tag.

Bur 5-4010

Issued 8-06

Printed in U.S.A.

6001-10

STEP 36

STEP 39

BD03A160

BD01F281

Position fill tube, two new seals, and metal strainer on transmission; metal strainer is installed between seals. Secure using two bolts. Tighten bolts to a torque of 17 to 33 Nm (12 to 24 pound feet).

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

STEP 40

STEP 37

BD01D314

BD03A161

Connect rear drive shaft to transmission then install two straps and four bolts. Tighten bolts to a torque of 61 to 81 Nm (45 to 60 pound feet).

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

STEP 41 STEP 38

BD01D316 BD03A165

Connect center drive shaft to transmission and install two straps and four bolts. Tighten bolts to a torque of 61 to 81 Nm (45 to 60 pound feet). Connect parking brake hose to parking brake following tag installed during removal. Remove and discard tag. Bur 5-4010

Install socket head bolt to secure wiring harness clamp.

Issued 8-06

Printed in U.S.A.

6001-11

STEP 42

STEP 45

BD01D312

BD01D315

Connect transmission wiring harness connectors to turbine speed sensor, intermediate speed sensor, and engine speed sensor following tags installed during removal. Remove and discard tags.

Install socket head bolt to secure wiring harness clamp. Connect transmission wir ing har ness connector to control valve connector.

STEP 46 STEP 43

BD01D306 BD01D310

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

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

STEP 44 STEP 47

BD01D317

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

Bur 5-4010

BD03A177

Check that transmission drain plug is tight.

Issued 8-06

Printed in U.S.A.

6001-12

STEP 48

STEP 50

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

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

STEP 49

STEP 51

Refer to Section 8001 and install the hydraulic pump.

Start and run engine at idle speed with transmission in neutral. If transmission oil level is at or below bottom of crosshatch region, put articulation lock in LOCKED position and add engine oil, 15-40W, until oil level is up to crosshatch region. Shut down engine and put articulation lock in OPERATING position.

Bur 5-4010

Issued 8-06

Printed in U.S.A.

6001-13

FRONT AXLE Removal

STEP 4

STEP 1

BD03A167

BD03A040

Park machine on level surface. Have assistant put articulation lock in LOCKED position.

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

STEP 5

IMPORTANT: If machine is equipped with quick-attached components, disconnect them from machine prior to proceeding.

STEP 2

BD03A166

BD03A092

Raise bucket and have assistant install safety link. Lowe r loa der ar ms slowly until sa fety link is supporting loader arms.

Remove clamp securing lubrication hose to machine and nut securing opposite end of hose. Remove four bolts and two straps securing center drive shaft to front drive shaft. Use a pry bar to separate drive shafts. While supporting center bearing and front drive shaft, remove four nuts and bolts and eight washers. Lower center bearing and front drive shaft from mounting plate and remove from machine.

STEP 3 Stop engine. Actuate brake pedal several times to discharge brake accumulators. Put key switch in ON position and move loader control lever back and forth at least 30 times to release any pressure from hydraulic circuit. Put key switch in OFF position.

Bur 5-4010

Issued 8-06

Printed in U.S.A.

6001-14

STEP 6

STEP 9

BD03A168

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

BD01F297

Use an acceptable jack to hold front axle.

STEP 10 STEP 7

BD01F295 BD01F298

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

STEP 11

BD01D392

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

BD01F296

STEP 8

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

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

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

Bur 5-4010

Issued 8-06

Printed in U.S.A.

6001-15

Front Axle Mounting

1

2

5

3 4

BS03B151

1. BOLT 2. WASHER 3. WASHER

Bur 5-4010

4. NUT 5. FRONT AXLE

Issued 8-06

Printed in U.S.A.

6001-16

Installation

STEP 15

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

STEP 14

BD01F295

BD01F296

Apply one drop of engine oil to threads prior to assembly. Install eight washers, bolts, washers, and nuts to secure front axle to machine. Tighten bolts to a torque of 765 to 865 Nm (565 to 630 pound feet).

BS06G052

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.

Bur 5-4010

Issued 8-06

Printed in U.S.A.

6001-17

STEP 17

STEP 20

BD01F298

BD03A166

Position and support center bearing and front drive shaft and install eight washers and four bolts and nuts. Tighten bolts to a torque of 99 to 128 Nm (73 to 94 pound feet). Install two straps and four bolts. Tighten bolts to a torque of 61 to 81 Nm (45 to 60 pound feet). Secure lubrication hose to machine using clamp; secure opposite end of hose using nut.

STEP 21

BD01D392

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

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

STEP 19 BD03A167

Secure drive shaft to front axle using two straps and four bolts. Tighten bolts to a torque of 61 to 81 Nm (45 to 60 pound feet).

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

STEP 23 Refer to Section 7002 and bleed brakes. BD03A168

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

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

STEP 25 Put articulation lock in OPERATING position. Bur 5-4010

Issued 8-06

Printed in U.S.A.

6001-18

REAR AXLE Removal

STEP 5

STEP 1 Park machine on a level surface; be sure to allow adequate space at side of machine for removal of rear axle. Stop engine. Actuate brake pedal several times to discharge brake accumulators. Put key switch in ON position and move loader control lever back and for th at least 30 times to release any pressure from hydraulic circuit.

STEP 2 BD03A169

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

STEP 6

BD03A040


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

BD01F299

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

STEP 4

STEP 7

BD03A162

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

Use an acceptable jack to hold rear axle.

Bur 5-4010

Issued 8-06

Printed in U.S.A.

6001-19

STEP 8

STEP 10 Carefully lower rear axle and remove through side of machine.

STEP 11 Remove and discard two seals from rear axle pivot point.

BD01F295

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

STEP 9

A

A

BD03A170

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

Bur 5-4010

Issued 8-06

Printed in U.S.A.

6001-20

Rear Axle Mounting

6 5

1 4 3 2

6 5

7 10 6

5

2

9

3 11 5

8

12

6

BS01D132

1. 2. 3. 4.

Bur 5-4010

TRUNNION O-RING SEAL FRONT CAP

5. 6. 7. 8.

WASHER BOLT WASHER BOLT

9. 10. 11. 12.

REAR AXLE PIVOT PIN SHIM(S) REAR CAP

Issued 8-06

Printed in U.S.A.

6001-21

Installation

STEP 13

NOTE: If shim(s) (11) have been lost or pivot pin (10) has been replaced, do Step 12 to determine required shim(s) otherwise go to Step 13.

A

STEP 12 6

1

1

10 12

6

4

BD01D482A

A B BS01E091A

Install pivot pin (10) and caps (4 and 12) in trunnion (1) without rear axle or shim(s). Install washers (5) a n d b o l t s ( 6 ) . T i g h t e n b o l t s s e c u r e l y. P u s h assembled pivot pin and caps to rear of machine as far as possible. Measure and record gap (A) between rear cap (12) and trunnion. Select shims from the following: NOTE: Shims are available in following sizes: 0.50 mm (0.020 inch), 1.0 mm (0.039 inch), and 1.50 mm (0.059 inch). MEASURED GAP (mm)

SHIM(S) REQUIRED (mm)

0.07 to 0.55

None

0.56 to 1.09

0.50

1.10 to 1.59

1.0

1.60 to 2.09

1.50

2.10 to 2.59

0.50 plus 1.50

2.60 to 3.02

1.0 plus 1.50

BD01D499

Clean front (A) and rear (B) pivot area of rear axle where seals (3) will be installed.

STEP 14 A 3 4 12

2 BS01E092

Lubricate two new seals (3) and new O-rings (2) using Molydisulfide Grease. Install seals, smooth side out, into front and rear of axle housing (A) until flush with housing or recessed 2.0 mm (0.079 inch). Install an O-ring in each cap (4 and 12).

STEP 15 Carefully move rear axle under machine. Raise axle into position in trunnion and align pivot holes in trunnion with pivot holes in axle. Bur 5-4010

Issued 8-06

Printed in U.S.A.

6001-22

STEP 16 11 12

6

1

STEP 17 4

A

10

6

1 BS01E091

BD01F295

Lubricate pivot pin (10) using Molydisulfide Grease. At rear of trunnion (1), install pivot pin into trunnion and axle (A). Install shim pack (11), rear cap (12) with O-ring installed, and two washers and bolts (6). At front of trunnion install front cap (4) with O-ring installed, and two washers and bolts (6). Tighten bolts (6) to a torque of 651 to 678 Nm (480 to 500 pound feet).

BS06G052

Install both wheels on front axle and secure. Tighten bolts to a preliminary torque of 298 Nm (220 pound feet) in sequence indicated; then tighten to a torque of 640 to 720 Nm (475 to 530 pound feet) in same sequence.

STEP 18 Remove hydraulic jack supporting rear axle and jack stands supporting loader.

Bur 5-4010

Issued 8-06

Printed in U.S.A.

6001-23

STEP 19

STEP 21 If necessary, fill axle with gear lubricant specified in Section 1002.

STEP 22 Refer to Section 7002 and bleed brakes.


BD03A169

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

STEP 20

BD03A162

Connect rear drive shaft to rear axle. Install two straps and four bolts. Tighten bolts to a torque of 61 to 81 Nm (45 to 60 pound feet).

Bur 5-4010

Issued 8-06

Printed in U.S.A.

6001-24

NOTES

Bur 5-4010

Issued 8-06

Printed in U.S.A.

6002

Section 6002 TRANSMISSION SPECIFICATIONS, PRESSURE CHECKS, AND TROUBLESHOOTING


Bur 5-2840


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

Bur 5-2840

Issued 8-06

3 3 9 9 9 9 9 10 10 10 10 10 11 11 11 11 11 11 12 12 12 12 12 12 13 15 16 16 16 16 16 17 17 17 17 17 17 17 17 17 17 18 19 19 19

Printed in U.S.A.

6002-3

SPECIAL TOOLS CAS-1953A Transmission supplemental fitting kit. Includes: CAS-2324 special 90 degree adapter and CAS-2325 plug and cap set. CAS-1804 Master pressure test kit

CAS-1808 Flowmeter kit CAS-2702 Flowmeter adapter CAS-2278 Flow test kit

SPECIFICATIONS Main pressure and clutch pressure ................................................................................16 to 18 bar (232 to 261 psi) Converter in pressure .......................................................................................................8 to 10 bar (116 to 145 psi) Pressure reduction for solenoids ........................................................................................7 to 9 bar (102 to 131 psi) Converter out pressure.....................................................................................................3.5 to 6.5 bar (51 to 96 psi) Lubrication pressure ...........................................................................................................0.2 to 1.2 bar (3 to 18 psi) Minimum pump output (at 2000 rpm) .....................................................................................80 L/min (21 U.S. gpm) Transmission oil operating temperature..........................................................................80 to 120 °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)

Bur 5-2840

Issued 8-06

Printed in U.S.A.

6002-4

4

1 3

2

5

12

9 6 8

11 14 7

13 10

BS01A190

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

TRANSMISSION ELECTRONIC CONTROL MODULE DOWNSHIFT BUTTON DECLUTCH ROCKER SWITCH MANUAL/AUTOMATIC ROCKER SWITCH SHIFTER SUPPLY SYSTEM CONNECTIONS B+ AND RETURN TRANSMISSION

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

INDUCTIVE TRANSMITTER - INTERMEDIATE SPEED SENSOR INDUCTIVE TRANSMITTER - TURBINE SPEED SENSOR INDUCTIVE TRANSMITTER - ENGINE SPEED SENSOR HALL SENSOR - OUTPUT SPEED SENSOR TRANSMISSION CONTROL VALVE CABLE DECLUTCH LIMIT SWITCH PLUG

COMPONENT LOCATIONS SYSTEMS

Bur 5-2840

Issued 8-06

Printed in U.S.A.

6002-5

12 11 1

2 10 3

9 4

5

15

6

14 8 13

7

BS03A262

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

CLUTCH SHAFT KR POWER TAKE OFF CLUTCH SHAFT KV CLUTCH SHAFT K2 CLUTCH SHAFT K3 OUTPUT FLANGE REAR OUTPUT FLANGE CONVERTER SIDE OUTPUT SHAFT

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

TRANSMISSION PUMP INPUT FLANGE CONVERTER INDUCTIVE TRANSMITTER FOR ENGINE SPEED CLUTCH SHAFT K4 CONVERTER RELIEF VALVE CLUTCH SHAFT K1

COMPONENT LOCATIONS TRANSMISSION LAYOUT

Bur 5-2840

Issued 8-06

Printed in U.S.A.

6002-6

2

2

2

2

3

1

4

BS01A191

1. ATTACHMENT FOR OIL FILLER PIPE WITH OIL DIPSTICK 2. TRANSMISSION SUSPENSION BORES

3. OUTPUT FLANGE CONVERTER SIDE 4. OIL DRAIN PLUG

COMPONENT LOCATIONS FRONT VIEW

Bur 5-2840

Issued 8-06

Printed in U.S.A.

6002-7

1

2

3

4

5 9 10 8

6

7

BS01A192

1. 2. 3. 4. 5.

CONVERTER BELL HOUSING BREATHER TRANSMISSION CASE COVER FILTER HEAD FILTER

6. 7. 8. 9. 10.

OUTPUT FLANGE REAR OIL DRAIN PLUG OUTPUT FLANGE CONVERTER SIDE TRANSMISSION CASE PARKING BRAKE

COMPONENT LOCATIONS SIDE VIEW

Bur 5-2840

Issued 8-06

Printed in U.S.A.

6002-8

2

1

1

3

7

6

5

4

4

BS01B048

1. 2. 3. 4.

LIFTING LUGS POWER TAKE OFF TRANSMISSION CONTROL VALVE TRANSMISSION SUSPENSION BORES

5. OUTPUT FLANGE REAR 6. FILTER 7. FILTER HEAD

COMPONENT LOCATIONS REAR VIEW

Bur 5-2840

Issued 8-06

Printed in U.S.A.

6002-9

TRANSMISSION OPERATION General

Transmission ECM Tasks

The transmission is equipped with a Transmission ECM (Electronic Control Module). This module controls modulation and shifting that were normally a s s o c i a t e d w i t h hy d r a u l i c a l l y m o d u l a t e d transmissions, providing smoother shifts and enhanced clutch life.

The Transmission ECM performs a variety of tasks in the overall system. The Transmission ECM:

The Transmission ECM relies on signals from several sensors that are incorporated into the design. These sensors measure the speed of several components, as well as other sensors that measure temperature. These solenoids and sensors are further defined in the following paragraphs. In a d d i t i o n , th e t ra n s m i s s i o n i n c o r p o ra t e s a two-piece transmission case for ease of transmission maintenance, helical cut gears that help reduce noise, and all external hoses have been eliminated (all oil passages are internal).

A. Determines which clutches to engage in the transmission. B. Protects the engine and transmission turbine from overspeed conditions dur ing downloading. C. Receives speed information from the engine speed sensor, the turbine speed sensor, the intermediate shaft speed sensor and the transmission output shaft speed sensor. T h e s e s p e e d s e n s o r s a r e c h e ck e d t o deter mine if nor mal sensor operation is present. The data is also used to control modulation during shifting and to determine the appropriate shift patterns. D. Detects system failures and determines the appropriate alternative actions.

Transmission ECM Modulation and shifting are controlled by the Tr a n s m i s s i o n E l e c t r o n i c C o n t r o l M o d u l e (Transmission ECM). This module replaces the oil and springs that are found in hydraulically modulated transmissions. T h e Tr a n s m i s s i o n E C M c o n t r o l s t h e c l u t c h e n g a g e m e n t , p r ov i d i n g s m o o t h e r s h i f t s a n d enhanced clutch life, whether the transmission is set to the automatic or manual shift mode. The Transmission ECM also informs the Information Center, by the use of diagnostic codes, of any transmission error and the hours of operation that the error occurred.

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.

Bur 5-2840

Issued 8-06

Printed in U.S.A.

6002-10

Transmission Sensor Data Collection The Transmission ECM collects and uses information from four sensors to accurately shift the transmission and determine if any clutches are slipping. These sensors are: Engine (Speed) Sensor - monitors engine speed to determine the load on the engine for shift points and sends the engine rpm to the Transmission ECM, which sends the information to the tachometer in the Information Center. Turbine (Speed) Sensor - assists the engine speed sensor in deter mining the load going into the transmission and helps determine shift points. Intermediate (Shaft Speed) Sensor - determines differential gear speed in the transmission to check for clutch slippage. Output (Speed) Sensor - monitors transmission output shaft speed to help determine the load on the transmission and to assist in determining shift points. Sends output shaft speed to Transmission ECM which sends the information to the speedometer in the Information Center. T h e t ra n s m i s s i o n E C M a l s o r ev i ew s vo l t a g e infor mation from the shifter and transmission solenoids to determine if there are any short circuits or open circuits in the system.

Automatic Problem Modes If the Transmission ECM detects an error condition in the transmission system, it will generate a service code in the Information Center and will enter one of three modes: A. Clutch Modulation Substitute Mode B. Limp-Home Mode C. Transmission/Transmission ECM Shutdown Mode

Clutch Modulation Substitute Mode In this mode, the transmission clutch modulation is time dependant rather than load dependant. The transmission will go into the Clutch Modulation Substitute Mode if any of the four speed sensors fail. If the output speed sensor is working and the transmission is in gear, the shift points in Automatic mode will be speed dependant but the modulation will be a predetermined amount of time. If the output speed sensor is not working and the transmission is in gear, the shift points will be load d e p e n d a n t bu t t h e m o d u l a t i o n w i l l s t i l l b e a predetermined amount of time. If the transmission is shifted from neutral into a direction in the Clutch Modulation Substitute Mode in automatic, the transmission will shift into 4th gear and shift down until it gets the correct output speed from the turbine.

Limp-Home Mode In this mode, the transmission will go into second gear, forward or reverse, no matter what gear is selected. If second gear is not obtainable, the Transmission ECM selects a series of prioritized g e a r s u n t i l a n o p e r a b l e g e a r i s fo u n d . T h e transmission will go into the Limp Home Mode if there is a fault on one clutch, a fault on one clutch valve, or a fault on more than one speed sensor.

Transmission/Transmission ECM Shutdown Mode In this mode, the Transmission ECM has detected a s e ve r e fa i l u r e t h a t d i s a b l e s c o n t r o l o f t h e transmission. The transmission will go into Shutdown Mode if there is a fault on more than one clutch, a fault on the solenoid power supply, or invalid voltage. In this mode, the Transmission ECM will shut off all solenoid valves and the power supply and the transmission shifts into and stays in neutral. If the Transmission ECM generates a code, the wren ch over th e se r vice m anual ico n will be displayed on the Information Center.

Bur 5-2840

Issued 8-06

Printed in U.S.A.

6002-11

Transmission Clutch Calibration

Gear Selections

The Transmission ECM has the capability to find the optimal adjustment of the clutch filling parameters for each individual transmission, providing the ability to individually adjust the optimum fill time for the individual transmission in the machine. Clutch Filling Parameter Calibration is performed on each machine at the plant and should be repeated at the first 250 hours of use and every 1000 hours thereafter.

The transmission provides 4 forward and 3 reverse gear selections. The transmission ratios were designed to give optimized speed and torque for each gear selection. The torque converter is a single stage torque converter (one locking unit in the torque converter).

Before doing the following transmission clutch calibration procedures make sure of the following:

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

1. The machine is running and the transmission oil is warm. 2. Engine low idle speed is correct.

Automatic/Manual Modes

3. The transmission is in neutral. 4. The park brake is applied.

Upshifting in Automatic Mode

5. If steps 1 through 4 have been accomplished, calibrate the transmission clutches as follows:

Upshifting is determined by machine speed and the torque on the transmission.

A. Press and hold the enter key for 2 to 3 seconds and the monitor will change to SELECT.

The transmission will shift from first or second gear up to the highest gear selected as the accelerator is depressed, machine speed increases, and required torque is reduced.

B. Use the down arrow and high light “CONFIG”, press the enter key. C. Press the down arrow and high light “CALIB G/B”, press the enter key.

If the machine speed is increasing, but the operator is not depressing the accelerator (such as when going down a hill), the transmission will not upshift.

D. Monitor will state “CALIB G/B” “CONFIRM PLEASE”, press the enter key.

As the operator depresses the accelerator and the torque on the transmission is lowered, the transmission will upshift.

E. If the conditions are not correct for clutch calibration the monitor will display the problem that needs to be corrected.

Downshifting in Automatic Mode

F. Clutch calibration status will be displayed on the monitor, “ADJUST K1, K2, K3, K4, KV, KR”. G. After completing the Clutch Calibration procedure, turn the machine OFF for 15 seconds. This sets the calibration in the controller.

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

Upshifting in Manual Mode In the manual mode, the transmission starts out in the selected gear and stays in that gear until the operator selects another gear or direction. The transmission can be upshifted without reducing engine speed or machine speed. If the gear selected is two or more gears higher than the present gear, the transmission will shift up through the gears at 2.5 second intervals until the selected gear has been reached. Bur 5-2840

Issued 8-06

Printed in U.S.A.

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 10° C (14° 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 retur n to the full range automatic mode when: A. Another gear is selected. B. The shifter is moved into neutral and then into forward or reverse. C. The autoshift switch is recycled.

When the transmission sump temperature warms up to minus 10° C (14°F) (within approximately one minute), the machine will operate in all gears.

Brake Pedal Transmission Declutch A transmission declutch feature concentrates more engine power on the loader when digging in heavy or tough conditions, providing smoother stops and starts. Total disconnection of the transmission from the engine is prevented. This feature will function in 1st, 2nd, or 3rd gear only. It will not function in 4th gear. When the transmission declutch switch is in the on p o s i t i o n a n d t h e b ra ke p e d a l i s p u s h e d , t h e Transmission ECM reduces the pressure to the transmission forward or reverse clutch. T h e Tr a n s m i s s i o n E C M w i l l n o t c o m p l e t e l y disconnect the clutch from the engine, but gradually reduces the forward or reverse clutch pressure down to a lower level. When the brake pedal is released, the Transmission ECM gradually increases the forward or reverse clutch back up to system clutch pressure. If the direction is changed while the transmission is declutched, the selected forward or reverse clutch will be filled and maintain a low pressure until the brake pedal is released. Then the selected forward or reverse clutch pressure will gradually increase up to system clutch pressure.

Bur 5-2840

Issued 8-06

Printed in U.S.A.

6002-13

TRANSMISSION PRESSURE TEST POINTS DIAGRAM No.

IDENTIFICATION/LOCATION

CONNECTION

DESIGNATION ON VALVE BLOCK H

Measuring Points for Pressure Oil and Temperature 51

Before the Converter - Opening Pressure 8 bar (116 psi)

M10x1

52

Behind the Converter - Opening Pressure 2.5 bar (36 psi)

M14x1.5

53

Clutch Forward 16+2 bar (232 + 29 psi)

KV M10x1

B

55

Clutch Reverse 16+2 bar (232 + 29 psi)

KR M10x1

E

56

Clutch 16+2 bar (232 + 29 psi)

K1 M10x1

D

57


K2 M10x1

A

58


K3 M10x1

C

60


K4 M10x1

F

63

Behind the Converter Temperature 100° C, Short Time 120° C

M14x1/5

65

System Pressure 16+2 bar (232 + 29 psi)

M10x1

K

Measuring Points for Delivery Rates 15

Connection to the Heat Exchanger

1 5/16” - 12 UNF-2B

16

Connection from the Heat Exchanger

1 5/16” - 12 UNF-2B

Inductive Transmitter and Speed Sensor 21

Inductive Transmitter for Turbine Speed

34

M18x1.5

Output Speed Sensor

47

Inductive Transmitter for Central Gear Train Speed

M18x1.5

48

Inductive Transmitter for Engine Speed

M18x1.5

Connections 49

Plug Connection on the Hydraulic Control Unit

68

System Pressure

M16x1.5

G

69

Pilot Pressure

M16x1.5

J

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

Bur 5-2840

Issued 8-06

Printed in U.S.A.

6002-14

BC01B047

MEASURING POINTS AND CONNECTIONS

Bur 5-2840

Issued 8-06

Printed in U.S.A.

6002-15

CHART FOR RECORDING PRESSURE READINGS Use this chart to record the pressure readings. P.I.N. Number:

Date: TEST POINTS

Shift Speed

P 65

V 53

R 55

1 56

2 57

3 58

4 60

5 51

6 52

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

Bur 5-2840

LP= LUBE PRESSURE

Issued 8-06

Printed in U.S.A.

6002-16

PRESSURE TEST RESULTS All or Most Pressures Low and/or Flow Test Low Possible causes include: 1. Oil level not correct. 2. Oil type and grade not correct. 3. Oil operating temperature high. 4. Screen for suction tube plugged. 5. Suction tube or gaskets leak. 6. Main pressure valve, springs, or valve bore. 7. Reduction valve, springs, or valve bore.

Not Enough Power Possible causes include: 1. Check Electrical Troubleshooting in this Section to verify actual gear selected. 2. Engine RPM below Stall Test specified RPM. (Refer to Section 2002 for specifications.) A. Check engine and fuel system for problem. B. Check that torque converter installation is correct. 3. Engine RPM above Stall Test specified RPM. (Refer to Section 2002 for specifications.)

8. Charge pump seals or gaskets leak.

A. Check converter pressures and flow.

9. Charge pump worn.

B. Check that torque converter installation is correct.

10. Oil supply flange not sealing correctly.

Some Pressures Low Possible causes include: 1. Circuit isolation does not correct low pressure. A. Control valve or gasket. B. Channel plate or gasket. 2. Circuit isolation corrects low pressure. A. Clutch shaft or seals. B. Clutch drum or piston.

Bur 5-2840

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 8-06

Printed in U.S.A.

6002-17

CONVERTER OUT PRESSURE CHECK Test Equipment Required

3. Install the pressure gauge.

0 to 28 bar (400 psi) gauge with hose long enough to take readings in the cab and CAS-2324 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 CAS-1808 Flowmeter Kit; CAS-2702 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 CAS-2702 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).

Bur 5-2840

Issued 8-06

Printed in U.S.A.

6002-18

TRANSMISSION OVERHEATING 1. Operate machine in normal operating conditions and observe: A. Verify actual oil temperature at test point. Normal operating temperature can be 56°C (100°F) above the ambient temperatures. B. Use a stop watch to establish the exact length of time required to reach the overheating condition. C. Observe engine temperature, does the engine overheat? Which overheats first - engine or transmission? 2. When the transmission reaches overheated condition, shift to Neutral and maintain engine RPM at a fast idle (1250 to 1450 RPM). A. Oil temperature returns to Normal - establish length of time. 1. Check oil level, type and grade is correct (See Section 1002). 2. Check operator’s gear selection is correct for conditions. 3. Make sure brakes are fully released. 4. Check the engine full throttle and stall speeds are correct as specified (See Section 2002). B. Oil temperature remains overheated. 1. Check for dirty radiator - airflow restricted. 2. Check for engine overheating problem. 3. Check for faulty oil temperature gauge and sender or switch (See Section 4002). 3. Perform all the pressure and flow tests. 4. Compare the pressure and flow test results to the specifications in this section to determine if any circuits are not within specifications. 5. Refer to Pressure Test Results to determine possible cause of any test results not within specifications.

Bur 5-2840

Issued 8-06

Printed in U.S.A.

6002-19

ERROR CODES In case of possible errors in the system, an amber or red warning appears on the instrument panel, combined with a recorded error number. See section 4005 for error code retrieval procedures and definitions.

TRANSMISSION SHIFTER LOGIC INFORMATION Function

Shifter

Shifter Wire Color

Shifter Tower Connector

Shifter Shroud Connector

Harness Wire #

Harness ped/cab #

Trans. ECM #

power

B+

black/red

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

Bur 5-2840

Issued 8-06

Printed in U.S.A.

6002-20

NOTES

Bur 5-2840

Issued 8-06

Printed in U.S.A.

6003

Section 6003 TRANSMISSION


Bur 5-2850


6003-2

TABLE OF CONTENTS SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TORQUES (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 5-2850

Issued 8-06

3 3 4 4 5 16

Printed in U.S.A.

6003-3

SPECIAL TOOLS

CAS2885 TRANSMISSION VALVE ADJUSTMENT TOOL SET CAS2807 TRANSMISSION INPUT/OUTPUT SHAFT SEAL INSTALLATION TOOL

CAS2869 TRANSMISSION OUTPUT SHAFT SEAL INSTALLATION TOOL (521 AND 621 MODELS ONLY)

CAS2803 TRANSMISSION TORQUE CONVERTER SEAL INSTALLATION TOOL

BS02C093 THRU 096

CAS40075 TRANSMISSION TOOL KIT

CAS2802 ALIGNMENT DOWEL SET

CAS2799 CLUTCH PACK H0LDER AND SPRING COMPRESSOR TOOLS CAS2801 TRANSMISSION MOUNTING BRACKETS

CAS2796 NESTING PLATE

CAS2798 GEAR PULLER COLLET SET

CAS2800 CLUTCH ASSEMBLY HOLDING KNOB SET

CAS2797 LIFTING EYEBOLT SET

CAS2868 CLUTCH SPRING COMPRESSOR (521 AND 621 MODELS ONLY)

BS02C097 THRU 104

CAS40079 TRANSMISSION OVERHAUL KIT

SPECIAL TORQUES Oil pipes Studs ............................................................................................................................... 9 Nm (80 pound inches) Socket head screw ...................................................................................................... 23 Nm (204 pound inches) Screw plug.......................................................................................................................... 51 Nm (38 pound feet) Clutch K1, K2, K3, K4 Stud ............................................................................................. 17 Nm (150 pound inches) Plugs................................................................................................................................. 25 Nm (221 pound inches) Output shaft Output shaft screws (apply Loctite 243 to threads) ..................................................... 23 Nm (204 pound inches) Housing cover screws (apply Loctite 574 to threads).................................................. 46 Nm (407 pound inches) Output flange screws................................................................................................... 34 Nm (301 pound inches) Oil feed housing and transmission pump Transmission pump screws ......................................................................................... 46 Nm (407 pound inches) Oil feed housing screws .............................................................................................. 25 Nm (221 pound inches) Engine connection and converter Input shaft screws ............................................................................................................ 115 Nm (85 pound feet) Converter housing screws.................................................................................................. 68 Nm (50 pound feet) Cover............................................................................................................................ 23 Nm (204 pound inches) Converter cover........................................................................................................... 46 Nm (407 pound inches) Input flange .................................................................................................................. 34 Nm (301 pound inches) Bur 5-2850

Issued 8-06

Printed in U.S.A.

6003-4

SPECIAL TORQUES (CONTINUED) Duct plate Screws......................................................................................................................... 25 Nm (221 pound inches) Screw plug................................................................................................................... 30 Nm (265 pound inches) Hydraulic control unit ........................................................................................................ 9.5 Nm (84 pound inches) Filter Filter head screws ....................................................................................................... 25 Nm (221 pound inches) Oil distribution cover screws........................................................................................ 25 Nm (221 pound inches) Speed sensor and inductive transmitter Speed sensor screw.................................................................................................... 23 Nm (204 pound inches) Inductive transmitter .................................................................................................... 30 Nm (265 pound inches) Cover plate .................................................................................................................. 23 Nm (204 pound inches) Screw plug...................................................................................................................... 140 Nm (103 pound feet)

SPECIFICATIONS Clutch KV and KR plate clearance ......................................................................... 2.7 to 2.9 mm (0.106 to 0.114 in) Clutch K1plate clearance........................................................................................ 2.4 to 2.6 mm (0.094 to 0.102 in) Clutch K2 and K3 plate clearance .......................................................................... 1.8 to 2.0 mm (0.071 to 0.079 in) Clutch K4 plate clearance....................................................................................... 1.2 to 1.4 mm (0.047 to 0.055 in)

Bur 5-2850

Issued 8-06

Printed in U.S.A.

6003-5

DISASSEMBLY STEP 1

STEP 4

GD98M833

GD98M837

Fasten transmission on an assembly stand using CAS2801 transmission mounting brackets.

R e m ove t wo s o cke t h e a d s c r ews a n d i n s t a l l CAS2885 transmission valve adjustment tool set. Remove remaining 21 socket head screws securing control valve. Loosen and remove hex rods (part of CAS2885) from studs then remove control valve.

STEP 2

STEP 5

GD98M835

Remove and discard oil filter.

STEP 3

GD98M838

Remove both gaskets and the intermediate plate.

STEP 6

GD98M836

Remove hex head screws securing filter head. Remove filter head from transmission.

GD98M839

Remove socket head screws and hex nuts. Remove duct plate. Remove flat gasket. Bur 5-2850

Issued 8-06

Printed in U.S.A.

6003-6

STEP 7

STEP 10

GD98M844

GD98M847

Bend lock plate away from hex head screws. Remove two hex head screws, lock plate, and washer. Remove input flange from shaft.

Using proper size rod, press input shaft and converter from cover.

STEP 11

STEP 8

GD98M845

Put alignment mar ks on conver ter cover and housing to aid in assembly. Remove 12 nuts and hex head screws.

GD98M848

Remove retaining ring then remove bearing.

STEP 12

STEP 9

GD98M849 GD98M846

C o n n e c t s u i t a bl e l i f t i n g e q u i p m e n t t o s h a f t . R e m o v e c o v e r, s h a f t , a n d c o n v e r t e r f r o m transmission and place in hydraulic press.

Bur 5-2850

R e m o ve fo u r h ex h e a d s c r e w s a n d r e m o ve diaphragm and input shaft.

Issued 8-06

Printed in U.S.A.

6003-7

STEP 13

STEP 16

GD98M850

GD98M853

Put input shaft and diaphragm in vise as shown. Remove 12 hex head screws to separate diaphragm and input shaft.

Remove the socket head screws for removal of the transmission pump.

STEP 17

STEP 14

GD98M854 GD98M851

Remove the inductive transmitter.

STEP 15

Apply a bearing separator on the splines shoulder of the stator shaft and pull the pump out of the housing bores, using two-leg puller. NOTE: If traces of wear should be encountered in the pump housing or the cam disk, the complete pump has to be replaced.

STEP 18

GD98M852

Remove the hex head screws and remove the converter housing. GD98M855

Separate the transmission pump from stator. Separate the cam plate from pump. Bur 5-2850

Issued 8-06

Printed in U.S.A.

6003-8

STEP 19

STEP 23 Turn the transmission 180 degrees and remove the rear output flange.

STEP 24

GD98M856

Remove the hex head screws and remove the oil feed housing. Remove the flat gasket.

STEP 20

GD98M862

Remove the speed sensor and both inductive transmitters.

STEP 25

GD98M860

Remove the hex head screws, cover, and flat gasket.

STEP 21 GD98M863

Remove the hex nuts and the two covers.

STEP 26

GD98M861

Remove the lock plate, hex head screws, and pry the converter side output flange from the shaft.

STEP 22 Pry the shaft seal out of the housing bore.

GD98M864

Install CAS2802 alignment dowel set. NOTE: The following steps describe the common removal of all clutches.

Bur 5-2850

Issued 8-06

Printed in U.S.A.

6003-9

STEP 27

STEP 30 Remove CAS2800 clutch assembly holding knob set and lift cover free.

STEP 31

BK00D029

Install CAS2800 clutch assembly holding knob set. With knobs installed on all clutches in housing cover, install CAS2797 lifting eyebolt set and lifting device to transmission cover.

GD98M867

Remove the socket head screws and remove the output shaft and both oil baffle plates.

STEP 28

STEP 32

BK00D028

Separate the cover along with clutches from the transmission housing, using lifting device.

GD98M872

Remove clutch K2.

STEP 29

STEP 33

BK00D026

Place clutch disc carriers onto CAS2796 nesting plate.

Bur 5-2850

GD98M873

Remove clutch K1 while lifting clutch K4.

Issued 8-06

Printed in U.S.A.

6003-10

STEP 34

STEP 37

GD98M877

GD98M874

Remove the bearing outer race and pull output shaft out of the housing bore.

Remove clutch K3.

STEP 35

STEP 38

GD98M875 GD98M878

Remove clutch K4 while lifting input shaft slightly.

STEP 36

Remove the rectangular ring and separate ball bearing from the shaft. NOTE: The following steps are for the disassembly of the clutch KV. The disassembly of the clutch KR is similar.

STEP 39

GD98M876

Remove clutches KV and KR together with input shaft. GD98M979

Remove the sealing ring. Pull the tapered roller bearing from the shaft. Remove the opposite tapered roller bearing. Bur 5-2850

Issued 8-06

Printed in U.S.A.

6003-11

STEP 40

STEP 43

GD98M881

BK00D020

Separate the clutch disc carrier from the shaft.

Remove snap ring.

STEP 41

STEP 44

GD98M882

Remove the snap ring and remove the clutch disc pack.

BK00D019

Remove the compression spring.

STEP 45

STEP 42

GD98M885 BK00D018

Preload compression spring using CAS2799 clutch pack holder and spring compressor tool.

Bur 5-2850

Remove piston from clutch pack holder. Remove and discard the O-rings from piston.

Issued 8-06

Printed in U.S.A.

6003-12

STEP 46

STEP 48

GD98M886

GD98M889

Remove the snap ring.

Remove the snap ring and remove the ball bearing.

STEP 47

NOTE: The following steps are for disassembly of clutch K3. Disassembly of clutches K1 and K2 is similar

STEP 49

GD98M887

GD98M890

Remove the rectangular ring. Pull the tapered roller bearing from the shaft.

STEP 50

GD98M888

Press the idler gear from the shaft using a bearing separator. Remove released needle bearing.

GD98M892

Remove the thrust washer, thrust bearing, and thrust washer.

Bur 5-2850

Issued 8-06

Printed in U.S.A.

6003-13

STEP 51

STEP 54

GD98M893

Remove the idler gear.

BK00D018


STEP 52

STEP 55

GD98M894

Remove the needle bearings and thrust bearing.

BKOOD020


STEP 53

STEP 56

GD98M895


Bur 5-2850

BK00D019


Issued 8-06

Printed in U.S.A.

6003-14

STEP 57

STEP 59

BS00G001

GD98M800

Remove the sealing ring. Remove bearing using bearing puller. Tap assembly until piston drops out of the clutch pack carrier. Then, remove and discard O-rings from piston.

Remove and discard two sealing rings. Pull two bearings from shaft using bearing puller. Remove the snap ring and separate the clutch disc carrier from the shaft.

STEP 58

STEP 60

GD98M801

BK00D022

Remove the clutch disc carrier from the shaft. NOTE: The following steps are for the disassembly of the clutch K4.


STEP 61

BK00D018


Bur 5-2850

Issued 8-06

Printed in U.S.A.

6003-15

STEP 62

NOTE: The following two steps are for disassembly of the input shaft. NOTE: A snap ring is used to lock turbine shaft in input shaft. Snap ring will be destroyed when turbine shaft is pressed from input shaft.

STEP 64

BK00D020


STEP 63

GD98M803

If turbine shaft is to be removed from input shaft, use proper size diameter sleeve or rod and press turbine shaft out of input shaft.

STEP 65 Remove bearings from input shaft using a bearing puller.

BK00D019


Bur 5-2850

Issued 8-06

Printed in U.S.A.

6003-16

ASSEMBLY NOTE: The following steps are for the reassembly of the oil pipes.

STEP 69

STEP 66

2 3

GD98M607

Install a new O-ring on plug. Tighten the plug to a torque of 51 Nm (38 pound feet).

1

STEP 70 GD98M603

Install suction tube (1), pressure pipes (2), and lubrication pressure pipe (3) in housing.

STEP 67 Secure suction tube (1) and pressure pipes (2) with socket head screw and hex nuts. Tighten to a torque of 23 Nm (204 pound inches)

STEP 68 GD98M608

Install all bearing outer races in housing bores.

STEP 71

GD98M605

Tilt the cover 180 degrees. Install the suction tubes and pressure pipes into the housing bores using a rolling tool. NOTE: Pipe end of the pressure pipes must be slightly below the housing plane face.

GD98M609

Install both oil pipes into the housing cover. Tilt the cover 180 degrees and install pipes into the housing bores using a rolling tool. NOTE: The pipe end must be slightly below the housing plane face.

Bur 5-2850

Issued 8-06

Printed in U.S.A.

6003-17

STEP 72

STEP 75

GD98M610

BK00D019

Install the studs. Tighten the studs to a torque of 9 Nm (80 pound inches). NOTE: The following steps are for the assembly of clutches KV and KR, starting with assembly of the clutch disc carrier.

STEP 73

BK00D018

Install compression spring and two spring cups in clutch disc carrier. Preload compression spring using CAS2799 clutch pack holder and spring compressor tool.

STEP 76 GD98M612

Check that drain hole is clear and free of foreign matter. Install both O-rings in recesses of the piston and apply oil.

STEP 74

BK00D020

Install the snap ring. NOTE: The following steps are for the KV and KR clutch disc packs. The disc stacking of clutches KV and KR is identical. GD98M613

Install piston in clutch disc carrier. Bur 5-2850

Issued 8-06

Printed in U.S.A.

6003-18

STEP 77

STEP 79 A

GD98M617 225B

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

PLATE CARRIER PISTON OUTER PLATE - ONE-SIDED COATED INNER PLATES OUTER PLATES - COATED ON BOTH SIDES SNAP RING END SHIM RUNNING CLEARANCE 2.7 TO 2.9 MM (0.106 TO 0.114 IN)

Install end shim and snap ring.

STEP 80

Install clutch disc plates in KV and KR clutch disc carriers in position and sequence shown above. Install outer plates (3) with steel faced side facing piston and end shim (7). NOTE: Snap rings of different thickness are available for adjustment of the running clearance. To ensure correct adjustment, do not apply oil to clutch discs until after adjustment is completed.

STEP 78

GD98M618

Adjust running clearance to 2.7 to 2.9 mm (0.106 to 0 . 1 1 4 i n ) . P r e ss d ow n o n t h e e n d s h i m w i th approximately 10 kg (20 lb). Measure and record dimension (A) from carrier face to end shim using depth gauge as shown. Example Dimension A . . . . . . . . . . . . . . . . . 7.25 mm (0.29 in)

GD98M616

Install the clutch disc pack.

Bur 5-2850

Issued 8-06

Printed in U.S.A.

6003-19

STEP 81

STEP 84

GD98M619

GD98M621

Use tools to lift the end shim against snap ring (upward) until contact is obtained. Measure and record dimension (B) from carrier face to end shim using depth gauge as shown. Subtract this measurement from the measurement of Step 80. The difference is the running clearance.

Apply Loctite 243 to stud. Tighten stud to a torque of 17 Nm (150 pound inches).

STEP 85

Example Dimension A . . . . . . . . . . . . . . . . . 7.25 mm (0.29 in) Dimension B . . . . . . . . . . . . . . . . . 4.45 mm (0.18 in) Difference = Running. . . . . . . . . . . 2.80 mm (0.11 in) Clearance Required running clearance is 2.7 to 2.9 mm (0.106 to 0.114 in). Use snap ring(s) of different thickness as necessary to obtain correct running clearance.

STEP 82 GD98M622

Remove clutch disc pack, apply oil to discs, and install clutch disc pack, end shim, and snap ring as determined in Step 81.

Install ball bearing until contact is obtained. Secure using snap ring.

STEP 83

STEP 86

GD98M623

GD98M620

Install idler gear to align and engage all inner discs, then remove idler gear.

Bur 5-2850

Install needle bearing.

Issued 8-06

Printed in U.S.A.

6003-20

STEP 87

STEP 90

GD98M624

Support the idler gear on the bearing inner race. Press the idler gear against the shoulder.

BP00G020

Install gear and shaft into heated bore.

STEP 91

STEP 88

BK00D024 GD98M625

Secure idler gear using snap ring.

Heat bearing.

STEP 92

STEP 89

WARNING: Always wear heat protective gloves to prevent burning your hand when handling heated parts. SM121A

BK00D023

Use heat gun to heat assembled clutch disc carrier inner bore. BK00D025

Install heated bear ing on shaft against shaft shoulder.

Bur 5-2850

Issued 8-06

Printed in U.S.A.

6003-21

STEP 93

STEP 96

Check operation of the clutch using compressed air. NOTE: The following steps are for assembly of clutch K1, K2, and K3.

STEP 94

GD98M632

Check that drain hole is clear and free of foreign matter. Install both O-rings in recesses of piston and apply oil. GD98M630

STEP 97

Press bearing against shoulder of shaft. Apply Loctite 243 to the stud and install the stud. Tighten the stud to a torque of 17 Nm (150 pound inches).

STEP 95

GD98M633

Install piston in clutch disc carrier.

STEP 98 GD98M631

Install the clutch disc carrier until contact is obtained.

GD98M634

Install the compression spring and spring cup.

Bur 5-2850

Issued 8-06

Printed in U.S.A.

6003-22

STEP 99

STEP 101 A

BK00D019

232A

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

BK00D018


STEP 100

PLATE CARRIER PISTON OUTER PLATE - ONE-SIDED COATED INNER PLATES OUTER PLATES - COATED ON BOTH SIDES SNAP RING END SHIM CLUTCH K1 RUNNING CLEARANCE 2.4 TO 2.6 MM (0.094 TO 0.102 IN); CLUTCHES K2 AND K3 RUNNING CLEARANCE 1.8 TO 2.0 MM (0.071 TO 0.079 IN)

Install clutch disc plates in K1, K2, and K3 clutch disc carriers in position and sequence shown above. Install outer plate (3) with steel faced side facing piston. NOTE: Snap rings of different thickness are available for adjustment of the running clearance. To ensure correct adjustment, do not apply oil to clutch discs until after adjustment is completed.

STEP 102

BK00D020

Install the snap ring. NOTE: The following steps are for K1, K2 and K3 clutches. The assembly of clutches K1, K2, and K3 is identical except for running clearance dimensions.

Bur 5-2850

GD98M636

Install the clutch disc pack.

Issued 8-06

Printed in U.S.A.

6003-23

STEP 103

STEP 105

GD98M637

Install the end shim and snap ring.

GD98M639

Use tools to lift the end shim against snap ring (upward) until contact is obtained. Measure and record dimension (B) from carrier face to end shim u s i n g d e p t h g a u g e a s s h ow n . S u b t r a c t t h i s measurement from the measurement of Step 104. The difference is the running clearance.

STEP 104

Example Dimension A . . . . . . . . . . . . . . . . . . .8.2 mm (0.32 in) Dimension B . . . . . . . . . . . . . . . . . . .6.1 mm (0.24 in) Difference = Running Clearance . . .2.1 mm (0.08 in)

GD98M638

Adjust running clearance for K1 to 2.4 to 2.6 mm (0.094 to 0.102 in); adjust running clearance for K2 and K3 to 1.8 to 2.0 mm (0.071 to 0.079 in). Press down on the end shim with approximately 10 kg (20 lb). Measure and record dimension (A) from carrier face to end shim using depth gauge as shown.

Required running clearance for K1 is 2.4 to 2.6 mm (0.094 to 0.102 in); for K2 and K3 required running clearance is 1.8 to 2.0 mm (0.071 to 0.079 in). Use snap ring(s) of different thickness as necessary to obtain correct running clearance.

STEP 106 Remove clutch disc pack, apply oil to discs, and install clutch disc pack, end shim, and snap ring as determined in Step 105.

STEP 107

Example Dimension A . . . . . . . . . . . . . . . . . . 8.2 mm (0.32 in)

3 2 1

GD98M640

Install the thrust washer (1), thrust bearing (2), and thrust washer (3). NOTE: Install the thrust washer (1) with the chamfer facing the thrust bearing. Bur 5-2850

Issued 8-06

Printed in U.S.A.

6003-24

STEP 108

STEP 111

GD98M641

BK00D024

Install both needle bearings.

Heat bearing.

STEP 109

STEP 112 WARNING: Always wear heat protective gloves to prevent burning your hand when handling heated parts. SM121A

GD98M642

Install idler gear until all inner discs are engaged.

STEP 110 BK00D025

1

Place heated bearing on the shaft.

STEP 113

2

Check operation of the clutch using compressed air.

3

GD98M643

Install the thrust washer (3), thrust bearing (2), and thrust washer (1). Install the thrust washer (1) with the chamfer facing the thrust bearing. NOTE: Ensure the thrust washer (1) is overlapping with the chaff collar to accommodate all the inner discs.

Bur 5-2850

Issued 8-06

Printed in U.S.A.

6003-25 NOTE: The following steps are for assembly of clutch K4.

STEP 116


GD98M649

Apply Loctite 243 to the stud and install the stud. Tighten the stud to a torque of 17 Nm (150 pound inches).

STEP 117 GD98M647

Heat the gear to about 120° C (248° F) and install until seated in position.

STEP 115

GD98M650

Check that drain hole is clear and free of foreign matter. Install both O-rings in recesses of the piston and apply oil.

STEP 118 GD98M648

Install retaining ring to secure gear.

GD98M651

Install piston in clutch disc carrier. Be sure piston bottoms out.

Bur 5-2850

Issued 8-06

Printed in U.S.A.

6003-26

STEP 119

STEP 121 A

BK00D019

BS02C131

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

PLATE CARRIER PISTON OUTER PLATE - ONE-SIDED COATED INNER PLATES OUTER PLATES - COATED ON BOTH SIDES SNAP RING END SHIM RUNNING CLEARANCE 1.2 TO 1.4 MM (0.047 TO 0.055 IN)

Install clutch disc plates in K4 clutch disc carrier in position and sequence shown above. Install outer plate (3) with steel faced side facing piston. BK00D018


NOTE: Snap rings of different thickness are available for adjustment of the running clearance. To ensure correct adjustment, do not apply oil to clutch discs until after adjustment is completed.

STEP 122

STEP 120

GD98M653

Install clutch disc pack. BK00D020

Install snap ring. NOTE: The following steps are for installing the clutch disc pack in clutch K4.

Bur 5-2850

Issued 8-06

Printed in U.S.A.

6003-27

STEP 123

STEP 125

GD98M654

Install end shim and snap ring.

GD98M656

Use tools to lift the end shim against snap ring (upward) until contact is obtained. Measure and record dimension (B) from carrier face to end shim u s i n g d e p t h g a u g e a s s h ow n . S u b t r a c t t h i s measurement from the measurement of Step 124. The difference is the running clearance.

STEP 124

Example Dimension A . . . . . . . . . . . . . . . . . . .7.2 mm (0.28 in) Dimension B . . . . . . . . . . . . . . . . . . .6.0 mm (0.24 in) Difference = Running . . . . . . . . . . . .1.2 mm (0.04 in) Clearance Required running clearance is 1.2 to 1.4 mm (0.047 to 0.055 in). Use snap ring(s) of different thickness as necessary to obtain correct running clearance. GD98M655

Adjust running clearance to 1.2 to 1.4 mm (0.047 to 0 . 0 5 5 i n ) . P r e s s d ow n o n t h e e n d s h i m w i t h approximately 10 kg (20 lb). Measure and record dimension (A) from carrier face to end shim using depth gauge as shown.

STEP 126 Remove clutch disc pack, apply oil to discs, and install clutch disc pack, end shim, and snap ring as determined in Step 125.

STEP 127

Example Dimension A . . . . . . . . . . . . . . . . . . 7.2 mm (0.28 in)

GD98M657

Install the idler gear until all inner discs are engaged, then remove idler gear.

Bur 5-2850

Issued 8-06

Printed in U.S.A.

6003-28

STEP 128

STEP 131 1 2 3

GD98M658

Assemble two thrust washers and thrust bearing. NOTE: Upper and lower thrust washers are the same thickness.

GD98M661

Assemble thrust washer (3), thrust bearing (2), and thrust washer (1). Install the thrust washer (1) with the chamfer facing the thrust bearing.

STEP 132

STEP 129

GD98M662 GD98M659

Install the assembled clutch disc carrier until all the inner discs are engaged.

Install both needle bearings.

STEP 130

STEP 133

GD98M660 GD98M663

Install the idler gear.

Bur 5-2850

Install snap ring to secure clutch disc carrier.

Issued 8-06

Printed in U.S.A.

6003-29

STEP 134


BK00D024

Heat bearing.

STEP 135 WARNING: Always wear heat protective gloves to prevent burning your hand when handling heated parts.

GD98M666

Heat gear to about 120° C (248° F) and install on input shaft until contact is obtained.

SM121A

STEP 139

BK00D025

Install heated bearing on the shaft shoulder.

STEP 136 Repeat Steps 134 and 135 to install bearing on opposite end of shaft.

GD98M667

Secure gear with snap ring.

STEP 140

STEP 137 Check operation of the clutch using compressed air. NOTE: The following steps are for the reassembly of the input shaft.

GD98M668

Install snap ring into recess of turbine shaft.

Bur 5-2850

Issued 8-06

Printed in U.S.A.

6003-30

STEP 141

STEP 144

GD98M669

GD98M672

Install the turbine shaft until the snap ring snaps into the recess of the input shaft.

Install output shaft into housing bore until contact is made.

STEP 142

NOTE: The following steps are for the installation of the output shaft and clutches. All clutches have a common installation.

WARNING: Always wear heat protective gloves to prevent burning your hand when handling heated parts.

STEP 145

SM121A

K1 AB

K3

K4

AN

KR

K2 KV

GD98M673 BK00D024

Heat bearings and install on turbine shaft until bearings are against shoulder.

Install bearing outer races into housing cover until contact is obtained.

STEP 146

STEP 143

BK00F003 GD98M671

Install the clutches onto CAS2796 nesting plate.

Install bearing then install rectangular ring. Bur 5-2850

Issued 8-06

Printed in U.S.A.

6003-31

STEP 147

STEP 150

BK00D029

GD98M681

Using CAS2797 lifting eye bolt set and acceptable liftin g eq uipm en t, in stall ho using cove r o nto clutches. Install CAS2800 clutch assembly holding knob set to secure clutch shafts to cover.

Install the sealing rings and insert rings in their respective grooves. Apply grease to the sealing rings and align the rings centrally.

STEP 151

STEP 148 KR KV K4

K2

K3

K1

GD98M692 GD98M679

The above photo shows the position of the single clutches in the housing cover.

Install both the O-rings into the annular groove of the oil pipes and apply grease.

STEP 152

STEP 149 AN

KV K2

Tilt the housing cover 180 degrees.

KR K4 K1

K3

AB

GD98M866

The above shows the position of the single clutches and the input and output clutches.

Bur 5-2850

Issued 8-06

Printed in U.S.A.

6003-32

STEP 153

STEP 156

BK00D028

GD98M686

Install output gear and shaft in transmission housing. Install alignment screws. Carefully lower the cover and clutches into the gear box housing.

Install screen sheet on output shaft. Press front and rear bearings on output shaft until contact with shoulder of output shaft is made.

STEP 154

STEP 157

Remove CAS2800 clutch assembly holding knob set.

STEP 155

GD98M688

Install the screening plate. GD98M685

STEP 158

Separate the housing cover from the gearbox, using a lifting device. NOTE: The following steps are for the reassembly of the output shaft.

GD98M689

Install the output shaft.

Bur 5-2850

Issued 8-06

Printed in U.S.A.

6003-33

STEP 159

STEP 162

GD98M690

GD98M697

Apply Loctite 243 to the socket head screws and install the screws. Tighten the screws to a torque of 23 Nm (204 pound inches).

Heat the output flange to about 90° C (194° F). Apply Loctite 574 to the contact area and assemble the flange with the washers and hex head screws. Tighten the screws to a torque of 34 Nm (301 pound inches). Bend corner of lock plate over hex head screws.

STEP 160

STEP 163 Repeat Steps 161 and 162 to install shaft seal and output flange on converter side. NOTE: The following steps are for the assembly of the oil feed housing and transmission pump.

STEP 164

GD98M691

Install rectangular rings in grooves of clutch shafts. Apply grease to rings and align rings.

STEP 161

GD98M702

Install two alignment studs and install the gasket.

GD98M696

Position shaft seal with sealing lip facing oil chamber. A p p l y g r e a s e t o s e a l i n g l i p. U s e C A S 2 8 0 7 transmission output shaft seal installation tool to install seal.

Bur 5-2850

Issued 8-06

Printed in U.S.A.

6003-34

STEP 165

STEP 168

GD98M703

Install the oil feed housing with washers and hex head screws. Screw the hex head screws in only until contact is obtained, do not tighten.

GD98M706

Install transmission pump.

STEP 169

STEP 166

GD98M707

GD98M704

Install the two alignment screws and install the stator shaft.

Apply grease to new O-rings. Install the O-rings on the socket head screws.

STEP 170

STEP 167

GD98M708

GD98M705

Apply oil and install the O-ring.

Bur 5-2850

Secure the transmission pump with the socket head screws. Tighten screws to a torque of 46 Nm (407 pound inches).

Issued 8-06

Printed in U.S.A.

6003-35

STEP 171

STEP 173

GD98M709

GD98M712

Install the oil feed housing with the hex head screws and flat washers. Tighten the screws to a torque of 25 Nm (221 pound inches).

Position converter housing. Secure with hex head screws. Tighten the screws to a torque of 68 Nm (50 pound feet).

STEP 172

STEP 174

GD98M711

GD98M713

Position the gasket and cover. Secure the cover with the hex head screws. Tighten the screws to a torque of 23 Nm (204 pound inches).

P u t in p u t s h a f t in a v i s e a s s h ow n . Po s i t io n diaphragm on input shaft and secure using 12 hex head screws. Tighten screws to a torque of 115 Nm (85 pound feet).

NOTE: The following steps are for the assembly of the engine connection and converter.

STEP 175

GD98M714

Position diaphragm and input shaft on converter. Apply Loctite 262 to threads of hex head screws. Install screws and tighten to a torque of 115 Nm (85 pound feet). Bur 5-2850

Issued 8-06

Printed in U.S.A.

6003-36

STEP 176

STEP 178

GD98M715

GD98M718

Position converter cover on converter housing. Make sure alignment marks made during removal of cover are aligned. Install input flange, two hex head screws, lock plate, and washer. Pull cover against housing by tightening two hex head bolts evenly.

STEP 179

GD98M716

Position converter. Check and ensure that impulse disk of converter is centered on the bore for the inductive transmitter.

STEP 177 GD98M719

Secure converter cover using 12 hex head screws and nuts. Tighten screws to a torque of 46 Nm (407 pound inches).

GD98M717

Position converter cover as shown. Install bearing against shoulder in cover. Secure using retaining ring.

Bur 5-2850

Issued 8-06

Printed in U.S.A.

6003-37

STEP 180

NOTE: The following steps are for installation of transmission control valve.

STEP 183

GD98M720

Tighten input flange hex head screws to a torque of 34 Nm (301 pound inches). Lock screws by bending corners of lock plate over screws.

STEP 181

258

Install CAS2885 transmission valve adjustment tool set. Be sure hex rods (par t of tool set) are not installed on studs. Mount the gasket (1), intermediate plate (2), and gasket (3).

STEP 184 Install the screw plug with new O-ring. Tighten the plug to a torque of 30 Nm (265 pound inches).

STEP 185

GD98M724

Install new sealing rings and both plugs in duct plate.

STEP 182

GD98M727

Install control valve on duct plate and CAS2885 studs. Install hex rods on studs and tighten against control valve. Install 21 socket head screws. Tighten screws to a torque of 9.5 Nm (84 pound inches). Remove CAS2885 transmission valve adjustment tool set. Install remaining two socket head screws. Tighten screws to a torque of 9.5 Nm (84 pound inches). GD98M725

Install the gasket and place the duct plate against shoulder. Install socket head screws and hex nuts. Tighten to a torque of 25 Nm (221 pound inches).

Bur 5-2850

NOTE: The following steps are for the installation of the filter.

Issued 8-06

Printed in U.S.A.

6003-38

STEP 186

STEP 189

GD98M729

GD98M735

Install new O-rings in recesses of oil filter head. Position filter head on transmission and secure using two socket head screws. Tighten screws to a torque of 25 Nm (221 pound inches).

Apply grease to the new O-ring and install the speed sensor with the socket head screw. Tighten the screw to a torque of 23 Nm (204 pound inches).

STEP 190

STEP 187

GD98M736

Install a new transmission filter.

With new O-rings, install the inductive transmitters. Tighten to a torque of 30 Nm (265 pound inches).

STEP 188

STEP 191

GD98M730

Install the breather.

STEP 192

GD98M733

Install new O-rings in oil distribution covers. Install the two oil distribution covers on the housing with hex nuts and flat washers. Tighten to a torque of 25 Nm (221 pound inches).

Bur 5-2850

GD98M737

Install the gasket and the cover plate. Tighten to a torque of 23 Nm (204 pound inches). With a new O-ring, install the screw plug. Tighten to a torque of 140 Nm (103 pound feet). Issued 8-06

Printed in U.S.A.

6004

Section 6004 FRONT AXLE


Bur 5-3190


6004-2

TABLE OF CONTENTS SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEAR TOOTH CONTACT PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WEAR MEASUREMENT ON MULTI-DISC BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WHEEL END AND BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LEAKAGE TEST OF THE BRAKE HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY OF DIFFERENTIAL CARRIER AND BRAKE TUBES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY OF LIMITED SLIP DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY OF DRIVE PINION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY OF THE BRAKE TUBES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY OF BRAKE TUBES AND DIFFERENTIAL CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY OF DIFFERENTIAL CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Determine Shim Thickness for a Perfect Tooth Contact Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Install the Drive Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjust Rolling Moment of Drive Pinion Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY OF LIMITED SLIP DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjust Backlash and Bearing Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 5-3190

Issued 8-06

3 4 6 6 7 7 13 23 23 23 24 27 28 29 30 32 32 33 34 36 40

Printed in U.S.A.

6004-3

SPECIAL TOOLS Planetary bearing puller collet set ............................................................................................................... CAS2881 Brake housing seal installer......................................................................................................................... CAS2880 Differential bearing cone puller collet set..................................................................................................... CAS2871 Differential bearing preload wrench ............................................................................................................. CAS2851 Brake housing inner bearing cup installer ................................................................................................... CAS2877 Brake housing outer bearing cup installer ................................................................................................... CAS2878 Brake housing inner bearing cup installer ................................................................................................... CAS2879 Wear ring installer adapter .......................................................................................................................... CAS2874 Wear ring installer adapter ......................................................................................................................... CAS2875 Pinion depth gauge set................................................................................................................................ CAS2872 Pinion depth gauge block ............................................................................................................................ CAS2873 Puller body and screw ................................................................................................................................. CAS2882 Support bracket ........................................................................................................................................... CAS2883 Slide hammer puller adapter ..................................................................................................................... CAS10846 Slide hammer ..............................................................................................................................................OEM4252 Replacer ...................................................................................................................................................... CAS2297 Magnetic base with indicator ................................................................................................................... CAS10066A Heat gun .................................................................................................................................................... CAS10810 Lifting sling...................................................................................................................................................OEM4106 Engine stand................................................................................................................................................OEM4135 Snap ring pliers............................................................................................................................................OEM6484 Snap ring pliers............................................................................................................................................OEM6177 Snap ring pliers............................................................................................................................................OEM6492 Step plate set (includes 8061, 8067, and 8073) ..........................................................................................OEM4288 Step plate ............................................................................................................................................................8061 Step plate ............................................................................................................................................................8067 Step plate ............................................................................................................................................................8073

Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-4

GEAR TOOTH CONTACT PATTERNS Ideal Tooth Contact Pattern

Pinion Distance Must Be Increased

BS01D011

BS01D009

COAST SIDE (CONCAVE)

BS01D013 BS01D012


DRIVE SIDE (CONVEX)

BS01D014

DRIVE SIDE (CONVEX)

Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-5

Pinion Distance Must Be Decreased

BS01D016 BS01D010

DRIVE SIDE (CONVEX)

BS01D015


Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-6

LUBRICATION 4

4 4

5

5

4

3 2 2

2

3

1

1

2 BS00M069

1. OIL DRAIN HOLE (AXLE CASING) 2. OIL DRAIN HOLE (OUTPUTS)

BS00M070

3. OIL FILLER HOLE 4. BRAKE BLEEDER

5. BLEEDER

WEAR MEASUREMENT ON MULTI-DISC BRAKE

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 wheel ends. Remove screw plug, actuate brake and determine dimension “X” using a feeler gauge. If dimension “X” is less than or equal to 4.0 mm (0.16 in) the lined discs on both output sides have to be replaced. Replace O-ring when installing the level plug. Tighten plug to 70 Nm (52 pound-feet).

Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-7

WHEEL END AND BRAKES Disassembly

STEP 3

STEP 1

BD00M238

Pry the cover off the wheel end. BD00M235

STEP 4

Fasten the axle on a stand.

STEP 2

BD03B008

BD00M236

Use OEM4252 slide hammer and CAS10846-3 adapter, remove the slotted pin from wheel end lock nut.

STEP 5

BD00M237 BD03B009

Loosen the screw plugs and drain the oil from the axle casting.

Bur 5-3190

Using CAS2876 locknut socket and CAS2883 support bracket, loosen and remove the locknut.

Issued 8-06

Printed in U.S.A.

6004-8

STEP 6

STEP 9

BD00M241

Use acceptable lifting equipment and hold the wheel end in place. Loosen and remove the bolts.

BD00M244

Remove the shim(s) from the sun gear shaft.

STEP 10 STEP 7

BD00M245 BD03B010

Pull the sun gear shaft out of the planet gears.

Separate the wheel end from the axle casing.

STEP 11 STEP 8

BD03B011 BD00M243

Pull the stub shaft out of the sun gear shaft.

Lift planet carrier out of the brake housing using OEM4054 pulling attachment.

NOTE: Watch for released shim(s).

Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-9

STEP 12

STEP 15

BD03B012

Remove the snap rings from the planet gear shaft using OEM6492 snap ring pliers.

BD03B015

Using suitable puller, remove planetary ring gear from brake housing.

STEP 13 STEP 16

BD03B013

Remove the planet gear using CAS2848 gear puller and 8061 step plate.

BD03B016

Remove O-rings from the annular grooves of the ring gear.

STEP 14

STEP 17

BD03B014

Remove the bearing from the planetar y using CAS2881 collet set, CAS2882 puller body and screw, and 8061 step plate.

Bur 5-3190

BD03B017

Remove O-ring from recess of the brake housing.

Issued 8-06

Printed in U.S.A.

6004-10

STEP 18

STEP 21

BD03B021

Remove the brake disc pack from the brake housing.

Use compressed air to raise piston out of the brake housing.

STEP 19

STEP 22

BD00M253

BD03B019

Drive slotted pins in the support shim until they are flush with the top of the support shim.

Remove the support shim out of the piston.

STEP 20

STEP 23

BD00M257

BD03B020

Remove the circlip using OEM6484 external pliers.

Bur 5-3190

BD03B022

Drive slotted pins out of the support shim.

Issued 8-06

Printed in U.S.A.

6004-11

STEP 24

STEP 27

BD00M259

Preload the cup springs using a press and remove the retaining ring.

BD00M262

Lift the piston out of the brake housing.

STEP 28 STEP 25

BD00M263 BD00M260

Pull the pin out of the support shim and remove the released cup springs.

STEP 26

Remove and discard the guide ring, support rings and U-rings from the grooves of the brake housing. NOTE: If replacing brakes only, go to step 44.

STEP 29

BD00M261

Press the gripping rings off of the pins.

Bur 5-3190

BD03B023

Using CAS2850 puller bridge and 8073 step plate, remove the brake housing from the wheel end shaft.

Issued 8-06

Printed in U.S.A.

6004-12

STEP 30

STEP 32

BD03B024

Use acceptable lifting equipment and lift the brake housing from the wheel end shaft.

Remove the shaft seal from the brake housing.

STEP 31

STEP 33

BD00M267

If the wheel end pressure ring or bearing needs to be replaced, remove the bearing from the wheel end shaft.

STEP 34

BD00M266

If necessary drive both bearing outer rings out of the brake housing.

BD00M269

If the wheel end pressure ring needs to be replaced, remove the pressure ring from the wheel end shaft.

Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-13

Assembly


STEP 35

SM121A

STEP 38

BD00M271

Install a new pressure ring on the wheel end shaft.

STEP 36

BD00M273

Heat the bearing inner ring and install it onto the wheel end shaft.

STEP 39

BD01F107

Install the CAS2874 pressure ring installer adapter on the wheel end shaft.

STEP 37

BD03B026

Freeze the bearing outer ring. Press the bearing outer ring into the brake housing using CAS2879.

STEP 40 Freeze the bearing outer ring. Press the bearing outer ring into the brake housing using CAS2853.

BD01F105

Press the pressure ring over the collar of the wheel end shaft using CAS2860 pressure ring installer.

Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-14

STEP 41

STEP 42

BD03B024 BD03B027

Use a solution of 50% water and 50% mineral spirits to wet the outer diameter of the shaft seal. Using CAS2880 install the shaft seal with the sealing lip showing to the oil chamber. See illustration below.

Use acceptable lifting equipment and install the brake housing over the wheel end shaft until contact. WARNING: Always wear heat protective gloves to prevent burning your hand when handling heated parts. SM121A

STEP 43

BS00M073

SHAFT SEAL 1. BRAKE HOUSING 2. SHAFT SEAL * GREASE FILLING

Bur 5-3190

BD00M277

Heat the bearing inner ring and install it into the brake housing until contact.

Issued 8-06

Printed in U.S.A.

6004-15

STEP 44

STEP 45

BD00M263

BD00M279

Clean the groove of the brake housing with solvent. Install the guide ring into the groove and fix it with Loctite 415. NOTE: Upon installation the guide ring must have contact on the whole circumference and the orifice must show upwards (12 o’clock).

STEP 46

BS00M072

1. 2. 3. 4.

BRAKE HOUSING GUIDE RING SUPPORT RING U-RING

5. U-RING 6. SUPPORT RING 7. WHEEL END SHAFT

Install the guide ring, support rings and U-rings in the grooves of the brake housing.

Bur 5-3190

BD00M280

Apply oil on the sliding surface of the piston. Care fully insert the piston into the brake housing.

Issued 8-06

Printed in U.S.A.

6004-16

STEP 47

BD00M281

Insert the pins into the assembly fixture until contact.

STEP 48 BS00M074

1. PIN 2. GRIPPING RINGS 3. CUP SPRINGS

4. SUPPORT SHIM 5. RETAINING RING X. 10.5 MM +0.3 (0.41 IN +0.02)

STEP 50

1

BD00M282

1. GRIPPING RINGS

Press the gripping rings onto the pins until contact on the assembly fixture. ATTENTION: Observe the installation position, install the gripping rings with the orifices offset by 180° to each other.

BD00M284

Insert the assembled pins into the support shim and install the snap ring.

STEP 49 STEP 51

BD00M283

Install the cup springs onto the pins. See illustration below. Bur 5-3190

BD00M285

Insert the assembled support shim into the piston. Issued 8-06

Printed in U.S.A.

6004-17

STEP 52

STEP 54

1 BD00M286

BD00M288

1. SPLINE

Install the circlip into the brake housing.

Drive the stop bolt into the planet carrier. Then coat the spline with anti-corrosive antiseize.

STEP 53

STEP 55

BD03B028

BD00M289

Insert the planet carrier into the spline of the wheel end shaft until contact.

BD03B034

1. BRAKE HOUSING 2. CIRCLIP 3. SLOTTED PIN

4. SUPPORT SHIM 5. PISTON X INSTALLATION DIMENSION 5.0 MM ± 0.5 MM

Drive slotted pins into the bores of the support shim to lock the circlip.

Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-18

STEP 56

STEP 58 2

1

BD03B016

Grease both O-rings.

STEP 59

3 4 BS06A166

1. BRAKE PISTON 2. BRAKE DISC

3. PLATE 4 MM 4. PLATE 2 MM BD03B030

Install the discs (2), plates (3), and plates (4) as shown. Lubricate the brake disc with clean axle oil.

Install two aligning dowels in the brake housing, install ring gear onto the brake housing.

NOTE: The number of brake discs may vary from your machine, the procedure is the same.

NOTE: Make sure alignment is correct on ring gear.

STEP 60

STEP 57

BD03B029

Insert O-ring into the recess of the brake housing.

Bur 5-3190

BD01C009

Heat the bearing inner rings with a hot air gun.

Issued 8-06

Printed in U.S.A.

6004-19 WARNING: Always wear heat protective gloves to prevent burning your hand when handling heated parts.


SM121A

STEP 61

SM121A

STEP 63

BD00M292

BD00M294

Install the bearings with the big radius showing to the planet carrier (downwards).

Heat the bearing inner rings and install into the planet gears.

STEP 62

STEP 64

BD00M293

Put the planet gears onto the bearing inner rings.

Bur 5-3190

BD03B031

Install the snap rings on the planet gear shafts using OEM6492 snap ring pliers.

Issued 8-06

Printed in U.S.A.

6004-20

Adjust end play of sun gear shaft 0.5 to 2.0 mm (0.02 to 0.08 inch)

STEP 67

STEP 65

BD00M298

Insert the sun gear shaft onto the stub shaft until contact. BD00M296

Determine dimension I, from the mounting face of the brake housing up to the face of the stop bolt. Dimension I e.g. . . . . . . . . . . . 46.20 mm (1.82 inch)

STEP 68

STEP 66

BD00M299

BD00M297

Insert the stub shaft into the spline of the axle bevel gear until contact.

Bur 5-3190

Determine dimension II from the face of the sun gear shaft up to the mounting face of the axle casing. Dimension II e.g. . . . . . . . . . . 43.00 mm (1.69 inch) Example: Dimension I +46.20 mm (1.82 inch) Dimension II −43.00 mm (1.69 inch) Difference 3.20 mm (0.13 inch) Required end play e.g. − 1.00 mm (0.04 inch) Difference = shim e.g. s = 2.20 mm (0.09 inch)

Issued 8-06

Printed in U.S.A.

6004-21

STEP 69

STEP 72

BD00M245

Insert the sun gear shaft into the planet carrier.

BD00M300

Install the washers and bolts by hand. Tightening torque . . . . . . . 390 Nm (288 pound-feet)

STEP 70 STEP 73

BD00M244

Install the determined shim(s), e.g. S. = 2.20 mm (0.09 inch) into the sun gear shaft with grease.

STEP 71

BD03B033

Install the locknut by hand and tighten it using CAS2876 locknut socket and CAS2883 suppor t bracket. Tighten torque . . . 700+300 Nm (516 +221pound-feet)

STEP 74

BD03B032

Install O-ring and hold into place with grease, install output housing onto axle. BD00M302

Secure the locknut with the slotted pin.

Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-22

STEP 75

STEP 76

1 BD00M303

1. O-RING

BD00M304

Insert the cover into the wheel end.

Install an O-ring on the cover.

Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-23

LEAKAGE TEST OF THE BRAKE HYDRAULICS NOTE: Prior to start the test, ventilate the brake hydraulics and then actuate it several times.

High Pressure Test Low Pressure Test

STEP 77

Reduce test pressure to p = 5 bar (72.5 psi) and close the shutoff valve again. During a 5 minute testing time a pressure drop is not allowed.

BD00M305

Increase test pressure up to p =100 bar (1450 psi) maximum and close connection to HD pump by means of shutoff valve. During a 5 minute testing time, a pressure drop of maximum 2 bar (29 psi) is allowed. ATTENTION: If the maximum pressure of 100 bar (1450 psi) is exceeded, there will be an excessive piston adjustment and a repeated disassembly of the brake or the adjusting is required to reset the gripping rings to the adjusting dimension.

Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-24

DISASSEMBLY OF DIFFERENTIAL CARRIER AND BRAKE TUBES STEP 1

STEP 3

BD00M235

Fasten the axle on a stand.

BD00M241

Use acceptable lifting equipment to hold the wheel end in place. Loosen and remove the bolts.

STEP 2 STEP 4

BD00M236

BD03B032

Separate the wheel end from the axle housing. Remove O-ring.

STEP 5

BD00M237

Loosen the screw plugs and drain the oil from the axle casing. BD00M243

Pull the stub shaft out of the sun gear shaft. Repeat steps 3 through 5 for the other wheel end. NOTE: Pay attention to the released shim(s). Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-25

STEP 6

STEP 9

BD00M395

BD00M398

Remove the bolts from the differential carrier.

Drive out the slotted pins from the differential carrier.

NOTE: Mark the location of the differential carrier to the axle casing.

STEP 10

STEP 7

BD01F072

BD03B035

Use suitable lifting equipment and lift the differential carrier out of the axle casing.

Loosen and remove both adjusting nuts using CAS2851 wrench.

STEP 11

STEP 8

BD00M400

Heat the axle drive housing with a hot air gun. BD03B036

NOTE: Bolts are installed with Loctite.

Fasten the differential carrier on OEM4135 engine stand using CAS2847 mounting bracket.

Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-26

STEP 12

STEP 13

BD00M401

Loosen the bolts and take off both bearing brackets. NOTE: Make an alignment mark between the bearing bracket and the housing.

BD00M402

Remove both bearing outer rings from the differential carrier.

STEP 14

ATTENTION: Loosen the bolts by hand only.

BD00M403

Use acceptable lifting equipment and lift the differential out of the differential carrier.

Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-27

DISASSEMBLY OF LIMITED SLIP DIFFERENTIAL STEP 15

STEP 17

BD00M406 BD01F089

Using CAS2294 cone puller and 8065 step plate, remove the bearing inner ring from the differential housing.

Place the differential in a press to prevent it from turning. Remove the bolts and the released housing cover.

STEP 18

STEP 16

BD00M407

Remove all the single parts from the differential housing. BD01F096

Remove the bearing inner ring from the housing cover using CAS2294 cone puller and 8065 step plate.

STEP 19

BD00M408

Press off the ring gear from the differential housing.

Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-28

DISASSEMBLY OF DRIVE PINION STEP 20

STEP 23

BD00M409

Heat the pinion shaft locknut with a hot air gun. NOTE: Locknut is held with Loctite Type No. 262.

BD00M412

Remove the shaft seal from the differential carrier.

STEP 24 Use a rubber hammer to remove the drive pinion out of the differential carrier.

STEP 21

STEP 25 Take off the spacer ring and pull the bearing inner ring from the drive pinion shaft.

STEP 26

BD01F091

Using CAS1579A yoke holding wrench, loosen the locknut and remove the washer behind it.

STEP 22 BD00M414

If necessary drive out both bearing outer rings from the differential carrier.

BD00M411

Pull the input yoke from the drive pinion shaft.

Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-29

DISASSEMBLY OF THE BRAKE TUBES STEP 27

STEP 30

BD00M334

BD00M337

Remove the screw plug with the vent valve from the axle casing.

Disconnect the pipe union and remove the released brake tube from the axle casing.

STEP 28

STEP 31

BD00M335

Loosen and remove the hexagon screw from the axle.

BD00M338

Remove the vent valve from the connection part.

STEP 32 STEP 29

BD00M339 BD00M336

Loosen and remove the union screw from the axle.

Bur 5-3190

Loosen the connection part and remove it from the axle. Repeat steps 28 to 32 for the other wheel end.

Issued 8-06

Printed in U.S.A.

6004-30

ASSEMBLY OF BRAKE TUBES AND DIFFERENTIAL CARRIER STEP 33

STEP 36

1

2 3 4 1

BD00M340

1. VENT VALVE

2. CONNECTION 3. O-RING 4. RECTANGULAR PART RING

BD00M343

1. O-RING

Install an O-ring into the groove of the brake tube.

Assemble the part as shown in the photo above.

STEP 37 STEP 34

2 1

BD00M344 BD00M341

Install the connection part on the axle casing. Tightening torque . . . . . . . . .130 Nm (96 pound feet)

1. BRAKE TUBE 2. UNION SCREW

Insert the brake tube into the axle casing, assembling the connection part through the union screw.

STEP 35

BD00M342

Install the union screw with a new O-ring on the axle. Tightening torque . . . . . . . 190 Nm (140 pound-feet) Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-31

STEP 38

Assemble the screw plug as shown in the above photo.

STEP 41

BD00M345

Fasten the brake tube with the hexagon nut and union nut. Tightening torque . . . . . . . . . 70 Nm (52 pound-feet)

MD00M348

Install the screw plug on the axle casing. Tightening torque . . . . . . . . 70 Nm (52 pound-feet)

STEP 39

BD00M346

Tightening torque . . . . . . . . . 80 Nm (60 pound-feet) NOTE: Repeat steps 33 to 39 for the other wheel end.

STEP 40 1 2 3

BD00M347

1. O-RING 2. SCREW PLUG 3. VENT VALVE

Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-32

ASSEMBLY OF DIFFERENTIAL CARRIER NOTE: If the ring gear or drive pinion are damaged, both parts have to be replaced together. For new installation of a complete bevel gear set pay attention to the same pair number of drive pinion and ring gear.

STEP 44

Determine Shim Thickness for a Perfect Tooth Contact Pattern NOTE: Make the following measuring steps at maximum accuracy. In exact measurements result in a faulty tooth contact pattern and require a repeated disassembly and assembly of the drive pinion as well as of the differential. BD00M350

STEP 42 Install the CAS2873 pinion depth gauge block and CAS2289-1 gauge tube on the differential carrier.

Determine Dimension I (bearing width). Dimension I e.g. . . . . . . . . . . 36.00 mm (1.417 inch)

STEP 45 STEP 43

1

BD00M351

1. 168.0 +0.05 BD01F106

Determine the gap between the measuring shaft and the measuring pin with a feeler gauge. Dim. B e.g. . . . . . . . . . . . . . . . 1.00 mm (0.039 inch) Example A.: Dimension A (tool constant) Dimension B (gap) Results in Dimension X

204.25 mm ------(8.041 inch) +1.00 mm ------(0.039 inch) s = 205.25 mm -----(8.08 inch)

Read Dimension II (dimension for pinion). Dimension II e.g. . . . . . . . . . 168.05 mm (6.62 inch) Example B: Dimension I Dimension II Results in Dimension Y Example C: Dimension X Dimension Y Difference = Shim e.g.

Bur 5-3190

36.00 mm ------(1.417 inch) +168.05 mm ------(6.616 inch) s = 204.05 mm -----(8.04 inch)

205.25 mm (8.081 inch) −204.05 mm (8.033 inch) s = 1.20 mm (0.048)

Issued 8-06

Printed in U.S.A.

6004-33

Install the Drive Pinion

STEP 49

STEP 46

BD01F065

BD00M352

Press the bearing inner ring on the drive pinion shaft using CAS2297 and 8073 step plate.

Place the determined shim e.g. S. =1.20 mm (0.05 inch) into the bearing bore in the differential carrier.

STEP 47

BD01F063

Freeze the bearing outer ring and insert into the differential carrier using CAS2293-1, CAS2293-2, and 8073 step plate.

STEP 48

BD01F087

Freeze the bearing outer ring on the input side and install using CAS2293-2 and 8073 step plate. Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-34

Adjust Rolling Moment of Drive Pinion Bearing

STEP 52

STEP 50

BD01F101

Press the dust shield onto the input yoke using CAS2882 puller tube. BD00M356

STEP 53

Install the spacer ring on the pinion shaft. NOTE: As per experience the required rolling movement is obtained by use of the spacer ring [e.g. s=8.70 mm (0.34 inch)] available at disassembly. However, a later checking of the rolling movement must be done. WARNING: Always wear heat protective gloves to prevent burning your hand when handling heated parts. SM121A

STEP 51 BD00M359

Install the input yoke on the pinion shaft.

STEP 54

BD00M357

Insert the assembled drive pinion into the differential carrier and install the heated bearing inner ring.

BD00M360

Install the washer on the pinion shaft.

Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-35

STEP 55

STEP 58

BD01F091

BD01F098

Install the locknut by hand. Using CAS1579A yoke holding wrench tighten the locknut. Tightening torque . . . . . . . 700 Nm (516 pound-feet)

Using CAS2288 and CAS2299, install the shaft seal with the sealing lip showing to the oil chamber (downwards).

NOTE: When tightening rotate the drive pinion in both directions several times.

ATTENTION: Just before the installation wet the outer diameter of the shaft seal with a solution of 50% water and 50% mineral spirits. Fill the space between the sealing and dust lip with grease.

STEP 56

STEP 59

BD00M362

Check rolling movement. Rolling movement should be 1.5 to 3.0 Nm (1.10 to 2.21 pound-feet). NOTE: For new bearings it should be tried to achieve the maximum value of the rolling movement. ATTENTION: If the required rolling movement is not obtained, correct it with an adequate spacer ring, according to the following indications: Rolling movement too low - install a thinner spacer ring. Rolling movement too high - install a thicker spacer ring.

BD01F091

Put the input yoke in place and install the washer and locknut. Using CAS1579A yoke holding wrench tighten the locknut. Tighten torque . . . . . . . . . 700 Nm (516 pound-feet) ATTENTION: Apply Loctite, Type No. 262, onto the thread of the locknut.

STEP 57 Remove the locknut again and pull off the input yoke from the drive pinion shaft.

Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-36

ASSEMBLY OF LIMITED SLIP DIFFERENTIAL STEP 60

STEP 63

BD00M427

BD00M430

Place both thrust washers into the differential housing.

Insert the axle bevel gear and slide the splined shaft into the clutch discs.

STEP 61

STEP 64

BD00M428

BD00M431

Starting with an outer clutch disc install alternately the outer and inner clutch discs.

Assemble the differential spider and insert it into the differential housing.

ATTENTION: Thickness of the disc pack must be identical on both sides.

STEP 65

STEP 62

BD00M432

Insert the second axle bevel gear. BD00M429

Insert the pressure ring into the differential housing. Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-37

STEP 66

Determine the Disc Clearance STEP 68

BD00M433

Insert the second pressure ring into the differential housing.

BD00M435

Determine dimension I, from the mounting face of the differential housing to the plane face of the outer clutch disc. Dimension I e.g. . . . . . . . . . . 38.05 mm (1.50 inch)

STEP 67

STEP 69

BD00M434

Starting with an inner clutch disc install alternately the inner and outer clutch disc. ATTENTION: The thickness of the clutch disc pack must be identical on both sides.

BD00M436

Determine dimension II, from the contact surface of the outer clutch disc to the mounting face of the housing cover. Dimension II e.g. . . . . . . . . . . 37.75 mm (1.48 inch) 38.05 mm

Dimension I

-------(1.50 inch) + 37.75mm

Dimension II Difference = Disc clearance

-------(1.49 inch) = 0.30 mm ------(0.01 inch)

NOTE: If the required disc clearance is not obtained, correct it with the adequate outer clutch discs [s=2.1, s=2.2, s=2.3, s=2.4 or s=2.5 mm (0.083, 0.087, 0.091, 0.094, 0.098 inch)], taking care that the difference in thickness between the left and the right disc pack must only be 0.1 mm (0.004 inch) at a maximum. Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-38

STEP 70

STEP 73

BD00M437

BD00M440

Fix the thrust washer with grease into the recess of the differential housing cover.

Press both bearing inner rings onto the differential housing.

STEP 71

STEP 74

BD00M438

BD00M441

Put the housing cover in place on the differential housing. Heat the ring gear and install onto the differential housing.

Use acceptable lifting equipment and insert the differential into the differential carrier.

STEP 75 STEP 72

BD00M442 BD00M439

Put the differential in a press to prevent it from turning and install the bolts on the ring gear. Tightening torque . . . . . . . 410 Nm (302 pound-feet)

Place the bearing outer ring into the differential carrier.

ATTENTION: Use new locking bolts. Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-39

STEP 76

STEP 79

BC00M443

BD00M446

Install the adjusting nut by hand on the differential carrier.

Install both bearing brackets and install the bolts and washers. Tighten torque . . . . . . . . . 280 Nm (207 pound-feet)

STEP 77

ATTENTION: Apply Loctite Type No. 262 onto threads of the bolts.

BD00M444

Install the ring gear sided bearing outer ring.

STEP 78

BD00M445

Install the adjusting nut by hand on the differential carrier.

Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-40

Adjust Backlash and Bearing Preload

STEP 82

STEP 80

NOTE: As the adjusting nut makes firm contact with the bearing, the adjusting nut will immediately begin to turn much harder.

Tighten the adjusting nut slowly until firm contact is made with the bearing.

STEP 83 To adjust the bearing preload, note the position of the adjusting nut. Now tighten the nut two additional notches.

STEP 84

BD00M447

Place a dial indicator right-angled at the outer diameter of the tooth flank (ring gear). Adjust the pinion to ring gear backlash to the low side of specifications (see value etched on the outer diameter of the ring gear) by alternately turning each of the adjusting nuts to move the ring gear closer to or further away from the pinion. Backlash is checked using a dial indicator against a tooth on the ring gear.

As the bearing preload is adjusted as described in steps 81, 82 and 83, pinion to ring gear backlash may increase slightly. Check pinion backlash to confirm that it is within specifications. If backlash is outside of specified range, repeat step 80 through 84 again.

STEP 85

NOTE: Rotate the differential several times and recheck the backlash.

STEP 81

BD00M449

Coat several teeth on the ring gear with marking ink and roll the ring gear in both directions over the drive pinion. Compare the obtained tooth contact pattern with the examples on page 4 and 5.

BD01F072

ATTENTION: If the tooth contact pattern differs, there has been a measuring error at determination of the shim. This must be corrected.

Go to the adjusting nut opposite the ring gear and loosen the nut approximately one turn to release pressure on the bearing. It should be very noticeable that pressure is released on the bearing, as the adjusting nut will turn much easier.

Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-41

STEP 86

1.

BD00M450

BD00M453

Install both adjusting nuts with the slotted pins on the differential carrier.

Insert the stub shaft into the spline of the axle bevel gear.

STEP 87

STEP 89

BD03B035

BD00M454

Use suitable lifting equipment and inser t the differential carrier into the axle casing.

Install the thrust washer removed at disassembly in the sun gear shaft with grease.

NOTE: Align the two alignment marks together. ATTENTION: Apply sealing compound on the mounting surface.

STEP 88

BD00M452

Install new bolts on the differential carrier. Tighten torque . . . . . . . . . 250 Nm (185 pound-feet) Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-42

STEP 90

STEP 91

BD03B032

BD00M456

Install O-ring and hold into place with grease. Use acceptable lifting equipment and place the wheel end on the axle housing.

Install the bolts and washers on the wheel end. Tightening torque . . . . . . . 390 Nm (288 pound-feet) NOTE: Repeat steps 1 to 91 for the other wheel end. NOTE: Prior to putting into operation of the axle, fill with oil. See section 1002.

Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004

Section 6004 REAR AXLE


Bur 5-3200


6004-2

TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEAR TOOTH CONTACT PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WEAR MEASUREMENT ON MULTI-DISC BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WHEEL END AND BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE HYDRAULICS LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACE HUB SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Pinion Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Pinion Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Pinion Bearing Rolling Torque Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting Backlash and Bearing Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact Pattern Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 5-3200

Issued 8-06

3 3 3 4 6 6 7 7 13 13 24 24 24 25 25 26 28 28 28 31 34 35 36 38 39 40

Printed in U.S.A.

6004-3

SPECIFICATIONS Lubricant Capacity............................................................................................................ 26.5 liters (28 U.S. Quarts) Distance Between Gripping Rings and Shoulder of Pin ......................................10.5 to 10.8 mm (0.41 to 0.43 inch) Top of Pins to Top of Support Shim .........................................................................4.0 to 4.5 mm (0.15 to 0.18 inch) Sun Gear Shaft End Play.............................................................................................................1.00 mm (0.04 inch) Drive Pinion Rolling Torque ................................................................................. 1.5 to 3.0 Nm (13.2 to 26.5 lb-inch) Differential Carrier Disc Clearance ..............................................................................................0.40 mm (0.02 inch)

SPECIAL TORQUES Bolts Securing Wheel End to Axle Housing......................................................................... 440 Nm (325 pound feet) Nut Securing Input Flange (Apply Loctite 262 to Threads).................................................. 700 Nm (516 pound feet) Bolts Securing Differential Ring Gear .................................................................................. 390 Nm (288 pound feet) Bolts Securing Axle Housing to Center Section .................................................................. 290 Nm (215 pound feet) Locknut Securing Planetary Carrier................................................................................... 1000 Nm (737 pound feet)

SPECIAL TOOLS Slide hammer puller adapter . . . . . . . . . CAS10846-3 Slide hammer . . . . . . . . . . . . . . . . . . . . . . OEM4252 Pressure Ring Installer . . . . . . . . . . . . . . . CAS2860 Planetary Bearing Puller . . . . . . . . . . . . . . CAS2881 Planetary Bearing Puller . . . . . . . . . . . . . . CAS2849 Bearing Cone Puller . . . . . . . . . . . . . . . . . CAS2843 Bearing Cone Puller Body . . . . . . . . . . . . . CAS2844 Pinion Shaft Seal Installer . . . . . . . . . . . . . CAS2841 Seal Driver. . . . . . . . . . . . . . . . . . . . . . . . . CAS2859 Step Plate . . . . . . . . . . . . . . . . . . . . . . . . . CAS2510 Lifting Bracket . . . . . . . . . . . . . . . . . . . . . . OEM4106 Wheel Nut Socket . . . . . . . . . . . . . . . . . . 380100000 Bearing Cup Installer . . . . . . . . . . . . . . . . 380100001

Bur 5-3200

Issued 8-06

Printed in U.S.A.

6004-4

GEAR TOOTH CONTACT PATTERNS Ideal Tooth Contact Pattern

Pinion Distance Must Be Increased

BS01D011

BS01D009


BS01D013 BS01D012


DRIVE SIDE (CONVEX)

BS01D014

DRIVE SIDE (CONVEX)

Bur 5-3200

Issued 8-06

Printed in U.S.A.

6004-5

Pinion Distance Must Be Decreased

BS01D016 BS01D010

DRIVE SIDE (CONVEX)

BS01D015


Bur 5-3200

Issued 8-06

Printed in U.S.A.

6004-6

LUBRICATION 4 5

6

6

3

5

4

2 1

2 BC06G003

1. OIL DRAIN HOLE (AXLE HOUSING) 2. OIL DRAIN HOLE (OUTPUTS)

3. OIL FILL PLUG & DIPSTICK 4. BRAKE BLEEDER

5. BREATHER 6. BRAKE INLET

NOTE: Refer to section 1002 of this service manual for proper lubricant.

WEAR MEASUREMENT ON MULTI-DISC BRAKE A

BS00M071

BD00M234

NOTE: A wear measurement on the multi-disc brake must be made at least once a year. Wear measurement should also be made if brake noise is heard, if braking power is reduced, or anytime it is suspected that braking function is impaired. Wear measurement must be made on both wheel end sides. Remove plug, actuate brake and determine dimension (A) using a thickness gauge. If dimension (A) is less than or equal to 4.0 mm (0.16 inch) the lined discs on both output sides must be replaced. Replace O-ring when installing the plug. Tighten plug to a torque of 50 Nm (40 pound feet).

Bur 5-3200

Issued 8-06

Printed in U.S.A.

6004-7

WHEEL END AND BRAKE Disassembly

STEP 3

NOTE: Tools and axle shown in the following photographs may appear slightly different than the tools and axle you may have. The use of the tools and disassembly/assembly of axle is the same regardless of appearance.

STEP 1

BD06G004

Use lifting bracket, OEM4106, to hold wheel end. Loosen and remove the bolts and washers.

STEP 4

BD06G001

Fasten axle on a stand.

Carefully pull the wheel end from the axle housing. Remove and discard O-ring from axle housing wheel end.

STEP 5

STEP 2

BD06G005 BD06G002

Mount the wheel end on a stand.

BD06G003

Remove drain plugs and drain oil from axle housing. Bur 5-3200

Issued 8-06

Printed in U.S.A.

6004-8

STEP 6

STEP 9

BD06G006

BD06G009

Using pry bar, remove cover from output shaft. Remove and discard O-ring from cover.

Using OEM4054 pulling attachment, remove the planetary carrier.

STEP 7

STEP 10

BD06G007

Remove pin from lock nut using OEM4252 slide hammer and CAS10846-3 adapter.

BD06G012

Remove retaining ring.

STEP 11 STEP 8

BD06G013 BD06G008

Remove lock nut using socket 380100000.

Bur 5-3200

Using CAS2848 planetary gear puller and step plate 8061, remove planetary gear and outer bearing from planetary carrier shaft. Using a suitable puller, remove the inner bearing from carrier shaft.

Issued 8-06

Printed in U.S.A.

6004-9

STEP 12

STEP 15

BD06G014

Remove the bearing from the planetar y using CAS2881 collet set, CAS2849 puller body and screw.

STEP 13 Repeat Steps 10, 11, and 12 to remove the remaining three retaining rings, planetary gears, and six bearings.

BD00M250

Put alignment marks on planetary ring gear and brake housing to aid in assembly. Using suitable puller, remove planetar y ring gear from brake housing.

STEP 16

STEP 14

BD00M251

BD06G015

Inspect the stop pin for wear, if necessary drill a hole into the pin, use CAS10846-3 adapter and OEM4252 striker and remove the pin.

Remove and discard two O-rings from planetary ring gear.

STEP 17

BD06G017

Remove and discard O-ring from brake housing port, remove the brake disc pack from brake housing.

Bur 5-3200

Issued 8-06

Printed in U.S.A.

6004-10

STEP 18

STEP 21

BD06G020

BD06G018

Using suitable tool, push the three pins down until pins are even with top surface of shim.

Remove the support shim from the brake piston.

STEP 22

STEP 19

BD06G022 BD06G047


Remove three pins from support shim.

STEP 23

STEP 20

BD06G023 BD06G019

W E A R FAC E P R OT E C T I O N W H E N U S I N G COMPRESSED AIR. Apply compressed air to brake housing por t to push brake piston from brake housing.

Bur 5-3200

Put support shim in a press and compress Belleville washers. Remove retaining ring and pull pin with Belleville washers and rings installed from support shim. Repeat this step to remove the remaining five retaining rings and pins from support shim.

Issued 8-06

Printed in U.S.A.

6004-11

STEP 24

STEP 27

BD00M263

BD00M260

Remove seven Belleville washers from each pin.

STEP 25

BD06G024

Using a press, remove four gripping rings from each pin.

STEP 26

BS00M072

1. 2. 3. 4.

BRAKE HOUSING GUIDE RING SUPPORT RING GROOVED RING

5. GROOVED RING 6. SUPPORT RING 7. WHEEL END SHAFT

Remove the guide ring (2), support rings (3 and 6), and U-rings (4 and 5) from the grooves of the brake housing.

BD00M262

Lift and remove the piston from the brake housing.

Bur 5-3200

Issued 8-06

Printed in U.S.A.

6004-12

STEP 28

STEP 31

BD06G028

BD01F102A

Using the CAS2850 brake housing puller bridge and CAS2510 step plate, pull the brake housing from the wheel end shaft and remove the inner bearing.

Remove the face seal from the brake housing.

STEP 32

STEP 29

BD06G029

BD06G026

Remove and discard the face seal metal ring from the wheel end shaft.

Use acceptable lifting equipment and lift the brake housing from the wheel end shaft.

STEP 33

STEP 30

If the wheel end pressure ring or bearing need to be replaced, remove the bearing from the wheel end shaft.

BD06G027

If replacement of bearing cups is necessary, drive both bearing cups out of the brake housing.

Bur 5-3200

Issued 8-06

Printed in U.S.A.

6004-13

Cleaning and Inspection

Assembly

IMPORTANT: Do not use compressed air to dry bearings. Allow bearings to air dry.

STEP 39

STEP 34 Clean all parts except friction plates in brake disc p a c k u s i n g c l e a n i n g s o l v e n t . W E A R FAC E PROTECTION WHEN USING COMPRESSED AIR. Use compressed air to clear passages in planetary ring gear and brake housing.

STEP 35 I n s p e c t b e a r i n g r o l l e r s fo r p i t t i n g , s c o r i n g , deformation, or other damage. Check inner face and bearing cage for deformation, dents, and other da ma ge. Che ck asso ciat ed b e ar ing cup s for scratches, grooves, or cracks. Check bearings for rough spots or binding by holding bearing and rotating. If bearing binds or action is not smooth, replace the bearing.

BD06G033

Apply Loctite 574 to the seal ring mounting surface. WARNING: Always wear heat protective gloves to prevent burning your hand when handling heated parts.

STEP 36 Inspect bearing cups for pitting, scoring, cracks, or other damage. Replace if any of these conditions are seen.

SM121A

STEP 40

NOTE: If a bearing or bearing cup requires replacement, the associated part must also be replaced.

STEP 37 Check planetary ring gear, planetary gears, and planetary carrier gear teeth for cracks, breaks, chipping, or other damage. Replace the part if any of these conditions are seen. Check planetary carrier shaft splines for bro ken, cracke d, or twisted condition. Replace if necessary. BD06G034

STEP 38 Check wheel end shaft for cracked, broken, or twisted splines. Replace if any of these conditions are seen.

Bur 5-3200

Heat the seal ring to approximately 120° C (248° F), place the face seal ring on the wheel end shaft.

Issued 8-06

Printed in U.S.A.

6004-14

STEP 41

STEP 43

BD06G035

BD06G037

Use special tool CAS2860 and drive the busing into position onto the hub.

Using CAS2877 inner bearing cup installer, press the inner bearing cup into the brake housing until seated against the shoulder in the brake housing.

NOTE: Only use the special tool to install the sealing ring to ensure proper seating.


STEP 44 Using CAS2878 outer bearing cup installer press the outer bearing cup into the brake housing until seated against the shoulder in the brake housing.

SM121A

BD06G036

Heat the wheel end shaft outer bearing to 120° C (248° F) in a bearing oven. Wearing heat resistant gloves or mittens, install the bearing on the wheel end shaft until the bearing is against the shoulder on the wheel end shaft.

Bur 5-3200

Issued 8-06

Printed in U.S.A.

6004-15

STEP 45


BD06G032

A A

A 1 BD06G039

2

Heat the wheel end shaft inner bearing to 120° C (248° F) in a bearing oven. Wearing heat resistant gloves or mittens, install the bearing on the wheel end shaft until the bearing is against the bearing cup in the brake housing.

BS00M073

1. FACE SEAL 2. BRAKE HOUSING A FILL WITH GREASE

Wet the outer diameter of the face seal with a solution of 50% water and 50% mineral spirits. Use CAS2880 seal installer to install the face seal with the seal lip positioned as shown. Apply grease to seal as indicated by (A) above.

STEP 46

BD06G038

Use acceptable lifting equipment and install the brake housing on the wheel end shaft. Bur 5-3200

Issued 8-06

Printed in U.S.A.

6004-16

STEP 48

STEP 49 A

B

BD00M278

BD00M279

Clean the groove of the brake housing with cleaning solvent. Install the guide ring in the groove. Make sure the ends (A) of the guide ring are facing up towards the top (B) of the brake housing and the guide ring is installed completely in its groove in the brake housing. Apply Loctite 415 to ID of guide ring to secure guide ring in its groove.

STEP 50

BC06G002

GUIDE RING, SUPPORT RINGS AND U-RINGS LOCATION 1. SUPPORT RING 2. GROOVED RING 3. GROOVED RING

4. SUPPORT RING 5. GUIDE RING A. BRAKE HOUSING

Install the support rings and U-rings in the grooves of the brake housing.

Bur 5-3200

BD00M280

Apply oil on the sliding surface of the piston, support rings, U-rings and guide ring. Carefully install piston in the brake housing.

Issued 8-06

Printed in U.S.A.

6004-17

STEP 51

STEP 53

1

BD00M282

1. GRIPPING RINGS

Press the gripping rings on the pins. Ends of gripping rings must be 180° opposite from each other.

BD00M284

Put the assembled pins into the support shim and install the snap ring.

STEP 54 STEP 52

BD00M283 BD00M285

5

Put the assembled support shim in the piston.

4

STEP 55 3 A 2 1 BS00M074

1. PIN 4. SUPPORT SHIM 2. GRIPPING RINGS 5. RETAINING RING 3. BELLEVILLE SPRINGS A. 10.5 TO 10.8 MM (0.41 TO 0.43 INCH)

Install the Belleville springs on the pins. Make sure dimension (A) is 10.5 to 10.8 mm (0.41 to 0.43 inch).

Bur 5-3200

BD00M286

Install the snap ring to secure the support shim, slot of the snap ring must be between two pins.

Issued 8-06

Printed in U.S.A.

6004-18

STEP 56

STEP 58

BD00M287

BD06G051

Apply grease to new O-ring and install in the brake housing port.

A

STEP 59

BS00M075

1. BRAKE HOUSING 2. SNAP RING 3. PIN

4. SUPPORT SHIM 5. PISTON A. 4.0 TO 4.5 MM (0.15 TO 0.18 INCH)

BD00M251

Install the six pins (3) in the support shim (4) to lock the snap ring (2). Dimension (A) between top of pins (3) and top of support shim (4) must be 4.5 to 5.0 mm (0.18 to 0.20 inch).

Apply grease to new O-rings and install on planetary ring gear.

STEP 60

STEP 57

BD06G052 BD06G049

Apply oil to the clutch discs. Install the outer and inner clutch discs alternately starting with an outer clutch disc. Bur 5-3200

Install two alignment studs in the brake housing. Position the planetar y r ing gear on the brake housing. Make sure alignment marks made during disassembly are aligned. Use a soft faced hammer and tap the planetary ring gear into brake housing. Issued 8-06

Printed in U.S.A.

6004-19

STEP 61


BD06G053

If removed, drive the stop bolt into the planetary carrier until contact.

STEP 62 BD06G055


Heat the planetary gears outer bearings to 120° C (248° F) in a bearing oven. Wearing heat resistant gloves or mittens, install the bearings on the shafts until the bearing is against the gear.

STEP 65

BD06G054

Heat the planetary gears inner bearings to 120° C (248° F) in a bearing oven. Wearing heat resistant gloves or mittens, install the bearings on the shafts until the bearing is against the bottom of the shaft.

BD06G056

Install the retaining rings on the planetary gear shafts.

STEP 63 Install the planetary gears on the bearings.

Bur 5-3200

Issued 8-06

Printed in U.S.A.

6004-20

STEP 66

STEP 69

BD06G057

BD06G060

Coat the spline with Loctite No. 767 antiseize lubricant.

Rotate the housing until the planet carrier gears are flush with the ring gear.

STEP 67

STEP 70

BD06G058

Align the slots of the brake disks.

BD06G061

Pivot the housing on the stand and install the lock nut.

STEP 68 STEP 71

BD06G059

Install the planet carrier into the spline of the wheel end shaft using OEM4054.

Bur 5-3200

BD06G062

Tighten the lock nut to a torque of 1000 Nm (737 pound feet) using socket 380100000, rotate the brake housing several time in both directions and recheck torque.

Issued 8-06

Printed in U.S.A.

6004-21

STEP 72

STEP 74

BD06G063

Install a new slotted pin into the wheel end lock nut.

BD06G065

Install the cover into the wheel end.

NOTE: If the slot is not aligned tighten the nut to align the slot, never loosen the nut to align the slot.

STEP 73

BD06G064

Install a new O-ring on the wheel end cover.

Bur 5-3200

Issued 8-06

Printed in U.S.A.

6004-22

Sun Gear Shaft End Play Adjustment

STEP 79

STEP 75

BD06G068

BD06G066

Using two M18 bolts of suitable length, secure planetary ring gear to brake housing.

STEP 76 Take a measurement from the straight edge to the face of the planetar y gear ring, the difference between this measurement and the measurement in the next step will be dimension A.

STEP 77

Determine dimension B from the face of the stub shaft to the mounting face of the axle housing. Example: Dimension B . . . . . . . . . . . . . 100.20 mm (3.95 inch)

STEP 80 Subtract dimension A from dimension B. Then subtract 1.30 mm (0.05 inch) from the difference. The difference is the required shim size. Example: Dimension B Dimension A Difference Required end play Difference = shim size

100.20 mm (3.94 inch) −97.90 mm (3.85 inch) 2.30 mm (0.09 inch) − 1.30 mm (0.05 inch) 1.00 mm (0.04 inch)

STEP 81

BD06G067

Mount the sun gear into the planet gears. Then, determine dimension A, from the inner face of the sun gear to the face of the planetary ring gear. Example: Dimension A . . . . . . . . . . . . . 97.90 mm (3.85 inch)

STEP 78 Install the stub shaft in the spline of the axle bevel gear. Make sure the stub shaft is installed all the way into the axle bevel gear.

Bur 5-3200

BD06G069

Install the shim set (size as determined in Step 80 above) into the sun gear shaft with grease.

Issued 8-06

Printed in U.S.A.

6004-23

STEP 82

STEP 84

BD06G072 BD06G070.

Remove the two M18 bolts securing the planetary ring gear to brake the housing.

STEP 83

Use lifting bracket, OEM4106, and install the assembled wheel end onto the axle housing. NOTE: Turn the input flange to align splines of the stub shaft into the sun gear.

STEP 85

BD06G071

Apply grease to a new O-ring and install O-ring in brake port.

Bur 5-3200

BD00M300

Install the washers and bolts to secure the wheel end to the axle housing. Tighten the bolts to a torque of 440 Nm (325 pound feet).

Issued 8-06

Printed in U.S.A.

6004-24

BRAKE HYDRAULICS LEAKAGE TEST IMPORTANT: DO NOT EXCEED 100 BAR (1450 PSI) PRESSURE IN THE FOLLOWING STEPS. If the maximum pressure of 100 bar (1450 psi) is exceeded, the piston will move too much changing the gripping rings adjustment. If the gripping rings adjustment changes, the wheel end must be removed and disassembled and the gripping rings adjusted to the correct dimension (Step 51).

STEP 86

High Pressure Test STEP 87 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 88 Reduce pressure to 5 bar (72.5 psi) and close the shutoff valve. During a 5 minute period pressure shall not drop.

BD00M305

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.

Bur 5-3200

Issued 8-06

Printed in U.S.A.

6004-25

REPLACE HUB SEAL Removal

STEP 92

STEP 89

BD06G077

BD06G074

Remove drain plug and drain oil from the brake housing.

Loosen and remove the lock nut using socket 380100000.

STEP 93

STEP 90

BD06G078

Use pry bar and remove the end cover.

Use lifting bracket, OEM4106, to hold wheel end. Separate the output shaft using a puller.

STEP 91

STEP 94

BD06G075

BD06G076

Use a slide puller and remove the slotted pin from the lock nut.

Bur 5-3200

BD06G079

Use a pry bar and remove the seal form the brake housing.

Issued 8-06

Printed in U.S.A.

6004-26

STEP 95

STEP 98

BD06G080

BD06G082

Inspect the bushing for wear marks where the seal makes contact, if required remove the bushing.

Put a bead of Loctite 574 on the bushing mounting surface.

Installation


STEP 96

SM121A

BC06G005

Install the seal as shown above with wipers (3) facing out towards bushing (4).

BD06G083

Heat the bushing to 120° C (248° F) and place the bushing onto the output shaft.

STEP 97

BD06G081

Lubricate the outer diameter of the seal with water, use driver CAS2859 and install the seal.

Bur 5-3200

Issued 8-06

Printed in U.S.A.

6004-27

STEP 100

STEP 103

BD06G084

BD06G087

Use special tool CAS2860 and drive the busing into position onto the hub.

Install the lock nut, tighten the lock nut to a torque of 1000 Nm (737 pound feet) using socket 380100000, rotate the brake housing several time in both directions and recheck torque.

NOTE: Only use the special tool to install the sealing ring to ensure proper seating.

STEP 104

STEP 101

BD06G088 BD06G085

Heat the inner bearing to 120° C (248° F).

Install a new slotted pin into the wheel end lock nut. NOTE: If the slot is not aligned tighten the nut to align the slot, never loosen the nut to align the slot.

STEP 102

STEP 105

BD06G086

Grease the seal lip of the shaft seal, use lifting bracket, OEM4106, and install the wheel end onto the brake housing.

Bur 5-3200

BD00M304

Install a new O-ring on the wheel end cover, install the cover into the wheel end. Issued 8-06

Printed in U.S.A.

6004-28

DIFFERENTIAL Removal

STEP 108

STEP 106

BD06G127

BD06G002

Connect lifting equipment to the differential and remove the differential from axle housing. NOTE: Make sure that the right axle stub shaft releases from the differential.

Disassembly STEP 109

BD06G003

Remove drain plugs and drain oil from axle.

STEP 107 BD01F059

Remove the bearing from the differential housing using CAS2848 puller, OEM4175 pulling attachment, 1103 puller legs, and 8065 step plate.

BD06G126

Fasten the axle to a stand, support the center of the axle as shown, facing the input shaft attach suitable lifting equipment to the left axle housing, remove the mounting bolts and axle half. ATTENTION: Differential can fall out of housing when axle half is removed. Bur 5-3200

Issued 8-06

Printed in U.S.A.

6004-29

STEP 110

STEP 113

BD01F075

Remove the bearing from the housing cover using CAS2871 collet set, CAS2882 puller body, and 8067 step plate.

BD06G129

Remove all parts from the differential housing.

STEP 114

STEP 111

BD00M326 BD00M323

Place the differential in a press to prevent it from turning. Remove the bolts.

Press the ring gear from the differential housing.

STEP 115

STEP 112

BD06G131

BD00M324

Remove the housing cover from the differential housing.

Bur 5-3200

Pull the outer bearing ring and shims from both axle housings. NOTE: Make sure to identify the shims into which axle housing they were removed.

Issued 8-06

Printed in U.S.A.

6004-30

8

7 6

5 4

3 2 1

9

9 10

12 3 6 8

1

4 11

5

7 BC06G001

1. 2. 3. 4.

Bur 5-3200

BEARING HOUSING WASHER, THRUST SHIM

5. 6. 7. 8.

OUTER CLUTCH PLATE DIVIDER GEAR, BEVEL

9. 10. 11. 12.

PINION, BEVEL SHAFT COVER BOLT, M15 X 45

Issued 8-06

Printed in U.S.A.

6004-31

Assembly

STEP 118

NOTE: The ring gear and the drive pinion are a matched gear set and cannot be serviced separately.


BD06G151

Install the disk package starting with an outer clutch, refer to illustration on page 30.

STEP 119

BD06G149

Heat the ring gear to 120° C (248° F) in a bearing oven. Wearing heat resistance gloves or mittens, install the ring gear on the differential. NOTE: Make sure to align the bolt holes.

STEP 117 BD06G152

Install the divider in the differential housing.

STEP 120

BD06G150

Install both thrust washers into the differential carrier, the brass thrust washer must be towards the bevel gear as shown, refer to illustration on page 30. NOTE: Be sure to apply oil to all parts before assembly.

Bur 5-3200

BD06G153

Install the axle bevel gear. Make sure axle bevel gear splines mate with splines of all inner clutch plates.

Issued 8-06

Printed in U.S.A.

6004-32

STEP 121

STEP 124

BD06G154

BD06G157

Assemble the differential spider and install into the differential housing.

Starting with an clutch plate, install alternately the plate and outer clutch.

STEP 122

NOTE: Thickness of disc packs must be the same on both sides.

Determine Disc Clearance STEP 125

BD06G155

Install the second axle bevel gear.

STEP 123

BD06G158

Determine dimension A, from mounting face of the differential housing to face of the outer clutch disc. Dimension A (Example). . . . . . 38.05 mm (1.50 inch)

BD06G156

Install the second divider in the differential housing.

Bur 5-3200

Issued 8-06

Printed in U.S.A.

6004-33

STEP 126

STEP 128

BD06G159

BD06G161

Determine dimension B, from contact surface of the outer clutch disc to mounting face of the housing cover. Dimension B (Example). . . . . . 37.65 mm (1.48 inch) Example B: 38.05 mm Dimension A -------(1.50 inch) +37.65 mm Dimension B -------(1.48 inch) = 0.40 mm Difference = Disc clearance ------(0.02 inch)

Place the differential in a press to prevent it from turning. Install new bolts and tighten bolts to a torque of 390 Nm (288 pound feet). NOTE: Use new bolts only.

STEP 129

NOTE: If required disc clearance of 0.040 mm (0.02 inch) is not obtained, install new outer clutch discs of thickness necessary to obtain 0.040 mm (0.002 inch) disc clearance. The left and right clutch packs must be the same thickness. Outer clutch discs are available in following thicknesses: 2.9 mm (0.114 inch), 3.0 mm (0.118 inch), 3.1 mm (0.122 inch).

STEP 127

BD06G162

Press both bearings on the differential.

BD06G160

Install the thrust washers with grease in the recess of the housing cover. NOTE: Mount the brass thrust washer (on top) towards the bevel gear.

Bur 5-3200

Issued 8-06

Printed in U.S.A.

6004-34

Drive Pinion Removal

STEP 134

STEP 130 Heat lock nut securing flange with a hot air blower to loosen Loctite, approximately 120° C (248° F).

STEP 131

BD06G134

Press the input pinion out of the housing.

STEP 135 BD06G132

Install holding wrench on input flange. Hold flange using holding wrench, CAS1579A, and remove lock nut and washer. Remove holding tool from flange.

STEP 132 Remove the input flange from the drive pinion.

STEP 133 BD06G135

Remove the spacer ring from the drive pinion.

STEP 136

BD06G133

Remove the shaft seal from the axle drive housing.

BD06G136

Press the bearing inner ring from the drive pinion using CAS2843 and CAS2844 puller body and collet set.

STEP 137 Drive out both bearing cups from the differential carrier. Bur 5-3200

Issued 8-06

Printed in U.S.A.

6004-35

Drive Pinion Installation

STEP 140

STEP 138

1

3 2 BD06G139

BD06G137

Find and record the housing dimension “X”. Dimension X (Example). . . . . 205.30 mm (8.08 inch)

STEP 139

1. MATING NUMBER (MARKED MANUALLY) 2. PINION BASIC DIMENSION (STAMPED) 3. PINION DISTANCE DEVIATION + OR - (MARKED MANUALLY)

Distance deviation is indicated in 1/100 mm. If no distance deviation is indicated the pinion basic dimension is identical with the pinion dimension. Record this as dimension “II”. Dimension II (Example) 168 -0.05 mm = 167.95 mm . . . . . . . . . (6.614 inch -0.002 inch = 6.612 inch)

STEP 141 Calculation example A: Dimension I Dimension II Results in dimension Y BD06G138

Measure the thickness of the inner bearing and record its measurement, dimension “I”. Dimension I (Example) . . . . . 36.13 mm (1.422 inch) 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.

Bur 5-3200

36.13 mm -------(1.422 inch) +167.95 mm -------(6.612 inch) = 204.08 mm ------(8.034 inch)

Calculation example B: Dimension X Dimension Y Difference = shim thickness

205.30 mm -------(8.080 inch) −204.08 mm -------(8.034 inch) = 1.22 mm ------(0.046 inch)

NOTE: Shims are available in 0.10 mm (0.004 inch), round up or down to the next available shim thickness, s = 1.20 (0.044 inch)

Issued 8-06

Printed in U.S.A.

6004-36

STEP 142

STEP 145

BD06G140

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 of 380100001.

STEP 143

BD06G143

Press the inner bearing on the drive pinion shaft.

Drive Pinion Bearing Rolling Torque Adjustment STEP 146

BD06G141

Install the shim set determined in Step 141 in the bearing bore on the differential carrier.

STEP 144

BD06G144

Install an 9.03 mm (0.35 inch) thick spacer on the pinion shaft.

BD06G142

Heat the bearing hole to approximately 120° C (248° F) and pull the bearing into to the bearing hole using 380100001. Bur 5-3200

Issued 8-06

Printed in U.S.A.

6004-37

STEP 147

STEP 149


BD06G147

Install the input flange on the pinion shaft.

STEP 150 BD06G145

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.

STEP 148

Put the washer in place on the pinion shaft.

STEP 151 Install holding wrench, CAS1579A, on input flange. Hold flange using holding tool and tighten nut to a torque of 700 Nm (515 pound feet). Remove holding wrench. NOTE: When tightening rotate the pinion shaft in both directions several times.

STEP 152

BD06G146

Press the dust shield on the input flange.

BD06G148

Check the rolling torque of the drive pinion bearing. The rolling torque should be 1.5 to 3.0 Nm (13.3 to 26.5 lb-inch). If rolling torque is too low, install a thinner spacer (Step 146); if rolling torque is too high, install a thicker spacer (Step 146).

STEP 153 Remove the nut and input yoke from the drive pinion shaft.

Bur 5-3200

Issued 8-06

Printed in U.S.A.

6004-38

Setting Backlash and Bearing Preload Deviation Value

-20

-10

0

+10

+20

Shim A

1.20

1.10

1.00

0.90

0.80

Shim B

0.80

0.90

1.00

1.10

1.20

STEP 154

STEP 155 2

1

B

A

BD06G163

Record the deviation value on the ring gear, the value will be a + or -, use the table to determine shim thicknesses needed. Example: Deviation value of +10 requires the following shims: Shim A = 0.90 Shim B = 1.10

3

5

4 BC06G004

1. 2. 3. 4.

DIFFERENTIAL DRIVE HOUSING AXLE HOUSING INPUT PINION

5. AXLE HOUSING A. RING GEAR SIDE B. CARRIER SIDE

STEP 156

BD06G164

Insert shim A (0.90 mm) and install the bearing outer ring until seated.

Bur 5-3200

Issued 8-06

Printed in U.S.A.

6004-39

STEP 157

STEP 160

BD06G165

Insert shim B (1.10 mm) and install the bearing outer ring until seated.

Contact Pattern Check STEP 158

BD06G168

Position the axle housing on the drive housing, install 4 bolts, top center, bottom center, front center, rear center, torque bolts evenly to 390 Nm (285 pound feet).

STEP 161

BD06G166

Apply marking ink on several teeth of the ring gear.

STEP 159

BD06G169

Roll the input pinion several times in both directions over the ring gear. Remove the differential and compare the contact pattern with examples on page 4 and page 5. NOTE: If the tooth contact pattern differs, the wrong shim size was selected in Step 143. Remove differential and repeat Steps 138 though 144.

BD06G167

Position the differential assembly in the axle drive housing.

Bur 5-3200

Issued 8-06

Printed in U.S.A.

6004-40

Installation

STEP 164

STEP 162

BD06G172

BD06G170

Install a new O-ring on the axle housing. Position the axle housing on the drive housing, install bolts and torque bolts evenly to 290 Nm (215 pound feet).

Install the shaft seal with the sealing lip towards oil sump using pinion shaft seal install CAS2841. 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.

STEP 163 STEP 165

BD06G171

Loosen and remove the nut and input flange.

BD06G173

Install the input flange. Install holding wrench, CAS1579A, on input flange. Apply Loctite No. 262, on the threads of the locknut. Install the washer and locknut by hand. Hold flange using holding tool and tighten nut to a torque of 700 Nm (516 pound feet). NOTE: Rotate the input pinion several times in both directions when tightening.

Bur 5-3200

Issued 8-06

Printed in U.S.A.

DRIVE SHAFTS, CENTER BEARING, AND UNIVERSAL JOINTS


Bur 5-3210


6005

Section 6005

6005-2

TABLE OF CONTENTS SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CENTER BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CENTER BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CENTER DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UNIVERSAL JOINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 5-3210

Issued 8-06

3 3 3 4 4 5 5 6 6 7 7 7 8 8 8 9 9 9 10 10 10

Printed in U.S.A.

6005-3

SPECIAL TORQUES Coupler to Flywheel Bolts...................................................................................... 53 to 62 Nm (39 to 46 pound feet) Engine Drive Shaft to Coupler Bolts ...................................................................... 53 to 62 Nm (39 to 46 pound feet) Engine Drive Shaft to Transmission Bolts.............................................................. 75 to 81 Nm (55 to 60 pound feet) Center, Rear and Front Drive Shaft Bolts .............................................................. 75 to 81 Nm (55 to 60 pound feet) Carrier Bearing Bolts ........................................................................................... 99 to 128 Nm (73 to 94 pound feet) Lock Nut for Yoke on Front Drive Shaft.......................................................... 339 to 375 Nm (250 to 275 pound feet)

FRONT DRIVE SHAFT Removal

STEP 4

STEP 1

Use an acceptable puller and remove the yoke from the end of the front drive shaft.

STEP 5 Loosen the set screws that secure the center bearing to the front drive shaft.

STEP 6 Remove any paint or rust from the rear of the front drive shaft and apply WD40 or similar oil to loosen any rust between the inner race and the front drive shaft.

STEP 7 BD03A166

Loosen and remove the bolts and straps that fasten the center drive shaft to the yoke of the front drive shaft.

STEP 2

BD03A167

Loosen and remove the bolts and straps that fasten the front drive shaft to the front axle.

STEP 8 BD03A183

Remove the lock nut that fastens the yoke to the front drive shaft.

STEP 3

Use a prybar to disengage the front drive shaft from the front axle and remove the front drive shaft from the machine. NOTE: If necessary, use a brass hammer to drive the front drive shaft out of the center bearing.

Make an alignment mark on the yoke and the end of the front drive shaft to make sure that the yoke is installed correctly. Bur 5-3210

Issued 8-06

Printed in U.S.A.

6005-4

FRONT DRIVE SHAFT Installation

STEP 14

STEP 9 Apply antiseize compound to the bearing area of the front drive shaft.

STEP 10 Place the front drive shaft into position in the center bearing of the machine.

STEP 11 BD03A183

Install the lock nut and washer which fastens the yoke to the front drive shaft. Tighten the lock nut to a torque of 339 to 375 Nm (250 to 275 pound feet).

STEP 15 Tighten the set screws that secure the center bearing to the front drive shaft alternately until they stop turning and the hex head socket wrench starts to spring. BD03A167

Install the bolts and straps that fasten the front drive shaft to the front axle. Tighten the bolts to a torque of 75 to 81 Nm (55 to 60 pound feet).

STEP 16

STEP 12 Apply antiseize compound to the splines on the front drive shaft.

STEP 13 Install the yoke to the front drive shaft, making sure the alignment marks made during removal are aligned. NOTE: If a new front drive shaft has been installed, make sure the yoke being installed is 90° to the yoke on the other end of the front drive shaft.

Bur 5-3210

BD03A166

Install the bolts and straps that fasten the front drive shaft to the center drive shaft. Tighten the bolts to a torque of 75 to 81 Nm (55 to 60 pound feet).

Issued 8-06

Printed in U.S.A.

6005-5

CENTER BEARING Removal

STEP 20

STEP 17

Make an alignment mark on the yoke and the front drive shaft to be sure that the yoke is installed correctly.

STEP 21 Use an acceptable puller and remove the yoke from the end of the front drive shaft.

STEP 22 Remove any paint or rust from the rear of the front drive shaft and apply WD40 or similar oil to loosen any rust between the inner race and the front drive shaft. BD03A166

STEP 23

Loosen and remove the bolts and straps that fasten the center drive shaft to the front drive shaft.

Loosen the set screws that secure the center bearing to the front drive shaft.

STEP 18

STEP 24

BD03A183

BD03A183

Loosen and remove the lubrication hose from the center bearing

Loosen and remove the bolts, washers and nuts that fasten the bearing housing to the front frame.

STEP 19

STEP 25 Install two longer bolts, at least 3 inches, to hold the bearing housing during removal. Use an acceptable puller to remove the bearing housing from the front drive shaft.

BD03A183

Loosen and remove the lock nut that fastens the yoke to the front drive shaft. Bur 5-3210

Issued 8-06

Printed in U.S.A.

6005-6

CENTER BEARING Installation

STEP 30

NOTE: The center bearing and the bearing housing are not serviced separately. If the center bearing is worn or damaged or if the bearing housing is cracked, a new center bearing and bearing housing must be used.

Apply antiseize compound to the splines on the front drive shaft. Install the yoke to the front drive shaft, making sure the alignment marks made during removal are aligned.

STEP 31

STEP 26 Apply antiseize compound to the bearing area of the front drive shaft.

STEP 27 Install the bearing housing so that the lubrication fitting is at the top.

STEP 28

BD03A183

Install the washer and lock nut that fasten the yoke to the front drive shaft. Tighten the lock nut to a torque of 339 to 375 Nm (250 to 275 pound feet).

STEP 32

BD03A183

Apply Loctite 242 to bolt threads. Install the bolts, washers and nuts that fasten the bearing housing to the front frame. Tighten the bolts to a torque of 99 to 128 Nm (73 to 94 pound feet).

STEP 29 BD03A166

Install the straps and bolts that fasten the center drive shaft to the yoke on the front drive shaft. Tighten the bolts to a torque of 75 to 81 Nm (55 to 60 pound feet).

STEP 33 Install the lubrication hose into the fitting on the bearing housing. BC05M214

Turn the set screw down to the shaft and then back it off 1/4th turn and lock it with the jam nut. Repeat the procedure with the other set screw.

Bur 5-3210

STEP 34 Lubr icate the center bear ing with the grease specified in Section 1002.

Issued 8-06

Printed in U.S.A.

6005-7

CENTER DRIVE SHAFT Removal

Installation

STEP 35

STEP 39

BD03A166

BD03A165

Loosen and remove the bolts and straps that fasten the center drive shaft to the yoke of the front drive shaft.

Hold the center drive shaft in position and install the bolts and straps that fasten the center drive shaft to the transmission. Tighten the bolts to a torque of 75 to 81 Nm (55 to 60 pound feet).

STEP 36 Use a prybar to disengage the center drive shaft from the yoke of the front drive shaft.

STEP 40

STEP 37

BD03A166

BD03A165

Loosen and remove the bolts and straps that fasten the center drive shaft to the transmission.

Install the bolts and straps that fasten the center drive shaft to the yoke of the front drive shaft. Tighten the bolts to a torque of 75 to 81 Nm (55 to 60 pound feet).

STEP 38 Hold the center drive shaft and remove from the machine.

Bur 5-3210

Issued 8-06

Printed in U.S.A.

6005-8

REAR DRIVE SHAFT Removal

Installation

STEP 41

STEP 45

BD01D323

BD01F304

Loosen and remove the bolts and straps that fasten the rear drive shaft to the transmission.

STEP 42

Hold the rear drive shaft into position and install the bolts and straps that fasten the rear drive shaft to the rear axle. Tighten the bolts to a torque of 75 to 81 Nm (55 to 60 pound feet).

Use a prybar to disengage the rear drive shaft from the transmission.

STEP 46

STEP 43

BD01D323

BD01F304

Loosen and remove the bolts and straps that fasten the rear drive shaft to the rear axle.

Install the bolts and straps that fasten the rear drive shaft to the transmission. Tighten the bolts to a torque of 75 to 81 Nm (55 to 60 pound feet).

STEP 44 Hold the rear drive shaft and remove from the machine.

Bur 5-3210

Issued 8-06

Printed in U.S.A.

6005-9

ENGINE DRIVE SHAFT Removal

Installation

STEP 47

STEP 50

BD01D342

BD01D342

Remove and discard the bolts and straps that fasten the engine drive shaft to the transmission.

Place the engine drive shaft into position on the transmission and install new straps and bolts. Tighten the bolts to a torque of 61 to 81 Nm (45 to 60 pound feet).

IMPORTANT: The bolts and straps that fasten the engine drive shaft to the transmission must be replaced when removed.

STEP 51

STEP 48

BD03A172 BD03A172

Loosen and remove the six bolts that fasten the engine drive shaft to the engine.

Apply Loctite 242 to bolt threads. Install the six bolts that fasten the engine drive shaft to the engine. Tighten the bolts to a torque of 53 to 62 Nm (39 to 46 pound feet)

STEP 49 Remove the engine drive shaft from the machine.

Bur 5-3210

Issued 8-06

Printed in U.S.A.

6005-10

UNIVERSAL JOINTS Removal

Installation NOTE: The bearing race and journal that make up the universal joint are not serviced separately. If the bearing race or journal is worn or damaged, a new universal joint must be used.

STEP 52 Remove the drive shaft from the machine.

STEP 53 STEP 55 2

Clean the slots in the yoke of the drive shaft.

1

STEP 56 Install the universal joint and install the bearings (2) and the rings (1). Refer to the photo in Step 53.

STEP 57 Install the drive shaft.

BD01F304

1. RING

2. BEARING

Remove the ring (1) and the bearing (2) from the drive shaft. NOTE: The above photo shows the drive shaft on the machine and is for reference of the ring and bearing only.

STEP 54 Remove the universal joint from the drive shaft.

Bur 5-3210

Issued 8-06

Printed in U.S.A.

Section 6006

6006

WHEELS AND TIRES


Bur 5-3220


6006-2

TABLE OF CONTENTS WHEELS AND BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TIRE PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHANGING TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING A WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheel Bolt Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 5-3220

Issued 8-06

3 3 3 3 3 3 4

Printed in U.S.A.

6006-3

WHEELS AND BOLTS General Information

Torque Specification

The wheel bolts must be tightened after every 20 hours of operation until the wheel bolts stay tight:

Tighten the wheel bolts to 298 Nm (220 pound-feet) in the sequence shown in Figure 1. Then a final torque of 640 to 720 Nm (475 to 530 pound-feet) in the same sequence.

A. If the machine is new. B. If a wheel has been removed and installed.

TIRE PRESSURES 23.5 x 25 L3.......................................................................................................................................2.75 bar (40 psi) 23.5R25 Dirt/Traction.........................................................................................................................2.75 bar (40 psi) 23.5R25 Rock ....................................................................................................................................2.75 bar (40 psi)

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 whee l against the planetar y housing. DO NOT use an impact wrench to tighten the wheel bolts.

Bur 5-3220

Issued 8-06

Printed in U.S.A.

6006-4

BS06G052

WHEEL BOLT TORQUE SEQUENCE

Bur 5-3220

Issued 8-06

Printed in U.S.A.

Section 6007

6007

TRANSMISSION CONTROL VALVE

CNH America LLC. 245 E NORTH AVENUE CAROL STREAM, IL 60188 U.S.A.

Bur 6-81450

Copyright © 2006 CNH America LLC. All rights reserved. Printed in U.S.A. Issued March, 2006

6007-2

TABLE OF CONTENTS Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 6-81450

Issued 3-06

3 3 5 5

Printed in U.S.A.

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. Bur 6-81450

Issued 3-06

Printed in U.S.A.

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.

Bur 6-81450

Issued 3-06

Printed in U.S.A.

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 1

1 2

2 BD06A018

1. VIBRATION DAMPER 2. PISTONS

3. PRESSURE REDUCING VALVE

Install components in positions shown.

STEP 13

BD06A019

Preload the compression springs of the pistons, install a roll pin of a diameter of 5.0 mm (0.20 inch). Bur 6-81450

Issued 3-06

Printed in U.S.A.

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.

3

1

1 2

2 BD06A025

1. VIBRATION DAMPER 2. PISTONS

3. MAIN PRESSURE VALVE

Install components in positions shown. Bur 6-81450

Issued 3-06

Printed in U.S.A.

6007-7

STEP 20

STEP 23

BD06A026

BD06A028

Preload the compression springs of the pistons, install a roll pin of a diameter of 5.0 mm (0.20 inch). Install the adjusting screws, gasket, and housing cover.

Install the wiring harness with connector on side of valve body marking made during disassembly. Connect wiring harness to the solenoids.

STEP 24 STEP 21

BD06A029

Install the cap screws and torque in a criss cross pattern to 7.5 Nm (66.3 pound-inch).

Install the gasket, install the wiring harness plug in the cover. Install the cap screws and torque in a criss cross pattern to 7.5 Nm (66.3 pound-inch).

STEP 22

STEP 25

BD06A023

BD06A027

Install the solenoids and secure them with the retaining plates and cap screws. Torque the cap screws to 5.5 Nm (48.5 pound-inch).

BD06A030

Install the wiring harness retaining clamp.

NOTE: Install the retaining plate with the neck towards valve body, install controllers with connectors as shown. Bur 6-81450

Issued 3-06

Printed in U.S.A.

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.

Bur 6-81450

BD06A034

Install new o-rings on the plugs, install and torque plugs to 6 Nm (53 pound-inch).

Issued 3-06

Printed in U.S.A.

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


Bur 5-3230


7001 Section 7001 REMOVAL AND INSTALLATION OF BRAKE COMPONENTS


Bur 5-3240


7001-2

TABLE OF CONTENTS BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SERVICE BRAKE AND PARKING BRAKE ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 5-3240

Issued 8-06

4 4 4 6 6 6 8 8 8

Printed in U.S.A.

7001-3

3 1 4

5 6

7

2

8 BC05M136

1. 2. 3. 4.

FRONT AXLE REAR AXLE BRAKE VALVE PARKING BRAKE ACCUMULATOR

5. 6. 7. 8.

FRONT ACCUMULATOR REAR ACCUMULATOR BRAKE PUMP CONNECTOR TO FAN VALVE

COMPONENT LOCATION ILLUSTRATION

Bur 5-3240

Issued 8-06

Printed in U.S.A.

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).

Bur 5-3240

Issued 8-06

Printed in U.S.A.

7001-5

1 6 2

7

3 9

4

10

8

5

BC05M137

1. 2. 3. 4. 5.

BRAKE VALVE REAR ACCUMULATOR LINE PARKING BRAKE LINE BRAKE PUMP INPUT BRAKE VALVE DISCHARGE

6. 7. 8. 9. 10.

FRONT BRAKE LINE REAR BRAKE LINE FRONT ACCUMULATOR RETURN TO TANK PARKING BRAKE ACCUMULATOR

BRAKE VALVE ILLUSTRATION

Bur 5-3240

Issued 8-06

Printed in U.S.A.

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. Push down and release the brake pedal at least 30. 4. Turn the master disconnect switch to the OFF position. 5. Remove the left cab skirt located under the cab or canopy to gain access to accumulators. 6. To release the pressure on the parking brake accumulator, the line at the accumulator must be SLOWLY cracked open. A pan will be needed to catch the hydraulic oil. 7. Connect a drain hose to the quick disconnect couplings in each brake circuit to release any pressure in the brake circuit. 8. Clean the brake accumulators (1), parking brake accumulator (2) and lines. Refer to illustration on page 7. 9. Put identification tags on the line that is connected to the parking brake accumulator (2).

1. Mount the accumulators (1) in the accumulators clamps (7), do not tighten clamps at this time. Refer to illustration on page 7. 2. Connect the tubes to both brake accumulators (1) and tighten. 3. Tighten accumulator clamp studs (7) to 17Nm (13 pound feet). 4. Install the parking brake accumulator (2) into the bracket. 5. Install the nut (3) and tighten. 6. Connect the line accumulator (2).

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.

Bur 5-3240

Issued 8-06

Printed in U.S.A.

7001-7

2

3

5 6 4

7

8 8

7 1

1 BC05M138

1. 2. 3. 4.

BRAKE ACCUMULATORS PARKING BRAKE ACCUMULATOR MOUNTING NUT HOSE PARKING BRAKE ACCUMULATOR

5. 6. 7. 8.

TUBE FRONT BRAKE ACCUMULATOR TUBE REAR BRAKE ACCUMULATOR CLAMP ACCUMULATOR CLAMP STUD

BRAKE AND PARKING BRAKE ACCUMULATORS ILLUSTRATION

Bur 5-3240

Issued 8-06

Printed in U.S.A.

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. 2. Put blocks on both sides of each tire to prevent machine movement. 3. Turn the master disconnect switch to the OFF position. 4. Clean the brake pump (1) and lines, refer to the illustration on page 9. 5. Put identification tags the lines connected to the brake pump (1).

that

are

6. Connect a vacuum pump to the hydraulic reservoir. Start the vacuum pump.

1. Install gear (6) onto the pump shaft, install washer (7) and slotted nut (8), torque nut to 70 to 79 Nm (52 to 58 pound feet). Refer to the illustration on page 9. 2. Install the cotter pin (9). 3. Install the brake pump (1), mounting bolts (2) and washers (3). 4. Torque mounting bolts (2) to 57 to 65 Nm (42 to 48 pound feet). 5. Remove the plugs or caps and connect the lines to the brake pump (1). 6. Stop the vacuum pump and remove.

7. Disconnect the lines from the brake pump (1) and put plugs in each line.

7. Turn the master disconnect switch to the ON position.

8. Remove the mounting bolts (2) and washers (3) from the brake pump (1) and remove the brake pump (1).

8. Bleed the brake system. See Section 7002.

Bur 5-3240

9. Check the hydraulic reservoir oil level and add oil as required. See Section 1002 for the correct oil.

Issued 8-06

Printed in U.S.A.

7001-9

9 6

8

7

1

5

3 2 4

BC05M139

1. BRAKE PUMP 2. MOUNTING BOLT (2) 3. WASHER (2)

4. SUCTION HOSE 5. PRESSURE HOSE 6. DRIVE GEAR

7. WASHER 8. SLOTTED NUT 9. COTTER PIN

BRAKE PUMP ILLUSTRATION

Bur 5-3240

Issued 8-06

Printed in U.S.A.

7001-10

NOTES

Bur 5-3240

Issued 8-06

Printed in U.S.A.

7002

Section 7002 HYDRAULIC BRAKE TROUBLESHOOTING


Bur 5-3250


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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE PUMP OUTPUT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake Valve Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 5-3250

Issued 8-06

3 3 4 5 5 6 7 7 8 9 10 11

Printed in U.S.A.

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

CAS-10899 NITROGEN CHARGING KIT USED TO CHECK AND CHARGE THE ACCUMULATOR WITH NITROGEN. BC04A001

380001168 ACCUMULATOR CHARGING ADAPTER

Bur 5-3250

Issued 8-06

Printed in U.S.A.

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 alar ms (buzzer, master warning light and brake pressure war ning 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 war ning 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.

Bur 5-3250

Issued 8-06

Printed in U.S.A.

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.

E

C

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.

F

D

B

A

4. Turn the stem out of valve F until the stem stops. 94L95

5. Remove the cap screws and guard from the accumulator. 6. Remove the cap from the accumulator valve stem. 7. Connect valve F to the accumulator valve stem.

NITROGEN CHARGING KIT

8. Make sure that valve D is open. 9. Turn the stem into valve F and read the pressure gauge E. 10. The pressure must be 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 m o v i n g a n d o p e n va l ve D t o c h a r g e t h e 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. I n s t a l l t h e g u a r d a n d c a p s c r ew s o n t h e accumulator.

Bur 5-3250

Issued 8-06

Printed in U.S.A.

7002-6

BLEEDING THE BRAKE SYSTEM 1. Check the level of hydraulic fluid in the reservoir. Add fluid to the reservoir if necessary. IMPORTANT: If machine is equipped with quick-attached components, disconnect them from machine prior to proceeding.

8. Start the engine and run at low idle. 9. Push the brake pedal all the way down and slowly release for one cycle. 10. Close all four wheel end bleed screws. 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.

Bur 5-3250

Issued 8-06

Printed in U.S.A.

7002-7

BRAKE MODULATION PRESSURE CHECK

1

2

3

4 BD06F145

1. FRONT AXLE TEST PORT 2. REAR AXLE TEST PORT

Testing the Brake Modulation Pressure 1. Make sure the hydraulic accumulator cut-in and cut-out pressures are correct. Refer to page 4 of this section.

3. FRONT BRAKE ACCUMULATOR TEST PORT 4. REAR BRAKE ACCUMULATOR TEST PORT

6. Start the engine. 7. Operate the machine at low idle and watch the pressure gauges on the brake accumulators until the gauges rise above 170 bar (2645 psi). 8. Apply and hold the brakes for 10 to 15 seconds.

2. Stop the engine. Pump the brake pedal until there is no pressure in the brake system.

9. Make a note of the pressure on the gauges for the front and rear brakes.

3. Remove the cab skirts to gain access to the brake test ports.

10. The front brake pressure should read 80 to 87 bar (1160 to 1260 psi). This is the modulation pressure for the front axle.

4. Connect two 207 bar (3000 psi) pressure gauges to the front brake test port (1) and the rear brake test port (2). 5. Connect two 207 bar (3000 psi) pressure gauges to the front brake accumulator test port (4) and the rear brake accumulator test port (3).

Bur 5-3250

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 ra n g e, i t w i l l b e n e c e s s a r y t o a d j u s t t h e modulation pressures.

Issued 8-06

Printed in U.S.A.

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. Turn the adjusting bolt (2) to adjust the modulation pressure. NOTE: The rear brake modulation pressure cannot be adjusted separately from the front brake modulation pressure. 3. Repeat steps 5 through 10 in the Testing the Brake Modulation Pressure procedure.

2

4. Repeat these steps until the brake modulation pressure is within the specified range.

1

BD00N121

1. TAMPER RESISTANT COVER 2. ADJUSTING BOLT

Bur 5-3250

Issued 8-06

Printed in U.S.A.

7002-9

SERVICE BRAKE SYSTEM PERFORMANCE (STORED ENERGY) 1

2

3

4 BD06F145

1. FRONT AXLE TEST PORT 2. REAR AXLE TEST PORT

3. FRONT BRAKE ACCUMULATOR TEST PORT 4. REAR BRAKE ACCUMULATOR TEST PORT

NOTE: Prior to doing this procedure make sure that the accumulator pressures are correct. 1. Check the level of the hydraulic fluid in the reservoir, add as needed.

6. Start the engine and let idle until both the front and rear accumulators 3 and 4 are fully charged. The accumulators are fully charged at 190 to 196 bar (2755 to 2842 psi). 7. Stop the engine. 8. Push the brake pedal down slowly, allowing for full piston actuation. NOTE: Depress the brake pedal at the rate of three strokes per minute. 9. Continue pressing the brake pedal down. The low brake pressure light should activate when the pressure reaches 106 to 115 bar (1530 to 1670 psi). After the low brake pressure light activates, press the brake pedal eight more times.

1 BD00M030


2. Install the articulation lock (1) before doing this test. 3. Remove the left side cab skirt to gain access to the brake accumulator test ports. 4. Pump the brake pedal until there is no hydraulic pressure in the brake system (approximately 20 pumps).

10. Record the readings on the pressure gauges. The pressure gauges should read at or above 48 to 59 bar (700 to 850 psi). 11. If the pressures are at or above 48 to 59 bar (700 to 850 psi), the test is complete. 12. If the pressures are not within the required specifications, then the brake system must be bled. 13. After bleeding the brake system, perform the brake system check again.

5. Connect two 207 bar (3000 psi) pressure gauges to the test ports 3 and 4.

Bur 5-3250

Issued 8-06

Printed in U.S.A.

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 NOTE

6

1

4 3 2

BS03B021

1. BRAKE PUMP 3. FLOWMETER INLET HOSE 5. FILTER INLET MANIFOLD 2. PUMP OUTPUT ELBOW 4. FLOWMETER OUTLET HOSE 6. FILTERS NOTE: IF UNIT IS EQUIPPED WITH AUXILIARY STEERING A TEE FITTING WILL HAVE TO BE USED IN THIS LOCATION

Bur 5-3250

Issued 8-06

Printed in U.S.A.

7002-11

NOTES

Bur 5-3250

Issued 8-06

Printed in U.S.A.

7002-12

1 2 3 1 4

2

5

30

31

6

32 14

33 34

5

21

5

30 7

2

35

29

5

36

8 9 15

27 28

10

15

26

11 16 24

14 12

25 14 17 5 23 22 21

15

19

18

2

5

13 5 20 BC05G011

BRAKE VALVE EXPLODED VIEW

Bur 5-3250

Issued 8-06

Printed in U.S.A.

7002-13 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

CAP SCREW (T 22 NM (16 LB-FT)) O-RING BUSHING SLEEVE SPRING SPRING RETAINER SPRING RETAINER CIRCLIP SHAFT SEAL SLEEVE LVE GUIDE RING O-RING

Bur 5-3250

13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.

CAP (T 60 NM (44 LB-FT)) SPOOL PLUG (T 10 NM (88.5 LB-IN)) PLUG (T 60 NM (44 LB-FT)) PLUG (T 22NM (16 LB-FT)) VALVE SEAT THROTTLE SCREW PLUG (T 22NM (16 LB-FT)) CAP SLEEVE SPRING RETAINER SLEEVE

25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36.

CHECK VALVE CARTRIDGE PLUG (T 60 NM (44 LB-FT)) JET WVI UNIT PLUG (T 60 NM (44 LB-FT)) PLUG (T 100 NM (74 LB-FT)) RV UNIT SPRING RETAINER SLEEVE THRUST RING SLEEVE LVV

Issued 8-06

Printed in U.S.A.

7002-14

NOTES

Bur 5-3250

Issued 8-06

Printed in U.S.A.

7003

Section 7003 BRAKE PUMP


Bur 5-2920


7003-2

TABLE OF CONTENTS BRAKE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 5-2920

Issued 8-06

4 4 4 4

Printed in U.S.A.

7003-3

14 17

15 16

10

18 10 19 7

13

8 9 11 12 7

8

9

10

11

5 4 2

6

3

1 BC06F594

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

RETAINING RING SEAL RETAINER 0-RING OUTER LIP SEAL INNER LIP SEAL SHAFT END COVER HOUSING QUAD RING

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

BACKUP SEAL CHANNEL SEAL DOWEL PIN THRUST PLATE GEAR HOUSING PORT END COVER HOUSING

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

WASHER BOLT DRIVEN GEAR DRIVE GEAR DRIVE SCREW NAME PLATE

PUMP ILLUSTRATION

Bur 5-2920

Issued 8-06

Printed in U.S.A.

7003-4

BRAKE PUMP Disassembly 1. Secure the pump by the port end cover (13) in a soft jawed vise. 2. Draw a line the length of the pump to assist during assemble. 3. Loosen and remove bolts (15). 4. Tap the shaft end cover housing (6) with soft hammer to loosen it, remove the shaft end cover housing (6). 5. Remove the backup seal (8), channel seal (9), and thrust plate (11). 6. Remove the drive gear (17) from the gear housing (12). 7. Remove the driven gear (16) from the gear housing (12). 8. Tap the gear housing (12) with a soft hammer to loosen it, remove the gear housing (12). 9. Remove the backup seal (8), channel seal (9), and thrust plate (11). 10. Remove the retaining ring (1) form the shaft end cover housing (6). 11. Remove the seal retainer (2), O-ring (3), and outer lip seal (4) from the shaft end cover housing (6). 12. Remove the inner lip seal (5) from the shaft end cover housing (6).

Inspection 1. Discard all seals and quad rings. Clean all parts in cleaning solvent. Check all machined surfaces for damage or wear. 2. Hold a straightedge across each gear housing and use a feeler gauge to measure the amount of wear caused by the gear teeth in the gear pocket. If the wear in any gear pocket is more than 0.18 MM. (0.007 inch), use a new gear housing. 3. Inspect the thrust plates for scoring, pitting, or other damage. 4. Inspect the gears for wear and damage. There must be no scoring on the gear hubs or on the outside edges of the gear teeth. There must be no more than 0.05 MM. (0.002 inch) wear in the seal area of the drive shaft. If any gear must be discarded, you must use a new hydraulic pump.

Assembly 1. Install a new lip seal (3) into the seal retainer (2) so the lip of the seal will be facing away from the gears when the seal retainer (2) is installed into the shaft end cover housing (6). 2. Install a new lip seal (4) into the shaft end cover housing (6) with the lip of the seal facing towards the gears. 3. Install a new O-ring (3) onto the seal retainer (2), lubricate the O-ring with hydraulic oil. 4. Press the seal retainer (2) into the shaft end cover housing (6) and install the retaining ring (1). 5. Place the shaft end housing (6), facing down, into a soft jawed vise. 6. Install new backup seals (8) and channel seals (9) into the thrust plates (11). 7. Place a thrust plate (11) onto the shaft end cover housing (6). IMPORTANT: Be sure to place the thrust plate (11) onto the shaft end cover housing (6) in the position shown in the illustration on page 3. 8. Lubricate the driven gear (16) with hydraulic oil, slide the driven gear (16) through the thrust plate (11) into the shaft end cover housing (6). 9. Lubricate the drive gear (17) with hydraulic oil, slide the drive gear (17) through the thrust plate (11) into the shaft end cover housing (6). 10. Install a new quad ring (7) into the gear housing (12). Check that dowel pins (10) are in place either in the gear housing (12) or the shaft end cover housing (6). 11. Align the marks made during disassembly, carefully place the gear housing (12) onto the gears. 12. Slide the thrust plate (11) onto the shafts of the gears. IMPORTANT: Be sure to place the thrust plate (11) onto the gears in the position shown in the illustration on page 3. 13. Install a new quad ring (7) into the gear housing (12). Check that dowel pins (10) are in place either in the gear housing (12) or the port end cover housing (13). 14. Align the marks made during disassembly, place the port housing (12) onto the gear housing (12). 15. Install bolts (15) with clean and dry threads, washers (14). Torque bolts to 192 ± 5.5 Nm (141.5 ± 4 pound feet).

Bur 5-2920

Issued 8-06

Printed in U.S.A.

BRAKE ACCUMULATORS


Bur6-47761

Copyright © 2004 CNH America LLC. All rights reserved. Printed in U.S.A. Issued April, 2003/Revised February, 2004

7004

Section 7004

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

Bur 6-47761

Revised 2-04

3 3 3 4 4

Printed in U.S.A.

7004-3

SPECIAL TOOL E

C F

G D

B

A 94L95

CAS10899 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 CAS10899 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, charge the accumulator with dry nitrogen.

Bur 6-47761

Revised 2-04

Printed in U.S.A.

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 0° C 32° F 5° C 41° F 10° C 50° F 15° C 59° F 20° C 68° F 25° C 77° F 30° C 86° F 35° C 95° F 40° C 104° F

CHARGE PRESSURE 51.2 BAR 743 PSI 52.2 BAR 757 PSI 53.1 BAR 770 PSI 54.1 BAR 784 PSI 55.0 BAR 798 PSI 55.9 BAR 811 PSI 56.9 BAR 825 PSI 57.8 BAR 839 PSI 58.8 BAR 852 PSI

TEMPERATURE/CHARGE PRESSURE BRAKE ACCUMULATOR

Bur 6-47761

Revised 2-04

Printed in U.S.A.

Section 7008

7008

PARKING BRAKE


Bur 5-2930


7008-2

TABLE OF CONTENTS PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PARKING BRAKE TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 5-2930

Issued 8-06

3 3 4 4 5

Printed in U.S.A.

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, tur n adjusting bolt counterclockwise until the brake pads are loose.

STEP 8

BD01F143

Install the articulation lock.


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. Bur 5-2930

Issued 8-06

Printed in U.S.A.

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.

Bur 5-2930

Perfor m the Parking Brake Test Procedure as described in this section.

STEP 18 Remove the articulation lock.

STEP 19 Place the master disconnect switch to the ON position.

Issued 8-06

Printed in U.S.A.

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.

BD06F142

Use up or down arrow and highlight config, press the enter key to select the config menu.

STEP 22 Place the Transmission-Auto switch to the manual position.

STEP 26

STEP 23 Place the Parking Brake switch to the ON position.

STEP 24

BD06F143

Press the up or down arrow and high light brake test, press the enter key.

BD06F141

Press and hold the enter key for 2 to 3 seconds until the instrument cluster monitor display changes to the select screen.

Bur 5-2930

Issued 8-06

Printed in U.S.A.

7008-6

STEP 27

STEP 33 Verify that the machine does not move.

STEP 34 Reduce the engine speed to low idle and return the transmission to neutral.

STEP 35

BD06F144

Monitor will display Test Park Brake if all conditions are met to test the brake, press the enter key. NOTE: If all conditions are not met to test the brake the monitor will display the condition that needs corrected prior to proceeding.

STEP 28

BD06F141

Press the escape switch on the key pad to exit the test mode.

Monitor will display Test Park Brake Ready.

STEP 29 Shift the gear selector into third gear forward and slowly increase the engine speed to wide open throttle.

STEP 36 If any machine movement was detected, the parking brake must be adjusted, see procedures this section.

STEP 30 Verify that the machine does not move.

STEP 31 Reduce the engine speed to low idle and return the transmission neutral.

STEP 32 Shift the gear selector to third gear reverse and slowly increase the engine speed to wide open throttle.

Bur 5-2930

Issued 8-06

Printed in U.S.A.

SECTION INDEX

HYDRAULICS Section Title

Section Number

Removal and Installation of Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8001 Hydraulic Specifications, Troubleshooting, and Pressure Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8002 Cleaning the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8003 Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8004 Loader Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8005 Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8006 Coupler Solenoid Locking Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8007 Ride Control Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8013 Ride Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8014


Bur 5-3260


8001 Section 8001 REMOVAL AND INSTALLATION OF HYDRAULIC COMPONENTS


Bur 5-4050


8001-2

TABLE OF CONTENTS LOADER CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Valve Pilot Line Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loader Control Valve Line Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOTE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Joystick and 2 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 - Z-BAR LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUCKET CYLINDERS - XT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XT Loader Bucket Cylinder Removal And Installation Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RIDE CONTROL ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RIDE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FAN REVERSING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . THERMAL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 5-4050

Issued 8-06

3 3 4 5 6 8 8 9 11 12 12 13 13 14 15 15 17 17 18 20 20 22 24 24 25 26 27 27 28 29 29 30 31 31 32 33 33 34 35 35 35

Printed in U.S.A.

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.

Bur 5-4050

Issued 8-06

Printed in U.S.A.

8001-4 REAR OF MACHINE

8

6 7 5

1

3 2

4

BC05M094

1. GREEN WHITE GREEN 2. RED WHITE GREEN 3. YELLOW BLACK GREEN

4. ORANGE BLACK GREEN 5. GREEN WHITE GREEN 6. RED WHITE GREEN

7. GREEN BLACK GREEN 8. RED BLACK GREEN 9.

HYDRAULIC VALVE PILOT LINE CONNECTIONS

Bur 5-4050

Issued 8-06

Printed in U.S.A.

8001-5

2

1 3 4

5

6

7

BC05M093

1. DUMP LINE 2. ROLLBACK LINE 3. LOWER LINE LEFT

4. RAISE LINE RIGHT 5. LOADER VALVE

6. LOWER LINE RIGHT 7. RAISE LINE LEFT

LOADER CONTROL VALVE LINE CONNECTIONS

Bur 5-4050

Issued 8-06

Printed in U.S.A.

8001-6

Installation

STEP 9 Disconnect the hoses (3, 4, 7, 8 if equipped 1, 2, 5, and 6) from the remote control valve(s) at the loader control valve. Refer to the illustration on page 4 for color coding. Install a plug in each hose and a cap on each fitting.

IMPORTANT: Before installing the fittings or connecting the tubes to the fittings, install new O-rings on the fittings.

STEP 16

NOTE: Line 1, 2, 5, and 6 will need to be tagged as right or left of valve.

STEP 10 Loosen and remove tilt cylinder lines (1 and 2). Install a plug in each line and a cap on each fitting.

STEP 11 Loosen and remove lines (3 and 4). Install a plug in each line and a cap on each fitting.

STEP 12

BC05M096

Loosen and remove lines (6 and 7). Install a plug in each line and a cap on each fitting.

Install and align the loader control valve with the valve mounting plate.

STEP 13

STEP 17

Loosen and remove supply and return lines. Install a plug in each line and a cap on each fitting.

Install the bolts and washers that fasten the loader control valve to the valve mounting plate. Tighten the bolts.

STEP 14 Attach proper lifting equipment to lift loader control valve.

STEP 18

STEP 15

STEP 19

Tighten the left lift cylinder lines (6 and 7).

Install and tighten the supply and return lines.

STEP 20 Install and tighten right lift cylinder lines (3 and 4).

STEP 21 Install and tighten tilt cylinder lines (1 and 2).

STEP 22 BC05M096

Loosen and remove the three bolts and washers that hold the loader control valve to the valve mounting plate. Remove the loader control valve.

Bur 5-4050

Connect the hoses (3, 4, 7, 8 if equipped 1, 2, 5, and 6) to the remote control valve(s) at the loader control valve. Refer to the illustration on page 4 for color coding.

Issued 8-06

Printed in U.S.A.

8001-7

STEP 23

STEP 27

Fill the hydraulic reservoir with oil. Refer to Section 1002 for the correct oil.

Run engine at half throttle.

STEP 28 STEP 24 Tighten the accumulator manual bleeder valve located on the top of the ride control valve to a torque of 3.5 Nm (31 lb-in). Install the plug and torque to 7 Nm (62 lb-in).

Slowly and completely extend and retract all cylinders at least 10 times to remove any air from the circuits.

STEP 29 Stop the engine and check for leaks.

STEP 25 Place the master disconnect switch in the ON position.

STEP 30

STEP 26

STEP 31

Install the access cover on the front of the machine.

Check the level of the hydraulic oil and add hydraulic oil as required.

BD03A092

Raise the loader arms and remove the safety link.

Bur 5-4050

Issued 8-06

Printed in U.S.A.

8001-8

REMOTE CONTROL VALVE Removal

STEP 37

STEP 32 Park the machine on a level surface and lower the bucket to the floor. Stop the engine and apply the parking brake. IMPORTANT: With the engine NOT running, pump the brake repeatedly to be sure the brake accumulators have no hydraulic pressure, put the ignition switch in the ON position then move the loader control valve back and forth several times to release any hydraulic pressure in the pilot control circuit, turn ignition switch OFF.

BD06F208

Open and remove the access panel.


STEP 38

STEP 34 Unlatch and open the right hand side access door.

STEP 35 Lift the access door up and remove the access door from the pins.

STEP 36 BD06F209

Remove the front access panel.

STEP 39

BD06F207

Unlatch and open the window on the right hand side.

BD06F210

Disconnect the electrical connectors for the remote control valve.

STEP 40 Loosen the filler cap on the reservoir to release any air in the reservoir. Connect a vacuum pump to the hydraulic reservoir, turn on the pump. Bur 5-4050

Issued 8-06

Printed in U.S.A.

8001-9

STEP 41

Installation

Put identification tags on each hose and disconnect one at a time from the remote control valve. Install plugs in the hoses and caps on the fittings.

STEP 45

STEP 42 Loosen and remove the screws and washers holding the hydraulic control tower cover. Remove the cover.

STEP 43 Loosen and remove the screws that fasten the remote control valve to the hydraulic control tower.

STEP 44 Remove the remote control valve from the hydraulic control tower.

Install new O-rings on the adapters for the remote control valve.

STEP 46 Install the remote control valve and screws in the hydraulic control tower and tighten the screws.

STEP 47 Install the cover over the remote control valve and install the screws and washers.

STEP 48 Remove the plugs from the hoses and the caps from the fittings and connect the hydraulic hoses to the fittings according to the identification tags. (Refer to illustrations on pages 11, 12, and 13 as necessary.

STEP 49 Turn off the vacuum pump and disconnect from the hydraulic reservoir.

STEP 50

BD06F210

Connect the electrical connectors for the remote control valve.


STEP 52 Start the engine and run the engine at low idle.

STEP 53 Check to see that the remote control valve works correctly.

Bur 5-4050

Issued 8-06

Printed in U.S.A.

8001-10

STEP 54

STEP 57

Check for hydraulic oil leakage at the remote control valve.

STEP 55 Check the level of hydraulic oil in the reservoir and add as required.

STEP 56

BD06F208

Install and close the access panel.

STEP 58

BD06F209

Position the access panel on the ROPS cab or the ROPS canopy and install and tighten the screw.

BD06F207

Close the right hand window.

Bur 5-4050

Issued 8-06

Printed in U.S.A.

8001-11

3

8 4 6 7

1 5

2

7

8

7

5 2

1 8

3 6

4 BC05M092

1. PILOT TANK HOSE 2. PILOT PRESSURE HOSE 3. YELLOW BLACK GREEN

4. ORANGE BLACK GREEN 5. GREEN BLACK GREEN 6. RED BLACK GREEN

7. GREEN WHITE GREEN 8. RED WHITE GREEN

JOYSTICK AND 2 LEVER HOSE COLOR CODING

Bur 5-4050

Issued 8-06

Printed in U.S.A.

8001-12

5

5

7

1

4 3

4 6

3

1

2 7

7

6

3

6

2

7 1

2

4

7

7 1

2

6

3

5

4

5 BC05M091

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

Bur 5-4050

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



Issued 8-06

Printed in U.S.A.

8001-13

1 5 4

5

6

4

6

3

2 1

3 2

1

2

6

3 4

1

2

6

3

5

4

5 BC05M090

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

PILOT TANK HOSE PILOT PRESSURE HOSE RED BLACK GREEN ORANGE BLACK GREEN YELLOW BLACK GREEN GREEN BLACK GREEN


Bur 5-4050

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


JOYSTICK HOSE COLOR CODING

Issued 8-06

Printed in U.S.A.

8001-14

HYDRAULIC PUMP

10 15

7

4 5 6 4

16

5 8

15 6

1

13

2 3 14 11 9 12

BC05M095

1. 2. 3. 4.

PUMP MAIN HYDRAULIC MOUNT BOLTS DRAIN HOSE BOLT

Bur 5-4050

5. 6. 7. 8.

SPLIT FLANGE 9. STEERING HIGH PRESSURE TUBE 10. CLAMPS HOSE SUCTION 11. STEERING LOAD SENSE HOSE HOSE CASE DRAIN 12. LOADER LOAD SENSE HOSE

13. 14. 15. 16.

LOADER HIGH PRESSURE STEERING PRIORITY MANIFOLD CLAMPS FITTINGS

Issued 8-06

Printed in U.S.A.

8001-15

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


STEP 69 Connect lifting equipment to hydraulic pump (1). Take up all slack in lifting equipment. Remove four mounting bolts (2) and washers securing pump to transmission. Pull hydraulic pump from transmission and remove from loader. Remove and discard O-ring from pump.

Installation NOTE: Install new O-rings where required.


STEP 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 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 70 Install new O-ring on hydraulic pump flange. Move pump into position and install in transmission. Install four washers and bolts (2) to secure pump (1) to transmission, tighten the bolts. Disconnect lifting equipment from pump.

STEP 71 Connect pump pressure hoses (9 and 13) to steering priority manifold (14).

STEP 72 Connect drain hose (3).

STEP 73 Connect load sense hoses (11 and 12).

STEP 74 STEP 64

Install and connect case drain hoses (8).

Loosen clamps (10). Tag and disconnect suction hoses (7) from hydraulic reservoir and remove from machine.

STEP 75

STEP 65 Tag and disconnect case drain hoses (8) from fittings (16); remove hoses (8). Remove and discard O-ring face seals from fittings.

STEP 66 Tag and disconnect load sense hoses (11 and 12). Remove and discard O-ring face seals from fittings.

STEP 67 Tag and disconnect drain hose (3). Remove and discard O-ring face seals from fittings.

STEP 68 Tag and disconnect pump pressure hoses (9 and 13) from steering priority manifold (14). Remove and discard O-ring face seals from flange heads of hoses. Bur 5-4050

Install suction hoses (7), tighten clamps (10) to 10 to 11 Nm (90 to 100 pound inches).

STEP 76 Install four split flanges (5). Install eight bolts (4) and washers, tighten bolts (4) to 73 to 90 Nm (53.8 to 66.3 pound feet).

STEP 77 Refer to Section 9007 and install the ROPS cab or ROPS canopy.



Issued 8-06

Printed in U.S.A.

8001-16

STEP 80

STEP 81

Start the engine and run the engine at low idle for two minutes.

Stop the engine and check for hydraulic oil leakage at the hydraulic pump.

NOTE: If any unusual vibration is heard coming from the pump, stop the machine immediately and check for obstructions in the pump suction line.

Bur 5-4050

STEP 82 Check the level of the hydraulic oil in the reservoir and add hydraulic oil as required.

Issued 8-06

Printed in U.S.A.

8001-17

LIFT CYLINDERS Removal

STEP 87

STEP 83 Park the machine on a level surface and lower the bucket to the floor. Stop the engine and apply the parking brake. IMPORTANT: With the engine NOT running, pump the brake repeatedly to be sure the brake accumulators have no hydraulic pressure, put the ignition switch in the ON position then move the loader control valve back and forth several times to release any hydraulic pressure in the pilot control circuit, turn ignition switch OFF. BD01D709

STEP 84 Relieve the pressure in the ride control accumulator with the manual bleeder valve located at the rear of the front chassis.

Loosen and remove the bolt, washer and spacer that hold the pivot pin for the yoke.

STEP 88

STEP 85 Loosen the filler cap on the hydraulic reservoir to release any pressure.

STEP 86

BD01D711

Use a proper lifting device and secure a strap around the lift cylinder.

STEP 89 BD01D708

Tag and disconnect the hoses on each side of the lift cylinder. Install plugs in the hoses and caps on the fittings.

BD01D712

Remove the pivot pin from the yoke end of the lift cylinder.

Bur 5-4050

Issued 8-06

Printed in U.S.A.

8001-18

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.

Bur 5-4050

Issued 8-06

Printed in U.S.A.

8001-19

STEP 96

STEP 99

BD01D710

Align the pivot pin with the front frame and install the spacer, washer and bolt. Tighten the bolt.

BD01D712

Install the pivot pin for the yoke. Stop the engine.

STEP 100 STEP 97

BD01D709 BD01D708

Remove the caps and plugs and connect the hoses to the lift cylinder.

Align the pivot pin with the yoke and install the spacer, washer and bolt. Tighten the bolt.

STEP 101 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.

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.

Bur 5-4050

Issued 8-06

Printed in U.S.A.

8001-20

BUCKET CYLINDER - Z-BAR LOADER Removal

STEP 108


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

BD01D694

Disconnect the proximity switch connector from the wiring harness connector.

STEP 107 BD01D697

Loosen and remove the two bolts that fasten the mounting bracket for the proximity switch to the bucket cylinder. Remove the mounting bracket and switch.

BD01D696

Loosen and remove the two bolts that fasten the target bar to the mounting bracket. Remove the target bar.

Bur 5-4050

Issued 8-06

Printed in U.S.A.

8001-21

STEP 110

STEP 113

BD01D699

BD01D701

Disconnect the hoses from each side of the bucket cylinder. Install plugs in the hoses and caps on the fittings.

Remove the pivot pin from the rod end of the bucket cylinder.

STEP 114 STEP 111

BD01D704 BD01D700

Use acceptable equipment to hold the bucket cylinder.

STEP 112

Remove the pivot pin from the head end of the bucket cylinder. NOTE: It is not necessary to remove the grease line from the pivot pin unless the pivot pin is to be replaced.

STEP 115

BD01D698

Loosen and remove the bolt, washer and spacer that fasten the pivot pin from both ends of the bucket cylinder.

Bur 5-4050

BD01D706

Raise the bucket cylinder and remove the cylinder from the machine. Issued 8-06

Printed in U.S.A.

8001-22

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

BD01D699

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.

Bur 5-4050

Issued 8-06

Printed in U.S.A.

8001-23

STEP 124

STEP 127

BD01D697

BD01D694

Install the two bolts that fasten the mounting bracket for the switch to the bucket cylinder.

Connect the proximity switch connector to the wiring harness connector.

STEP 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.

BD01D696

Install the two bolts that fasten the target bar to the mounting bracket.

Bur 5-4050

Issued 8-06

Printed in U.S.A.

8001-24

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 135 Raise the engine hood and remove the shield on the right side of the machine between the tire and the oil cooler.

STEP 136

BD03A154

Disconnect the top hose and install a plug in the hose and a cap on the fitting.

STEP 139

BD03A120

Have assistant hold side panel in raised position, remove two mounting screws, remove side panel.

STEP 137 Loosen the filler cap on the hydraulic reservoir to release the air pressure in the reservoir. Connect a vacuum pump to the hydraulic reservoir, turn on the pump.

BD03A179

Loosen and remove the bolt and washer that fasten the oil cooler to the cooling frame.

STEP 140

BD06H195

Disconnect the hose from the bottom of the oil cooler. Install a plug in the hose and a cap on the fitting. Remove the two mounting nuts, remove the oil cooler from the machine. Bur 5-4050

Issued 8-06

Printed in U.S.A.

8001-25

Installation

STEP 144

STEP 141

BD03A120

BD06H195

Place the oil cooler in position in the cooling frame. Connect the lower hose to the oil cooler, install and tighten the two mounting nuts.

STEP 142

Have assistant hold side panel in raised position, install and tighten two mounting screws.



STEP 147 Start the engine and run the engine at low idle for two minutes. Stop the engine and check for hydraulic oil leakage at the ports on the oil cooler.

STEP 148 Install the shield between the right rear tire and the oil cooler and tighten the two bolts holding the shield. BD03A179

Install the bolt and washer that fasten the oil cooler to the cooling frame

STEP 149 Check the level of the hydraulic oil in the reservoir and add hydraulic oil as required.

STEP 143

BD03A154

Connect the hose to the top of the oil cooler.

Bur 5-4050

Issued 8-06

Printed in U.S.A.

8001-26

RIDE CONTROL ACCUMULATOR Removal

STEP 153


BD06H196

Disconnect the hose from the elbow at the bottom of the ride control accumulator. Install a plug in the hose and a cap on the fitting.

STEP 151

STEP 154

BD06H198



Bur 5-4050

BD06H197

Loosen and remove the nuts and washers from the U-bolt. Remove the U-bolt.

STEP 155 Loosen and remove the two bolts that fasten the accumulator bracket to the front frame. Remove the ride control accumulator from the machine.

Issued 8-06

Printed in U.S.A.

8001-27

Installation

STEP 159

STEP 156 Place the ride control accumulator in position on the front frame.

STEP 157 Install the two bolts that fasten the accumulator bracket to the front frame. Tighten the bolts.

STEP 158 BD06H196

Remove the caps and plugs and install the hose on the elbow at the bottom of the r ide control accumulator.

STEP 160 Turn off and disconnect the vacuum pump from the hydraulic reservoir.

STEP 161 BD06H197

Install the U-bolt, washers and nuts. Tighten the nuts.

Tighten the accumulator manual bleeder valve located on the top of the ride control valve to a torque of 3.5 Nm (31 lb-in). Install the plug and torque to 7 Nm (62 lb-in).

STEP 162 Refer to Section 8002 Testing the Ride Control for the proper charging of the accumulator to check for leaks.

STEP 163 Check the level of the hydraulic oil in the reservoir and add as required. Tighten the filler cap on the hydraulic reservoir.

Bur 5-4050

Issued 8-06

Printed in U.S.A.

8001-28

RIDE CONTROL VALVE Removal

STEP 166


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 168 Disconnect the electrical connector on top of the ride control valve.

STEP 169

STEP 165

Tag and disconnect the hoses from the ride control valve. Install a plug in the hoses and caps on fittings.

STEP 170 Loosen and remove the two bolts and washers that fasten the ride control valve to the frame.

STEP 171 Remove the ride control valve from the machine.

STEP 172 BD06H198

Remove and discard all O-rings.


Bur 5-4050

Issued 8-06

Printed in U.S.A.

8001-29

Installation

STEP 178

STEP 173

Connect the electrical connector to the ride control valve.

Install the ride control valve in position on the front frame.

STEP 179

STEP 174

Turn off the vacuum pump and disconnect from the hydraulic reservoir.

Install the washers and bolts through the frame and into the ride control valve. Tighten the bolts.

STEP 180

STEP 175

Place the master disconnect switch in the ON position.

STEP 181 Start and run the engine at low idle for two minutes.

STEP 182 Stop the engine and check for hydraulic oil leakage at the ride control valve.

STEP 183

BD06H198

Tighten the accumulator manual bleeder valve located on the top of the ride control valve to a torque of 3.5 Nm (31 lb-in). Install the plug and torque to 7 Nm (62 lb-in).

Check the level of the hydraulic oil in the reservoir and add as required. Tighten the filler cap on the hydraulic reservoir.

STEP 184 Refer to Section 8002 and perform the Ride Control Test Procedure.

STEP 176 Lubricate and install new O-rings.

STEP 177 Connect the hoses to the ride control valve.

Bur 5-4050

Issued 8-06

Printed in U.S.A.

8001-30

FAN REVERSING VALVE Removal

STEP 188

STEP 185 Park the machine on a level surface and lower the bucket to the ground. Stop the engine and apply the parking brake. IMPORTANT: With the engine NOT running, pump the brake repeatedly to be sure the brake accumulators have no hydraulic pressure, put the ignition switch in the ON position then move the loader control valve back and forth several times to release any hydraulic pressure in the pilot control circuit, turn ignition switch OFF.

2 1

BD03A174


Tag and disconnect the fan forward hose (1) from the fan reversing valve. Install a plug in the hose and a cap on the fitting. Tag and disconnect the fan reverse hose (2) from the fan reversing valve. Install a plug in the hose and a cap on the fitting.

STEP 187

STEP 189

3

4 BD03A173

BD03A174

Disconnect the electrical connector for the fan reversing valve.

Tag and disconnect the fan valve return hose (3) from the fan reversing valve. Install a plug in the hose and a cap on the fitting. Tag and disconnect the fan valve supply hose (4) from the fan reversing valve. Install a plug in the hose and a cap on the fitting.

STEP 190 Loosen and remove the nuts, washers and bolts.

STEP 191 Remove the fan reversing valve from the machine.

STEP 192 Remove and discard all O-rings from the fittings.

Bur 5-4050

Issued 8-06

Printed in U.S.A.

8001-31

Installation

STEP 198

STEP 193 Place the fan reversing valve into position on the machine.

STEP 194 Lubricate and install new O-rings in the fittings.

STEP 195 Install the bolts, washers and nuts. Tighten the nuts.

STEP 196 BD03A174

Connect the electrical connector for the fan reversing valve.


STEP 200

3

Check the level of the hydraulic oil in the reservoir.

4 BD03A173

STEP 201

Connect the fan valve supply hose (4) to the fitting on the fan reversing valve. Connect the fan valve return hose (3) to the elbow on the fan reversing valve.

Start the engine and run the engine at low idle for two minutes.

STEP 197

Stop the engine and check for hydraulic oil leakage at the fan reversing valve.

STEP 202

STEP 203 Check the level of the hydraulic oil in the reservoir and add as required. Tighten the filler cap on the reservoir.

2 1

BD03A174

Connect the fan reverse hose (2) to the fitting on the fan reversing valve. Connect the fan forward hose (1) to the fitting on the fan reversing valve.

Bur 5-4050

Issued 8-06

Printed in U.S.A.

8001-32

THERMAL VALVE Removal

Installation

STEP 204

STEP 208

Park the machine on a level surface and lower the bucket to the ground. Stop the engine and apply the parking brake.

Place the thermal valve into position on the machine.

IMPORTANT: With the engine NOT running, pump the brake repeatedly to be sure the brake accumulators have no hydraulic pressure, put the ignition switch in the ON position then move the loader control valve back and forth several times to release any hydraulic pressure in the pilot control circuit, turn ignition switch OFF.

Lubricate and install new O-rings in the fittings.


STEP 209 STEP 210 Install the bolts, washers and nuts. Tighten the nuts.

STEP 211 Connect the hoses to the thermal valve, remove and discard tags.


STEP 213

STEP 206

Check the level of the hydraulic oil in the reservoir.

STEP 214 Start the engine and run the engine at low idle for two minutes.

STEP 215 Stop the engine and check for hydraulic oil leakage at the thermal valve.

STEP 216 BD06F211

Tag and disconnect the hoses from the thermal valve. Install a plug in the hose and a cap on the fitting.

Check the level of the hydraulic oil in the reservoir and add as required. Tighten the filler cap on the reservoir.

STEP 207 Remove the mounting bolts from the thermal valve, remove the valve from the machine.

Bur 5-4050

Issued 8-06

Printed in U.S.A.

8002

Section 8002 HYDRAULIC SPECIFICATIONS, TROUBLESHOOTING, AND PRESSURE CHECKS


Bur 5-3270


8002-2

TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Problems in All Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Problem in All Loader Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Problem in the Braking Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Problem in a Single Loader Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Problem in the Steering Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Problem in the Ride Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING AND ADJUSTING THE HIGH PRESSURE PUMP DIFFERENTIAL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the High Pressure Pump Differential Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING AND ADJUSTING THE LOW PRESSURE PUMP DIFFERENTIAL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the Low Pressure Pump Differential Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING AND ADJUSTING THE LOADER LIMIT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the Loader Limit Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING AND ADJUSTING THE STEERING LIMIT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the Steering Limit Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING AND ADJUSTING THE LOADER PUMP CUTOFF PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the Loader Pump Cutoff Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING THE HYDAULIC CONTROLLER PILOT SUPPLY PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HIGH PRESSURE PUMP FLOW TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING AND ADJUSTING THE CIRCUIT RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING THE RIDE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 5-3270

Issued 8-06

3 4 5 5 5 5 6 6 6 7 7 8 9 9 10 11 11 12 13 13 14 15 15 16 17 17 18 20 20 20 21 22

Printed in U.S.A.

8002-3

SPECIFICATIONS Manufacturer........................................................................................................................................ Bosch-Rexroth High pressure pump (closest to transmission) .................................................... 120 L/min at 172 bar, at 2000 r/min (31.6 gpm at 2500 psi at 2000rpm) Low pressure pump (furthest from transmission) ................................................ 120 L/min at 172 bar, at 2000 r/min (31.6 gpm at 2500 psi at 2000rpm) Main relief valve pressure settings .........................................................................248 to 255 bar (3600 to 3700 psi) Circuit relief valve pressure setting Auxiliary A and B port.................................................................................................................290 bar (4200 psi) Bucket A port..............................................................................................................................290 bar (4200 psi) Bucket B port..............................................................................................................................290 bar (4200 psi) Pilot accumulator pressure .............................................................................................13 to 15 bar (188 to 218 psi) Steering relief valve pressure setting ............................................................................................. See Section 5002 Brake accumulator pressure .......................................................................................................... See Section 7002 NOTE: Both pump sections provide flow for both the steering and loader functions.

Bur 5-3270

Issued 8-06

Printed in U.S.A.

8002-4

SPECIAL TOOLS

B877168V

633L95

CAS-1808 FLOWMETER FITTING KIT

CAS-1904 PRESSURE FITTING KIT

B877895M

632L95

CAS-10090 HAND PUMP


B877558M

B785789M

CAS-10280 FLOWMETER

Bur 5-3270


Issued 8-06

Printed in U.S.A.

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.

Bur 5-3270

Issued 8-06

Printed in U.S.A.

8002-6

Problem in a Single Loader Circuit Star t and run the engine at full throttle. Operate the control for the bad circuit. Does the cylinder move in both directions?

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 che ck for wor n 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 ar ms 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.

Bur 5-3270

Issued 8-06

Printed in U.S.A.

8002-7

TESTING AND ADJUSTING THE HIGH PRESSURE PUMP DIFFERENTIAL PRESSURE Pressure Check

STEP 3

STEP 1

1

BD06G180

1 BD00M041

2


Install articulation lock (1).

STEP 2 Make sure that the temperature of the hydraulic oil is at least 54°C to 57°C (129°F to 135°F). The following is the procedure for heating the hydraulic oil. ●

To measure the oil temperature with the instrument cluster: A. Press the up or down arrow key. B. Stop at the info screen with the temperatures that need to be monitored are on.

●

To heat the hydraulic oil do the following: A. Start the engine and run at full throttle. B. Hold the bucket control lever in the RO L L B AC K p o s i t i o n w h i l e ra i s i n g a n d lowering the lift arms from ground level to full height. C. Continue this procedure until the temperature of the hydraulic oil is 54° to 57°C (129° to 135°F).

After heating oil to operating temperature, lower bucket to the ground, turn off the engine, and relieve all pressure in the hydraulic system.

BD06F148

1. TEST PORT (LOAD SENSE) 2. TEST PORT (PUMP PRESSURE)

Connect two 69 bar (1000 psi) test gauges, one to the test port (2) located on the priority valve, and one on the pump load-sense pressure tap (1 closest to transmission). 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 (1) and (2).

STEP 6 Subtract the reading of the test port (1) from the reading of the test port (2).

Bur 5-3270

Issued 8-06

Printed in U.S.A.

8002-8

STEP 7 The difference between the two readings should be 24 to 27 bar (350 to 390 psi).

STEP 8 If this reading is more or less than specified, it will be necessary to adjust the pump load-sense pressure.

Adjusting the High Pressure Pump Differential Pressure STEP 9 The load-sense adjusting screw is directly below the load-sense pressure tap. Turn the screw clockwise to increase the load-sense pressure. Turning the screw counterclockwise will decrease the load-sense pressure. NOTE: One turn of the adjustment screw will change the pressure approximately 16 bar (230 psi).

Bur 5-3270

Issued 8-06

Printed in U.S.A.

8002-9

TESTING AND ADJUSTING THE LOW PRESSURE PUMP DIFFERENTIAL PRESSURE Pressure Check

STEP 3

STEP 1

1

BD06G180

1 2 BD00M041



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. Press the up or down arrow key. B. Stop at the info screen with the temperatures that need to be monitored are on. ●

BD06F148

To measure the oil temperature with the instrument cluster:

To heat the hydraulic oil do the following: A. Start the engine and run at full throttle. B. Hold the bucket control lever in the RO L L B AC K p o s i t i o n w h i l e ra i s i n g a n d lowering the lift arms from ground level to full height. C. Continue this procedure until the temperature of the hydraulic oil is 54° to 57°C (129° to 135°F).


1. TEST PORT (LOAD SENSE) 2. TEST PORT (PUMP PRESSURE)

Connect two 69 bar (1000 psi) test gauges, one to the test port (2) located on the priority valve, and one on the pump load-sense pressure tap (1 furthest from the transmission). 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.

STEP 5 Make sure all of the controls are in the neutral position and record the readings on the test gauges (1) and (2).

STEP 6 Subtract the reading of the test port (1) from the reading of the test port (2).

Bur 5-3270

Issued 8-06

Printed in U.S.A.

8002-10

STEP 7 The difference between the two readings should be 25 to 28 bar (360 to 400 psi).

STEP 8 If this reading is more or less than specified, it will be necessary to adjust the pump differential pressure.

Adjusting the Low Pressure Pump Differential Pressure STEP 9 The differential adjusting screw is directly below the load-sense pressure tap. Turn the screw clockwise to increase the load-sense pressure. Turning the screw counterclockwise will decrease the differential pressure. NOTE: One turn of the adjustment screw will change the pressure approximately 16 bar (230 psi).

Bur 5-3270

Issued 8-06

Printed in U.S.A.

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. ●


●

To heat the hydraulic oil do the following: A. Start the engine and run at full throttle.

1 BD00M041


B. Hold the bucket control lever in the RO L L B AC K p o s i t i o n w h i l e r a i s i n g a n d lowering the lift arms from ground level to full height. C. Continue this procedure until the temperature of the hydraulic oil is 54° to 57°C (129° to 135°F).


STEP 2


STEP 4

1

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. BD06F148

1. TEST PORT (LOAD LIMIT)

STEP 7 Reading should be 248 to 255 bar (3600 to 3700 psi).

Connect a 345 bar (5000 psi) test gauge to the test port (1), located on the priority valve.

STEP 8 If this reading is more or less than specified, it will be necessary to adjust the pump limit pressure.

Bur 5-3270

Issued 8-06

Printed in U.S.A.

8002-12

Adjusting the Loader Limit Pressure

STEP 9 The limit adjusting screw is located on the left side of the loader valve. Tur n the screw clockwise to increase the limit pressure. Turning the screw counterclockwise will decrease the limit pressure. NOTE: One turn of the adjustment screw will change the pressure approximately 35 bar (500 psi).

BD06H193

Bur 5-3270

Issued 8-06

Printed in U.S.A.

8002-13

TESTING AND ADJUSTING THE STEERING LIMIT PRESSURE Pressure Check

STEP 3

STEP 1



●


1 BD00M041




STEP 2


STEP 4

1

Start the engine and run at full throttle.

STEP 5 Steer hard in either direction over relief pressure.


1. TEST PORT (LOAD LIMIT)


Connect a 345 bar (5000 psi) test gauge to the test port (1), located on the priority valve.

STEP 8 If this reading is more or less than specified, it will be necessary to adjust the steering limit pressure.

Bur 5-3270

Issued 8-06

Printed in U.S.A.

8002-14

Adjusting the Steering Limit Pressure

STEP 9 The steering priority valve is located on the hydraulic p u m p, t h e a d j u s t i n g va l ve i s l o c a t e d o n t h e 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

BD06F147

1. STEERING LIMIT VALVE

Bur 5-3270

Issued 8-06

Printed in U.S.A.

8002-15

TESTING AND ADJUSTING THE LOADER PUMP CUTOFF PRESSURE Pressure Check

STEP 3

STEP 1



●


1 BD00M041




STEP 2


1

STEP 4 Start the engine and run at full throttle.

STEP 5 Roll the loader bucket back against the stops.


1. TEST PORT (PUMP PRESSURE)


Connect two 345 bar (5000 psi) test gauge to the test port (1) located on the large hydraulic tube on the bottom of the pump.

Bur 5-3270

STEP 8 If this reading is more or less than specified, it will be necessary to adjust the pump cutoff pressure.

Issued 8-06

Printed in U.S.A.

8002-16

Adjusting the Loader Pump Cutoff Pressure STEP 9

BD06G179

The unloading adjuster is the longer of the two adjusters on the loader pump. Tur n 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.

Bur 5-3270

Issued 8-06

Printed in U.S.A.

8002-17

TESTING THE HYDAULIC CONTROLLER PILOT SUPPLY PRESSURE NOTE: This pressure is factory preset and is not adjustable.

Pressure Check

STEP 6 Open the right side compartment to gain access to the loader control handle.

STEP 7 STEP 1 Make sure that the temperature of the hydraulic oil is at least 54°C to 57°C (129°F to 135°F). The following is the procedure for heating the hydraulic oil. ●

To measure the instrument cluster:

oil

temperature

with

the

A. Press the up or down arrow key. B. Stop at the info screen with the temperatures that need to be monitored are on. ●

To heat the hydraulic oil do the following:

Attach a gauge capable of reading 70 bar (1000 psi) to the test port under loader control handle.

STEP 8 Start and run the machine at low idle, hold the bucket control lever in the ROLLBACK position to increase the system pressure.

STEP 9 A pressure reading of 29.5 to 39.5 bar (425 to 575 psi) should be obtained, if pressure is not as specified do the following steps.

A. Start the engine and run at full throttle. B. Hold the bucket control lever in the RO L L B AC K p o s i t i o n w h i l e ra i s i n g a n d lowering the lift arms from ground level to full height. C. Continue this procedure until the temperature of the hydraulic oil is 54° to 57°C (129° to 135°F).

STEP 2 Raise lift arms to the top and turn off the engine. Turn the ignition switch to the “RUN” position.

STEP 3 Repeatedly put the loader control lever into “FLOAT” position and back to neutral.

STEP 4 The system should allow a minimum of 10 actuations into float and still cause the lift arms to come down. NOTE: If 10 full actuations cannot be made, an internal hydraulic leak exists, proceed to next step.

STEP 10 Lower the bucket to the ground and turn off the engine. Tur n the ignition switch to the “RUN” position.

STEP 11 Operate the pilot controls several times until the gauge pressure suddenly drops to zero. The last pressure reading before the drop to zero is the nitrogen charge pressure in the accumulator. If the pressure is below 13 to 15 bar (188 to 218 psi), replace the accumulator. If accumulator test is good, go to next step.

STEP 12 Replace the pilot controls, see section 8001, retest the system, if test fails go to next step.

STEP 13 Replace the loader control valve, see section 8001, retest the system.

STEP 5 Start machine and lower the bucket to the ground and turn off the engine. Turn the ignition switch to the “RUN” position, operate the pilots controls a minimum of 30 strokes to relieve any pressure in the system.

Bur 5-3270

Issued 8-06

Printed in U.S.A.

8002-18

HIGH PRESSURE PUMP FLOW TEST NOTE: The pump differential pressure must be set before attempting any other tests. Refer to page 7 of this section.

STEP 1 Connect the flow meter (3) by disconnecting the inlet hose (6) to the valve supply tube (13), installing a cap (12) on the fitting at the valve supply tube (13). Refer to illustration on page 19.

STEP 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 2

STEP 8

Disconnect the load sense hose (7) and install a cap (12) the fitting at the loader valve (15).

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).

NOTE: This is the line that returns to the pump compensator valve.

STEP 9 STEP 3 Connect a “T” fitting (10) into the loader control valve inlet hose (6) and to the flow meter inlet hose (11).

Close the flow meter valve slowly and read the flow at 34.5 bar (500 psi) the flow should be 249 to 255 L/min (65.8 to 66.8 gpm).

STEP 4

STEP 10

Use a union (9) and connect an in line needle valve (8) to the open port in the “T” fitting (10), connect the load sense hose (7) to the needle valve (8).

Close the flow meter valve slowly and read the flow at 2000 psi @ 2000 rpm. The flow should read 244.5 to 247.5 L/min (64.6 to 65.4 gpm).

STEP 5

STEP 11

Make sure that the flow meter valve and the installed needle valve are in the open position. Start and run the engine at high idle, slowly close the flow meter valve until a pressure reading of 103 bar (1500 psi) is obtained.

Continue to close the flow meter valve slowly, at approximately 2900 psi the flow should drop significantly, this will be the low pressure pump destroking.

STEP 12 Continue slowly closing the flow meter valve until 3500 psi is reached. The flow should read between 120 to 122 L/min (31.6 and 32.1 gpm).

STEP 13 If any of the pump flow readings are not within specifications, the pump may be out of calibration a n d Te c h n i c a l S u p p o r t S e r v i c e s s h o u l d b e contacted.

Bur 5-3270

Issued 8-06

Printed in U.S.A.

8002-19

1

2

4

3 5 6 11 12

13

7 10 9 12 8

14 15

BS06G117

1. HYDRAULIC RETURN MANIFOLD 6. HOSE M42 ORB 11. FLOW METER INLET HOSE 2. FLOW METER RETURN HOSE 7. LOAD SENSE HOSE M14 ORB 12. CAP 3. FLOW METER 8. NEEDLE VALVE 13. VALVE TUBE SUPPLY 4. PUMPS 9. UNION 14. ELBOW M14 ORB 5. PRIORITY VALVE 10. T FITTING 15. LOADER VALVE NOTE: IF UNIT IS EQUIPPED WITH AUXILIARY STEERING A TEE FITTING WILL HAVE TO BE USED IN THIS LOCATION

Bur 5-3270

Issued 8-06

Printed in U.S.A.

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.

3

STEP 5

4 1

1

5

2

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.

6

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.

1 3

4

5

Adjustment

BS03B022

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.

STEP 3

STEP 1 Loosen the lock nut. Turn the adjustment screw clockwise to increase the pressure or counterclockwise to decrease the pressure. NOTE: One turn of the adjusting screw will change the pressure approximately 138 bar (2000 psi).

STEP 2 Check the pressure again. Repeat the adjustment as necessary.

Loosen and remove the bolts and washers that fasten the access cover plate for the loader control valve. Remove the cover plate.

Bur 5-3270

Issued 8-06

Printed in U.S.A.

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 ar ticulation lock, star t 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.

Bur 5-3270

Issued 8-06

Printed in U.S.A.

8002-22

HYDRAULIC COMPONENT LOCATIONS 5 6

8

7 9 4

10

2 3

8

11 15 14 16 19 18 17

12 13

1

BC00N140

1. REAR BRAKE CYLINDERS 2. BRAKE ACCUMULATOR PRESSURE DIAGNOSTIC COUPLER 3. BRAKE ACCUMULATORS 4. FRONT AND REAR AXLE BRAKE PRESSURE DIAGNOSTIC COUPLERS 5. BRAKE LIGHT PRESSURE SWITCH 6. BRAKE WARNING PRESSURE SWITCH 7. BRAKE AND ACCUMULATOR CHARGING VALVE 8. LIFT CYLINDERS 9. BUCKET CYLINDER (TILT CYLINDER) 10. RIDE CONTROL ACCUMULATOR

11. FRONT BRAKE CYLINDERS 12. RIDE CONTROL ACCUMULATOR BLEEDER VALVE AND RIDE CONTROL VALVE (OPTIONAL) 13. PARKING BRAKE CYLINDER 14. STEERING PRESSURE DIAGNOSTIC COUPLER 15. STEERING PRIORITY VALVE 16. STEERING CYLINDERS 17. AUXILIARY STEERING PUMP AND MOTOR 18. AUXILIARY STEERING PRIORITY VALVE 19. AUXILIARY STEERING PRESSURE SWITCH

NOTE: The hydraulic schematic is located in the rear pocket. All numbers are coordinated with the hydraulic schematic for reference.

Bur 5-3270

Issued 8-06

Printed in U.S.A.

8002-23

23 24 21 22

26

25

20

30 31

29

28

27

32 33 34

BC00N140

20. 21. 22. 23. 24. 25. 26. 27.

FAN DRIVE MOTOR HYDRAULIC RESERVOIR BREATHER HYDRAULIC RESERVOIR PILOT PRESSURE DIAGNOSTIC COUPLER PILOT CONTROL VALVE PILOT PRESSURE ACCUMULATOR LOADER CONTROL VALVE PARKING BRAKE ACCUMULATOR

28. 29. 30. 31. 32. 33. 34.

PUMP PRESSURE DIAGNOSTIC COUPLER LOAD SENSING DIAGNOSTIC COUPLER IMPLEMENT HYDRAULIC PUMP HYDRAULIC FILTER HYDRAULIC COOLER BRAKE HYDRAULIC PUMP FAN VALVE

NOTE: The hydraulic schematic is located in the rear pocket. All numbers are coordinated with the hydraulic schematic for reference.

Bur 5-3270

Issued 8-06

Printed in U.S.A.

8002-24

NOTES

Bur 5-3270

Issued 8-06

Printed in U.S.A.

8003

Section 8003 CLEANING THE HYDRAULIC SYSTEM


Bur 7-49641

Copyright © 2003 CNH Ameica LLC. All rights reserved. Printed in U.S.A. Issued April, 2003 Revised August, 2006

8003-2

TABLE OF CONTENTS SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TYPES OF CONTAMINATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLEANING THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FLUSHING WATER FROM THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 7-49641

Revised 8-06

3 4 4 5 7

Printed in U.S.A.

8003-3

SPECIAL TOOLS

806128

CAS10508, fitting kit.

806127

CAS101162A, filter unit, portable.

TR98H032

CAS10192, vacuum pump.

Bur 7-49641

Revised 8-06

Printed in U.S.A.

8003-4

GENERAL INFORMATION Contamination in the hydraulic system is a major cause of the malfunction of hydraulic components. Contamination is any foreign material in the hydraulic oil. Contamination can enter the hydraulic system in several ways. 1. When you drain the oil or disconnect any line.

1. Cylinder rod seals leak. 2. Control valve spools do not return to neutral. 3. Movement of control valve spools is difficult. 4. Hydraulic oil becomes too hot.

2. When you disassemble a component.

5. Pump gears, housing, and other parts wear rapidly.

3. From normal wear of the hydraulic components.

6. Relief valves or check valves held open by dirt.

4. From damaged or worn seals.

7. Quick failure of components that have been repaired.

5. From a damaged component in the hydraulic system. All hydraulic systems operate with some contamination. The design of the components in this hydraulic system permits efficient operation with a small amount of contamination. An increase in this amount of contamination can cause problems in the hydraulic system. The following list includes some of these problems.

8. Cycle times are slow; machine does not have enough power. If your machine has any of these problems, check the hydraulic oil for contamination. See types of contamination below. If you find contamination, use the Portable Filter to clean the hydraulic system.

TYPES OF CONTAMINATION There are two types of contamination, microscopic and visible. 1. Microscopic contamination occurs when very fine particles of foreign material are in suspension in the hydraulic oil. 2. These particles are too small to see or feel. Microscopic contamination can be found by identification of the following problems or by t e s t i n g i n a l a b o r a t o r y. E x a m p l e s o f t h e problems:

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.

Bur 7-49641

Revised 8-06

Printed in U.S.A.

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.

Bur 7-49641

in

the

C. Repeat steps A and B until the oil in the hydraulic system is at operating temperature. 17. Continue to run the engine at full throttle. Continue to run the portable filter. 18. Operate each hydraulic circuit to completely extend and retract the cylinders. Continue to operate each hydraulic circuit two times, one after the other for 45 minutes. 19. Decrease the engine speed to low idle. 20. Continue to run the portable filter for 10 minutes. 21. Stop the portable filter. 22. Stop the engine. 23. Remove the hose from the hydraulic reservoir.

Revised 8-06

Printed in U.S.A.

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.

Bur 7-49641

34. Stop the engine. 35. Check the oil level in the hydraulic reservoir. Add o i l a s r e q u i r e d . S e e S e c t i o n 1 0 0 2 fo r specifications.

Revised 8-06

Printed in U.S.A.

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 o i l a s r e q u i r e d . S e e S e c t i o n 1 0 0 2 fo r specifications.

6. Remove the hydraulic filter elements from the machine.

23. Install the filler cap on the reservoir.


24. Remove the hydraulic filter elements from the machine.

8. Install the drain plug in the bottom of the reservoir.


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.

Bur 7-49641

Revised 8-06

Printed in U.S.A.

8003-8

NOTES

Bur 7-49641

Revised 8-06

Printed in U.S.A.

8004

Section 8004 HYDRAULIC PUMP


Bur 5-2970

Copyright © 2006 CNH America LLC. All rights reserved. Printed in U.S.A. Issued August, 2006

8004-2

TABLE OF CONTENTS PUMP SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PREPARING THE EQUIPMENT PUMP FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIPMENT PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 5-2970

Issued 8-06

3 3 4 5 9 11

Printed in U.S.A.

8004-3

PUMP SPECIFICATIONS Manufacturer................................................................................................................................................... Rexroth High pressure pump (steering pump next to transmission) ............. 120 L/min at 20 680 kPa, 170 bar, at 2000 r/min (31.6 U.S. gpm at 2500 psi at 2000rpm) Low pressure pump (loader pump farthermost from transmission) ... 86 L/min at 20 680 kPa, 170 bar, at 2000 r/min (22.5 U.S. gpm at 2500 psi at 2000rpm) Rotation ................................................................................................. Clockwise as seen from the end of the shaft Special torques Pump end cover bolts...................................................................................................165 Nm (121.5 pound-feet) Pump housing plug ........................................................................................................127 Nm (93.5 pound-feet) Control piston plug ..............................................................................................................90 Nm (66 pound-feet)

PREPARING THE EQUIPMENT PUMP FOR USE Do the following procedure any time you install a new or overhauled equipment pump: 1. Start and run the engine at half throttle for three minutes. 2. With the engine running at half throttle, move the bucket control lever into roll back position. Hold the bucket control lever in this position until the bucket stops moving.

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.

Bur 5-2970

Issued 8-06

Printed in U.S.A.

8004-4

EQUIPMENT PUMP 7

9

8

5

6 4

5 4 3

10 1

2

11 12 13 21

22

23

24

20 19 18 14

17

15

16

30 29 15 26

27

28

25

BC06F550

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Bur 5-2970

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 8-06

Printed in U.S.A.

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.

Bur 5-2970

Issued 8-06

Printed in U.S.A.

8004-6

STEP 5

STEP 6

BC06F555

BC06F554

Remove the end cover. NOTE: Watch for the flow plate, it can be stuck to either the end cover or pump body.

Bur 5-2970

Use a suitable bearing race puller and pull the bearing race from the end cover. NOTE: Do not damage the sealing surfaces.

Issued 8-06

Printed in U.S.A.

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.

Bur 5-2970

Issued 8-06

Printed in U.S.A.

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.

Bur 5-2970

Issued 8-06

Printed in U.S.A.

8004-9

Inspection

STEP 19

STEP 16 Clean all parts in cleaning solvent. Be careful not to remove the alignment mar ks made dur ing 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.

Bur 5-2970

Issued 8-06

Printed in U.S.A.

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.

Bur 5-2970

BC06F573

Check mounting surface for the flow plate for damage.

Issued 8-06

Printed in U.S.A.

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.

Bur 5-2970

Issued 8-06

Printed in U.S.A.

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 bear ing as required.

BC06F580

Put new bearings in the housing. Install the reaction spring.

Bur 5-2970

Issued 8-06

Printed in U.S.A.

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.

Bur 5-2970

Issued 8-06

Printed in U.S.A.

8004-14

STEP 36

STEP 39

BC06F584

Use a suitable compressor, compress the spring and install the snap ring.

STEP 37

BC06F585

BC06F587

Place the ball onto the pressure pins, install the pistons into the retaining plate.

Hold the pistons in the rotating housing using an O-ring, install the rotating group into the housing, remove the O-ring.

STEP 38

BC06F586

Lubricate the piston and retaining plate with clean oil, install the piston into the rotating housing.

Bur 5-2970

Issued 8-06

Printed in U.S.A.

8004-15

STEP 40

STEP 41

BC06F588

Use the shim that was required for the bearing pre load in step 30. Install the shim and bearing onto the shaft.

BC06F589

Install a new O-ring on the end cover, place the flow plate onto the rotating group with aligning notch up. Place the end cover onto the housing, make sure that the aligning pin in the end cover aligns with the slot in the flow plate.

Bur 5-2970

Issued 8-06

Printed in U.S.A.

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).

Bur 5-2970

Issued 8-06

Printed in U.S.A.

Section 8005

8005

LOADER CONTROL VALVE


Bur 5-2980


8005-2

TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Spool Valve Housing Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Spool Valve Spool Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Spool Mounting Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Spool Mounting Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 and 4 Spool Valve Spool Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISSASEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Relief Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Relief Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 5-2980

Issued 8-06

3 4 5 6 7 8 9 14 14 18 18

Printed in U.S.A.

8005-3

SPECIFICATIONS Manufacturer................................................................................................................................................... Rexroth Special Torques End plate mounting bolts.................................................................................................. 70 Nm (51.5 pound feet) Pressure relief, flow limit, and pilot pressure reducing valves .................. 20 to 25 Nm (177 to 221 pound inches) Allen head plugs.............................................................................................................. 240 Nm (177 pound feet) Allen head locking screw................................................................................................ 100 Nm (73.7 pound feet) Allen head cover screws (short) .................................................................................. 10.4 Nm (92 pound inches) Allen head cover screws (long) ........................................................................................ 6 Nm (53 pound inches) Anticavitation valves ....................................................................................................... 100 Nm (73.7 pound feet) Combination anticavitation and circuit relief ................................................................. 200 Nm (147.5 pound feet) Main relief valve pressure settings (XT and Z-Bar) ............................................... 248 to 252 bar (3596 to 3654 psi) Circuit relief valve pressure setting Auxiliary A and B port (XT and Z-Bar) .......................................................................................290 bar (4206 psi) Bucket A port (XT and Z-Bar) ....................................................................................................152 bar (2205 psi) Bucket B port (XT and Z-Bar) ....................................................................................................290 bar (4206 psi)

Bur 5-2980

Issued 8-06

Printed in U.S.A.

8005-4

1 2 4 3 5 22 6 6

21

7

6

20 19

8 18

6

17

9

16

10 11

6 15

14 8 12

12

13

BS03C033

1. BOLT 2. WASHER 3. LOCKING SCREWS 4. PLATE 5. REGENERATION RELIEF VALVE 6. O-RINGS

7. LOAD SENSE SHUTTLE CHECK 8. ANTICAVITATION AND CIRCUIT RELIEF

13. FLOAT SOLENOID

18. LOAD CHECK

14. PLUG

19. FLOW LIMIT VALVE

10. FLOW COMPENSATOR SPOOL

15. REGENERATION CHECK VALVE 16. LOCKING SCREW

21. CONE

11. HOUSING

17. SPRING

22. LOCKING SCREW

9. LOAD SENSE BLEED DOWN ORIFICE

20. PRESSURE RELIEF VALVE

12. PLUG 2 SPOOL VALVE HOUSING CONFIGURATION

Bur 5-2980

Issued 8-06

Printed in U.S.A.

8005-5

26

27

25 24 23 28

6 31

29 30

6 6 33 31

34 6 34

6

24

33 32

24

23 23 35

30

32

29 BC06F593

6. 23. 24. 25. 26.

O-RINGS SPRING RETAINER SPRING SPRING COVER

27. 28. 29. 30. 31.

BOLT PISTON CAP NUT JAM NUT PISTON

32. 33. 34. 35.

BOLT COVER ADJUSTING ROD SPOOL

2 SPOOL VALVE SPOOL CONFIGURATION

Bur 5-2980

Issued 8-06

Printed in U.S.A.

8005-6

37

36

37 BS03C036

36. HOUSING

37. ANTICAVITATION AND CIRCUIT RELIEF 3 SPOOL MOUNTING CONFIGURATION

Bur 5-2980

Issued 8-06

Printed in U.S.A.

8005-7

38 39

BS03C035

38. NUT

39. STUD

4 SPOOL MOUNTING CONFIGURATION

Bur 5-2980

Issued 8-06

Printed in U.S.A.

8005-8

31

29

30 33 6

34

6

23 24 32

23

35

33 31

23 24

6 34

6

29

32

30

BS03C037

3 AND 4 SPOOL VALVE SPOOL CONFIGURATION 6. 23. 24. 29. 30.

Bur 5-2980

O-RINGS SPRING RETAINER SPRING CAP NUT JAM NUT

31. 32. 33. 34. 35.

PISTON BOLT COVER ADJUSTING ROD SPOOL

Issued 8-06

Printed in U.S.A.

8005-9

DISSASEMBLY STEP 1

STEP 7

Remove valve from machine, see section 8001.

Remove pressure relief valve (20).

STEP 2

STEP 8

Remove bolts (27), cover (26), springs (24 and 25), and spring retainer (23).

Remove flow limit valve (19).

STEP 9 STEP 3 Remove bolts (32), covers (33), spring (24), and spring retainer (23).

Remove locking screw (16), spring (17), and cone (18).

STEP 10 STEP 4

Remove regeneration check valve (15).

Use wooden dowel or brass drift and push spools (35) from housing (11).

STEP 11

IMPORTANT: Do not force spools from housing, if spool binds work back and forth until spool comes out freely.

Remove locking screw (14).

NOTE: Repeat steps 3 and 4 for a 3 and 4 spool valve configuration.

Remove load sense shuttle check valve (7).

STEP 5

Remove locking screws (12).

Remove anticavitation valves (5, 8, 10, and 13). NOTE: Repeat step for a 3 and 4 spool anticavitation valves (37).

STEP 6 Remove locking screw (22) and cone (21).

STEP 12 STEP 13 STEP 14 Remove pilot pressure reducing valve (9).

STEP 15 Remove bolts (1) and washers (2), remove plate (4) from housing (11). NOTE: For 4 spool configuration remove nut (38) from stud (39), remove housings (36) from housing (11).

Bur 5-2980

Issued 8-06

Printed in U.S.A.

8005-10

STEP 16

STEP 18 2 1 2

1

1

1

BS03C025

BS03C027

Remove and discard O-rings and thrust rings from pilot pressure reducing valve (9).

Remove and discard O-rings and thrust ring from locking screw (14).

1. O-RINGS

2. THRUST RINGS

1. O-RINGS

2. THRUST RING

STEP 17 STEP 19

2

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 (19).

Bur 5-2980

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 8-06

Printed in U.S.A.

8005-11

STEP 20

1 2

1 1 2 2 BS03C029

1. O-RINGS

2. THRUST RINGS

Remove and discard O-rings and thrust rings from pressure relief valve (20).

STEP 21 1 1 2 1 2

2

1 BS03C030

1. O-RINGS

2. THRUST RINGS

Remove and discard O-rings and thrust rings from anticavitation and pressure relief valves (10).

Bur 5-2980

Issued 8-06

Printed in U.S.A.

8005-12

STEP 22 1

2 1

1

1

BS03C031

1. O-RINGS

2. COIL

Remove and discard O-rings and thrust rings from anticavitation valve (13).

Bur 5-2980

Issued 8-06

Printed in U.S.A.

8005-13

STEP 23

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 37).

Bur 5-2980

Issued 8-06

Printed in U.S.A.

8005-14

INSPECTION 1. Discard all O-rings, thrust rings, and spool seals. 2. Clean all parts in cleaning solvent. 3. Check the spools and the spool bores for damage and wear.

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 37). Torque relief valve (A) into anticavitation valve to 200 Nm (147.5 pound feet). NOTE: Spool seal mounting position is critical, seal must be mounted with lip facing as shown above, pressure is in direction of arrow.

Bur 5-2980

Issued 8-06

Printed in U.S.A.

8005-15

STEP 2 1

2 1

1

A 1

BS03C031

1. O-RINGS

2. COIL

Install new O-rings and thrust rings on anticavitation valve (13). Hand tighten coil nut (A).

STEP 3 1 1 2 1 2

2

A

1

BS03C030

1. O-RINGS

2. THRUST RINGS

Install new O-rings and thrust rings on anticavitation and pressure relief valves (10). Torque cap (A) to 100 Nm (73.7 pound feet).

Bur 5-2980

Issued 8-06

Printed in U.S.A.

8005-16

STEP 4

1 2

1 1 2 2 BS03C029

1. O-RINGS

2. THRUST RINGS

Install new O-rings and thrust rings on pressure relief valve (20).

Bur 5-2980

Issued 8-06

Printed in U.S.A.

8005-17

STEP 5

STEP 8 2

1

1

1 1

3

1

2 BS03C025

BS03C028

Install new O-rings and thrust rings on pilot pressure reducing valve (9).

Install new O-rings, thrust ring, and spool seal on anticavitation valve (5).

STEP 6

STEP 9

1. O-RINGS

2. THRUST RINGS

1. O-RINGS

2. THRUST RING

3. SPOOL SEAL

Install and torque regeneration check valve (15) to 100 Nm (73.7 pound feet).

2

STEP 10 Install and torque locking screw (14) to 100 Nm (73.7 pound feet).

2 1

STEP 11

1

Install and tighten load sense shuttle check valve (7).

STEP 12 BS03C026

1. O-RINGS

2. THRUST RINGS

Install and torque locking screws (12) to 240 Nm (177 pound feet).

Install new O-rings and thrust rings on flow limit valve (19).

STEP 13

STEP 7

Install and torque pilot pressure reducing valve (9) to 60 Nm (44 pound feet).

STEP 14 1

Install new O-rings on housing (11). Install plate (4), bolts (1) and washers (2), onto housing (11). Torque bolts to 70 Nm (51.5 pound feet).

2

NOTE: For 4 spool configuration install new O-rings between housings (36) and housing (11), install nuts (38) on studs (39). Torque nuts to 70 Nm (51.5 pound feet).

1

STEP 15 BS03C027

Install anticavitation valves (5, 10, and 13) and torque to 100 Nm (73.7 pound feet).

Install new O-rings and thrust ring on locking screw (14).

NOTE: Repeat step for a 3 and 4 spool anticavitation valves (37).

1. O-RINGS

Bur 5-2980

2. THRUST RING

Issued 8-06

Printed in U.S.A.

8005-18

STEP 16

Circuit Relief Pressure Test

Install anticavitation valves (8) and torque to 200 Nm (147.5 pound feet).

STEP 1

STEP 17

Connect the hand pump to the port for anticavitation and circuit relief valves (21).

Install and torque flow limit valve (19) to 20 to 25 Nm (177 to 221 pound inches).

STEP 18 Install cone (18), spring (17), locking screw (16). Torque locking screw to 100 Nm (73.7 pound feet).

STEP 19 Install cone (21) and locking screw (22). Torque locking screw to 40 Nm (30 pound feet).

NOTE: Repeat steps for machines configured with a 3 or 4 spool valve.

that

are

STEP 2 Make sure that the hand pump is full of hydraulic oil and that the temperature of the oil is approximately 21°C (70°F).

STEP 3

STEP 20

Operate the handle of the hand pump and read the highest pressure. Repeat this step several times to be sure of the reading.

Lubricate spools with hydraulic oil and push spools (35) into housing (11).

STEP 4

IMPORTANT: Do not force spools into housing.

Compare the reading to the specifications on Page 3.

STEP 21

STEP 5

Install spring retainers (23), springs (24), covers (33), and bolts (32). Torque bolts to 10.4 Nm (92 pound inches).

If the pressure is not correct, adjust the circuit relief valve.

NOTE: Repeat steps 18 and 19 for a 3 and 4 spool valve configuration.

Circuit Relief Adjustment STEP 1

STEP 22 Install spring retainers (23), spring (24 and 25), cover (26), and bolts (27). Torque bolts to 6 Nm (53 pound inches). NOTE: Prior to installation in the machine, circuit reliefs can be tested.

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 STEP 23 Install valve in machine, see section 8001.

Check the pressure again. Repeat the adjustment as necessary.

STEP 24 Check loader limit pressure, see section 8002.

Bur 5-2980

Issued 8-06

Printed in U.S.A.

Section 8006

8006

CYLINDERS


Bur 5-3280


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

Bur 5-3280

Issued 8-06

3 3 3 4 4 4 6 7 7 7 9 11 11 11 12 12 12

Printed in U.S.A.

8006-3

SPECIFICATIONS Approximate weight Lift Cylinder...........................................................................................................................142.2 kg (313.5 pounds) Bucket Cylinder........................................................................................................................199.2 kg (439 pounds)

SPECIAL TORQUES Gland Bolts Bucket Cylinder .......................................................................420 to 500 Nm (310 to 368.8 pound-feet) Screw in Gland for Lift Cylinders ...................................................................135 to 542 Nm (100 to 400 pound-feet) Piston Bolt for Lift Cylinders................................................................2830 to 3220 Nm (2087 to 2374.9 pound-feet) Lock Screw for Lift Cylinders ............................................................................................. 2.3 Nm (20 pound-inches)

SPECIAL TOOLS Torque Multiplier ......................................................................................................................................... CAS-1039

Bur 5-3280

Issued 8-06

Printed in U.S.A.

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. Loosen and remove self-tapping screw (12).

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. Use a spanner wrench to loosen and remove gland (4) from tube (1). 5. Pull piston rod (13) straight out of tube (1) to prevent damage to tube. 6. 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. 7. Use a torque multiplier, CAS-1039, to loosen and remove bolt (14) that fastens piston (15) to piston rod (13). 8. Remove piston (15) from piston rod (13). 9. Remove gland (4) from piston rod (13). 10. Remove and discard seal (16), ring (17), and wear ring (18) from piston (15).

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 (1) 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.

11. Remove and discard O-ring (10), backup ring (9), O-ring (11), wiper (5), rod seal (6), buffer seal (7), and bushing (8) from gland (4).

Bur 5-3280

Issued 8-06

Printed in U.S.A.

8006-5

13

5 6 7 4 8 11 9 10 15

12

17 16 18 14 1 3 2

2 3

BC05J002

1. 2. 3. 4. 5.

TUBE BUSHING WIPER GLAND WIPER

6. 7. 8. 9. 10.

ROD SEAL BUFFER SEAL BUSHING BACKUP RING O-RING

11. 12. 13. 14. 15.

O-RING SCREW ROD BOLT PISTON

16. SEAL 17. RING 18. WEAR RING

LIFT CYLINDER Bur 5-3280

Issued 8-06

Printed in U.S.A.

8006-6

Assembly

17. Install a new ring (17) in the other groove on the outside of the piston (15).

NOTE: If a new gland is being used, put part number of cylinder on new gland.

18. Install a new seal (16) on top of ring (17).

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. 3. Install buffer seal (7) in gland (4). The side of buffer seal with groove must be toward bushing (8). 4. Install a new wiper (5) in gland (4). Lips of wiper must be toward outside end of gland (4). 5. Install a new O-ring (11) in groove on OD of gland (4). 6. 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). 7. Install a new O-ring (10) next to backup ring (9) in groove on outside of gland (4). O-ring must be toward small end of gland. 8. Fasten piston rod (13) eye or yoke in vise. 9. Remove any marks and sharp edges on chamfer at end of piston rod (13). Make sure that piston rod is clean. 10. Lubricate bore of gland (4) and piston rod (13) with clean oil. 11. Push gland (4) onto piston rod (13). If necessary, use a soft hammer to drive gland onto piston rod. 12. 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. 13. Start piston (15) onto piston rod (13). 14. Clean the threads on the end of the piston rod (13) and the threads of the bolt (14) using Loctite cleaning solvent. Allow to dry. Apply Loctite 242 to piston rod threads 6.3 mm (1/4 inch) from open end of piston rod so that there is 13 mm (1/2 inch) of Loctite 242 on piston rod threads. DO NOT apply Loctite to first 6.3 mm (1/4 inch) of piston rod threads.

19. Fasten tube (1) in an acceptable repair stand or other holding equipment. Be careful to prevent damage to tube. 20. Lubricate inside of the tube (1) and piston (15) with clean oil. 21. Push piston (15) straight into tube (1). 22. When the piston (15) is in smooth part of tube (1), start gland (4) into tube. 23. Lubricate O-rings (10 and 11) on gland (4) with clean oil. 24. Turn gland (4) into tube (1). Tighten gland to a torque of 135 to 542 Nm (100 to 400 pound-feet). 25. If the original parts are being assembled: A. Tighten gland to a torque of 135 to 542 Nm (100 to 400 pound-feet). B. Install and tighten self-tapping screw (12) to a torque of 2.3 Nm (20 inch-pounds). C. If, after tightening gland, the self-tapping screw (12) holes are not aligned, a new hole for self-tapping screw must be drilled. See Step 26. 26. If a new gland (4) or a new tube (1) are being assembled: A. Tighten gland (4) to 135 to 542 Nm (100 to 400 pound-feet). B. Use a No. 27 drill bit and drill a hole half in gland (4) and half in tube (1). Drill to a depth of 11 mm (7/16 inch). Do not drill within 13 mm (1/2 inch) of a hole for gland wrench. C. Install and tighten self-tapping screw (12) to a torque of 2.3 Nm (20 inch-pounds). 27. If hoses were removed with cylinder, install new O-rings, if equipped, on hose fittings. Lubricate O-rings with clean oil. Install hoses.

15. Install bolt (14) into piston rod (13). Tighten bolt to a torque of 2830 to 3220 Nm (2087 to 2374.9 pound-feet). A torque multiplier can be used to help torque the bolt. 16. Install a new wear ring (18) in wide groove on outside of piston (15).

Bur 5-3280

Issued 8-06

Printed in U.S.A.

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 O-ring (16), backup ring (15), wiper (12), wide seal (13), narrow seal (14), and bushing (17) from the gland (3).

Bur 5-3280

Issued 8-06

Printed in U.S.A.

8006-8

19 20 19

4 2 18 3 17

15

12

16 11 7

13 14

8 8

9

6 1

5 10

19

20 19 BC05M026

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 O-RING

17. 18. 19. 20.

BUSHING HARDENED WASHER SEAL BUSHING

BUCKET CYLINDER

Bur 5-3280

Issued 8-06

Printed in U.S.A.

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 O-ring (16) next to the backup ring (15) in the groove on the outside of the gland (3). The O-ring (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).

Bur 5-3280

Issued 8-06

Printed in U.S.A.

8006-10 19. Install a new wear ring (5) in the wide groove on the OD of the piston (7). 20. Install a new seal (6) in the groove on the OD of the piston (7).

27. Tighten the cap screws (2) in the sequence shown. Torque to 420 to 500 Nm (310 to 368.8 pound-feet).

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). BC05M027

TUBE AND GLAND HOLE ALIGNMENT

Bur 5-3280

Issued 8-06

Printed in U.S.A.

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

Bur 5-3280

Issued 8-06

Printed in U.S.A.

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

4 1 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

Bur 5-3280

Issued 8-06

Printed in U.S.A.

Section 8007

8007

COUPLER SOLENOID LOCKING VALVE


Bur 6-42600


8007-2

TABLE OF CONTENTS coupler solenoid locking valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 6-42600

Issued 4-03

3 3 3 3

Printed in U.S.A.

8007-3

COUPLER SOLENOID LOCKING VALVE Disassembly

STEP 11 Install solenoid (2) on valve cartridge (3).

STEP 1 Clean exterior of valve.

STEP 12 Install nut (1) to secure solenoid (2).

STEP 2 Remove nut (1) and solenoid (2) from valve cartridge (3).

1

STEP 3 Remove valve cartridge (3) from valve housing (7).

2

STEP 4 Remove and discard all O-rings (4 and 5) and back-up rings (6).

Cleaning and Inspection STEP 5

3

Immerse valve cartridge (3) and valve housing (7) in cleaning solvent and agitate cleaning solvent. WEAR EYE PROTECTION WHEN USING COMPRESSED AIR. Use compressed air to remove foreign matter from interior of valve cartridge and housing and to ensure that all passage ways and bores are clear.

4 6

STEP 6

5

Check valve cartridge for (3) for cracks, breaks, chipping, or other damage. Replace if any of these conditions are seen.

6 6 5

STEP 7

6

6

Check bores in valve housing (7) for deep scratches, gouges, and other damage. Replace valve if any of these conditions are seen.

5 7

6

STEP 8 Connect an ohmmeter across terminals of solenoid (2) connector. Replace solenoid (2) and valve cartridge (3) if ohmmeter indicates short or open circuit.

Assembly STEP 9 Install new O-rings (4 and 5) and back-up rings (6) as shown.

GS98J818

1. 2. 3. 4.

NUT SOLENOID VALVE CARTRIDGE O-RING

5. O-RING 6. BACKUP RING 7. VALVE HOUSING

STEP 10 Lubricate O-rings (4 and 5) using clean oil then install valve cartridge (3) in valve housing (7). Bur 6-42600

Issued 4-03

Printed in U.S.A.

8007-4

NOTES

Bur 6-42600

Issued 4-03

Printed in U.S.A.

8013

Section 8013 RIDE CONTROL ACCUMULATOR


Bur 5-3000


8013-2

TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ACCUMULATOR SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHARGING THE ACCUMULATOR WITH NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 5-3000

Issued 8-06

3 3 3 4 5 5 5 5 7

Printed in U.S.A.

8013-3

SPECIFICATIONS Ride Control Accumulator Dry Nitrogen Pressure ...................................................................... See chart on page 8 Ride Control Accumulator Fluid Capacity ............................................................................. 3.79 liters (231 cu. inch) Ride Control Accumulator Maximum Operating Pressure ...........................................................248.4 bar (3600 psi)

ACCUMULATOR SPECIAL TORQUES Accumulator Gas Charging Valve Cap .................................................................................13.6 Nm (10 pound-feet) Gas Charging Valve.............................................................................................88 to 102 Nm (65 to 75 pound-feet) Cap screws for the protection bracket .......................................................... 54 to 61 Nm (480 to 540 pound-inches) Gland .............................................................................................................163 to 176 Nm (120 to 130 pound-feet)

SPECIAL TOOLS

94L95

CAS10899 NITROGEN ACCUMULATOR CHARGING KIT

Bur 5-3000

B786441M

CAS1456 GLAND WRENCH

Issued 8-06

Printed in U.S.A.

8013-4

DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR

E

C

F

D

A

B

94L95

CAS10899 NITROGEN CHARGING KIT

1. Use the CAS-10899 Nitrogen Charging Kit to d i s c h a r g e t h e a c c u m u l a t o r, r e fe r t o t h e 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.

Bur 5-3000

Issued 8-06

Printed in U.S.A.

8013-5

ACCUMULATOR Disassembly

Assembly

NOTE: Refer to Section 8001 for the proper procedure for the removal of the ride control accumulator. WA R N I N G : D O N O T a t t e m p t t o disassemble any accumulator until the nitrogen charge is properly discharged. SM386

1. Fasten the body (1) in a vise. Be careful not to damage the body (1), refer to the illustration on page 6. 2. Remove the screws (9) and guard (11) from the body (1). 3. Remove the pressure valve (12) from the body (1). 4. Remove and discard the O-ring (10) from the pressure valve (12). 5. Loosen and remove the cap (8) from the body (1). 6. Loosen and remove the gland (3) from the body (1).

1. Fasten the body (1) in a vise. Be careful not to damage the body (1). Refer to the illustration on page 6. 2. Install a new wear ring (5), O-ring (7) and backup ring (6) on the piston (4). 3. Lubricate the bore of the body (1) and the piston (4) with clean oil. 4. Start the piston (4) into the body (1), round surface first. Then push the piston (4) farther into the body (1). NOTE: The piston (4) must be installed squarely and slowly into the body (1). Once the piston (4) is started straight into the bore of the body (1), use a hammer and wood block to gently tap the piston into the polished area of the bore. Keep force on the piston (4) while tapping into the bore or damage may occur to the O-ring. 5. Install and tighten the cap (8) into the body (1). 6. Install new seals (2) on the gland (3).

7. Remove the piston (4) from the body (1).

7. Lubricate the seals (2) with clean oil and start the gland (3) into the body (1).

8. Remove and discard the wear ring (5), O-ring (7) and the backup ring (6) from the piston (4).

8. Tighten the gland (3).

9. Remove the seals (2) from the gland (3).

9. Install a new O-ring (10) on the pressure valve (12).

Inspection 1. Clean body (1), gland (3), cap (8) and piston (4) in cleaning solvent, refer to the illustration on page 6. 2. Inspect the piston (4) for cracks, burrs or other damage. 3. Inspect the bore of the body (1) for scratches or scoring using a light.

10. Install the pressure valve (12) in the body (1). 11. Install the guard (11), screws (9) in the body (1). 12. Charge the accumulator with dry nitrogen according to instructions on page 7. WA R N I N G : U s e o n l y n i t r o g e n w h e n charging the accumulator. DO NOT use air or oxygen that will cause an explosion. SM115A

NOTE: Minor scratches or scoring in the bore of the body (1) can be removed using crocus cloth. 4. Inspect the pressure valve (12) and replace as needed.

Bur 5-3000

Issued 8-06

Printed in U.S.A.

8013-6

1

5

2 3

6

7

4

9

8

10

9

11

12

BS01B224

1. 2. 3. 4.

BODY SEALS (2) GLAND PISTON

5. 6. 7. 8.

WEAR RING BACKUP RING O-RING CAP

9. 10. 11. 12.

SCREW O-RING GUARD PRESSURE VALVE

RIDE CONTROL ACCUMULATOR ILLUSTRATION

Bur 5-3000

Issued 8-06

Printed in U.S.A.

8013-7

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 CAS10899

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.

Bur 5-3000

Issued 8-06

Printed in U.S.A.

8013-8 1. Close the shutoff valve A by turning it all the way to the left (counterclockwise), refer to the illustration on page 7. 2. Open valve B by turning it out all the way to the left (counterclockwise). 3. Close valve C by turning it all the way to the right (clockwise). 4. Close the gauge valve D by turning it all the way to the right (clockwise). 5. Connect the charging hose to the nitrogen supply tank. 6. SLOWLY turn valve A clockwise while watching the high pressure gauge. Stop turning valve A when the needle on the gauge reaches 31 bar (450 psi). NOTE: If the needle goes over the needed pressure, quickly open and close valve D and check the pressure setting again. The charging kit is now ready to be installed on the accumulator. 7. Remove the two cap screws (9) and the protection bracket (11) from the body (1) on the accumulator, refer to the illustration on pages 6. 8. Remove the valve cap from the pressure valve (12) on the accumulator. 9. Back off the needle valve on the accumulator end of the charging hose by tur ning it counterclockwise to the maximum amount. This prevents nitrogen from escaping from the accumulator when the charging hose is attached to the accumulator gas charging valve. 10. Install the charging hose fitting onto the accumulator pressure valve (12). 11. Tighten the needle valve by turning it clockwise. Slowly open the gauge valve D and observe the reading on the gauge. This reading is the nitrogen pressure level inside the accumulator.

Bur 5-3000

12. Open the shutoff valve A on the nitrogen supply tank. While observing the pressure on the gauge, slightly open the needle valve on the accumulator charge hose. By regulating the needle valve, fill the accumulator to pressure according to temperature chart below. Close the needle valve. Close the shutoff valve A on the nitrogen supply tank. TEMPERATURE 10° C 50° F 13° C 55° F 16° C 60° F 18° C 65° F 21° C 70° F 24° C 75° F 27° C 80° F 29° C 85° F 32° C 90° F 35° C 95° F 38° C 100° F

CHARGE PRESSURE 1606 KPA 233 PSI 1634 KPA 237 PSI 1669 KPA 242 PSI 1696 KPA 246 PSI 1724 KPA 250 PSI 1751 KPA 254 PSI 1779 KPA 258 PSI 1813 KPA 263 PSI 1841 KPA 267 PSI 1868 KPA 271 PSI 1896 KPA 275 PSI

TEMPERATURE/CHARGE PRESSURE RIDE CONTROL ACCUMULATOR

13. Close valve B by turning to the right (clockwise). After a few minutes, check the accumulator for leakage. 14. Back off the needle valve on the accumulator end of the charging hose by tur ning it counterclockwise the maximum amount. This will p r eve n t n it r o g e n f r o m e s c a p i n g f r o m t h e accumulator as the hose is removed. Remove the charging hose from the accumulator pressure valve (12). 15. Install the valve cap onto the pressure valve (12) on the accumulator. 16. Install the protection bracket (11) over the pressure valve (12) and secure it with cap screws (9). 17. Remove the charging hose from the nitrogen supply tank.

Issued 8-06

Printed in U.S.A.

8014

Section 8014 RIDE CONTROL VALVE


Bur 5-3010


8014-2

TABLE OF CONTENTS RIDE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dissasembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 5-3010

Issued 8-06

3 3 3 4

Printed in U.S.A.

8014-3

RIDE CONTROL VALVE 9

10

11

8

13 12

7 15

6

14

5 4

16

3 2

17

1

BC05B015.

1. 2. 3. 4. 5.

PLUG CAP SCREW BUSHING SPRING CARRIER SPRING

6. 7. 8. 9.

SPRING SPOOL PLUG PLUG

10. 11. 12. 13.

Dissasembly

ACCUMULATOR DRAIN SCREW PLUG SOLENOID ORFICE

14. 15. 16. 17.

POPPET ORFICE VALVE BLOCK RELIEF VALVE

STEP 8 Remove the pressure relief valve (17).

STEP 1 Remove ride control valve, refer to section 8001.

STEP 2

Inspection 1. Discard all O-rings.

Remove plugs (1), (8), (9), and (11).

2. Clean all parts in cleaning solvent.

STEP 3

3. Check the spools and the spool bores for damage and wear.

Remove the solenoid (12).

4. Check the parts of the pressure relief valve.

STEP 4

If any of the parts are damaged, install new parts.

Remove the spool (7) from the valve block (16).

STEP 5 Remove cap screw (2), bushing (3), spring carrier (4), springs (5 & 6) from spool (7).

STEP 6 Remove orifice (13), poppet (14), and orifice (15).

STEP 7 Remove accumulator drain screw (10). Bur 5-3010

Issued 8-06

Printed in U.S.A.

8014-4

Assembly

STEP 6

STEP 1 Install new O-rings.

Install springs (5 &6), spring carrier (4), bushing (3), cap screw (2) onto spool (7) and torque cap screw (2) to 5.5 Nm (48.5 lb-in).

STEP 2

STEP 7

Install and torque pressure relief valve (17) to 50 Nm (37 lb-ft).

Install spool (7) into valve block (16).

STEP 3

Install and torque plug (1) to 270 Nm (199 lb-ft).

Install and torque accumulator drain screw (10) to 3.5 Nm (31 lb-in). Install the plug for accumulator drain screw and torque to 7 Nm (62 lb-in).

STEP 9

STEP 4 Install and torque orifice (15) to 15 Nm (11 lb-ft), install poppet (14), install and torque orifice (13) to 15 Nm (11 lb-ft).

STEP 8

Install plug (8) and torque to 140 Nm (103 lb-ft), plug (9) and torque to 30 Nm (22 lb-ft), and plug (11) and torque to 90 Nm (66 lb-ft).

STEP 10 Install the ride control valve in the machine, see section 8001.

STEP 5 Install and torque solenoid valve to 12 Nm (106 lb-in).

STEP 11 Test the ride control system, see section 8002.

Bur 5-3010

Issued 8-06

Printed in U.S.A.

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


Bur 5-3290


9002

Section 9002 AIR CONDITIONING TROUBLESHOOTING AND SYSTEM CHECKS FOR SYSTEMS WITH HFC-134A REFRIGERANT


Bur 5-4030


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

Bur 5-4030

Issued 8-06

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 U.S.A.

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 M171B PERSONAL INJURY OR DEATH.

ATTENTION: Only authorized technicians certified by an approved training and certification organization may service or repair motor vehicle or mobile air conditioning systems. It is mandatory that all refrigerant must be RECOVERED and RECYCLED when removed from a system during servicing. Refrigerant HFC-134a is the most stable, and easiest to work with of the refrigerants now used in air conditioner systems. Refrigerant HFC-134a does not contain any chlorofluorocarbons (CFC’s) which are harmful to the earth’s ozone layer. Safety procedures must be followed when working with Refrigerant HFC-134a to prevent possible personal injury. 1. Always wear safety goggles when doing any service work near an air conditioner system. Liquid refrigerant getting into the eyes can cause ser ious injur y. Do the following if you get refrigerant near or in your eyes: A. Flush your eyes with water for 15 minutes.

3. Keep refrigerant containers in the correct upright position. Always keep refrigerant containers away from heat and sunlight. The pressure in a container will increase with heat. 4. Always reclaim refrigerant from the system, if you are going to weld or steam clean near the air conditioner system. 5. Always check the temperature and pressure of the air conditioner system before reclaiming refrigerant and when you test the system. 6. Dangerous gas can form when refrigerant comes in contact with an open flame. Never permit fumes to be inhaled. 7. Never leak test with compressed air or flame testers. Tests have indicated that compressed mixtures of HFC-134a and air can for m a combustible gas. 8. Always reclaim refrigerant from the system before removing any air conditioning component.

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.

Bur 5-4030

Issued 8-06

Printed in U.S.A.

9002-4

299L7C

BELT TENSION TOOL CAS-10808

A22094

REFRIGERANT RECOVERY, RECYCLING AND CHARGING STATION, OEM-1415

A22090 109L7

ELECTRONIC LEAK DETECTOR OEM-1437 SAFETY GOGGLES CAS-10073-3

Bur 5-4030

Issued 8-06

Printed in U.S.A.

9002-5

OPERATION 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.

The refrigerant, still in a high pressure liquid form, then flows from the receiver-drier to the expansion valve. The expansion valve then causes a restriction in flow of refrigerant to the evaporator core. The evap orator mete rs refr ig erant flow based on evaporator heat load. 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 operator’s comfort.

The compressor receives the refrigerant as a low pressure gas. The compressor then compresses the refrigerant and sends it in the form of a high pressure gas to the condenser. The air flow through the c o n d e n s e r t h e n r e m o ve s t h e h e a t f r o m t h e refrigerant. As the heat is removed the refrigerant changes to a high pressure liquid. The high pressure refrigerant liquid then flows from t h e c o n d e n s e r t o t h e r e c e i v e r - d r i e r. T h e receiver-drier is a container filled with moisture removing material, which removes any moisture that may have entered the air conditioner system in order to prevent corrosion of the internal components of the air conditioner system.

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.

1

2

3 5 4

208L95

1. EXPANSION VALVE 2. EVAPORATOR

Bur 5-4030

3. COMPRESSOR 4. CONDENSER

5. RECEIVER-DRIER

Issued 8-06

Printed in U.S.A.

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

Bur 5-4030

Issued 8-06

Printed in U.S.A.

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.

Bur 5-4030

Issued 8-06

Printed in U.S.A.

9002-8

SYSTEM CHECKS Mechanical Compressor Check Compressor and Fan Belts

1. Too much belt wear - replace a worn belt, because a worn belt will cause too much slippage.

Compressor Mounting Brackets

1. Loose bracket mounting bolts - tighten the bolts to the correct torque. 2. Bracket has cracks or breaks - replace the bracket.

Compressor Clutch

1. The compressor belt will slip on the compressor pulley if there is compressor seizure. Remove the compressor for service or replacement. 2. Remove the dust cover and check the air gap on the compressor clutch. The gap b e t w e e n t h e f r o n t p l a t e a n d p u l l ey assembly must be 0.41 to 0.79 mm. 3. Use a socket wrench to slowly rotate the compressor clockwise. Compressor rotation should be smooth and not require much effort.

Pulley and Belt Alignment

1. The compressor pulley and the compressor drive pulley must be aligned within 1.6 mm (1/16 inch) of each other. Use a straight edge to check pulley alignment. Adjust the compressor mounting bracket if needed.

Bur 5-4030

Issued 8-06

Printed in U.S.A.

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

Bur 5-4030

NOTE: Blower must be operating, since electrical power to temperature control switch is received from blower switch. 2. Turn the blower off. Disconnect the wires from the temperature control. Using an ohmmeter, check the continuity between switch ter minals. If continuity is not present when switch is on maximum cold, replace switch.

Issued 8-06

Printed in U.S.A.

9002-10

Cab Temperature Check Air Louvers

1. Make sure louvers and recirculation vents are fully open for most efficient air conditioning operation. Defrost louvers must be closed. 2. Check blower; blower must be running.

ATTENTION: Use caution when feeling hoses. Hoses become very hot. Check temperature by slowly reaching for hose and touching briefly several times with finger tips, increasing the duration with each touch. Air Conditioning

1. Feel the air conditioning hoses. The high pressure hoses (small line) must be warmer than the low pressure hose (large line). 2. If no temperature difference, the system is low on refrigerant, or compressor is not working correctly.

1. Put a thermometer in the air duct behind the seat and r u n t h e c o m p r e s s o r fo r f i v e m i n u t e s t o m a k e temperature stable. Refer to page 12. 2. Duct temperature must be below 25° C (72° F) if the system is operating at maximum efficiency. Duct Temperature

Temperature Sensing Probe Check

Bur 5-4030

NOTE: Ambient temperature must be 27 to 43° C (80 to 110° F). 3. If temperature is above 25° C (72° F), system is low on refr igerant, there is a restr iction in the system, compressor is not working correctly, or air ducts are not sealed correctly.

1. Turn the engine OFF, key switch ON, blower switch ON and temperature control switch turned fully clockwise. 2. Remove the temperature sensing probe from the evaporator. Refer to Section 9004. 3. Put the end of the temperature sensing probe in a container with ice and water. 4. When the sensing tube has cooled to the temperature of the ice and water mixture, the temperature control switch should interrupt the current flow to the compressor. Check for current at the control switch terminals as on previous page. If current is not interrupted then replace the control switch.

Issued 8-06

Printed in U.S.A.

9002-11

Visual and Leak Check Compressor Hoses

1. Make sure that all hose connections are tight. 2. Check hoses for bends or cracks. Replace all hoses that have damage.

1. Shut off the engine.

Leak Finding Check

WARNING: When refrigerant comes in contact with an open flame, it can form dangerous gas. Never breathe these fumes. 2. Use electronic leak detector OEM -1437 to inspect all connections. Use instructions from manufacturer of leak finding tool. NOTE: When checking compressor seal for a leak, remove the dust cover and rotate the clutch shaft clockwise. NOTE: To properly check the expansion valve for leaks, remove the insulation tape. 3. Repair all leaks and recharge the system. See Section 9003.

Condenser

Bur 5-4030

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 8-06

Printed in U.S.A.

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 r e s t r i c t i o n s. I f t h e c o r e i s d r y, u s e compressed air or a brush and vacuum cleaner. If the core is wet or filled with mud, flush the core with water using a hose without pressure. Make sure the water drains freely from the evaporator/heater core. DO NOT USE STEAM. WARNING: Do not steam clean any air conditioning systems parts while the system is charged. The heat will cause the refrigerant to rise to a pressure that could cause the system to explode.

Evaporator/Heater Core Sealing

1. See Section 9004 for access to the evaporator/heater core. 2. Make sure seals are in place so blower will pull air only through the evaporator/heater core and not around the evaporator/heater core.

Filters

1. Make sure the filters are clean.

Bur 5-4030

Issued 8-06

Printed in U.S.A.

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 C o n n e c t t h e m a n ifo l d g a u g e s e t i n t o t h e a i r conditioning system as shown. Make sure that both valves in the manifold gauge set are closed.

LOW PRESSURE GAUGE - The low pressure gauge is a compound gauge. It is best used to judge eva cuat io n effe ctiven ess. A vac uum rea ding indicates a system malfunction. For this reason, it is necessar y to use a compound gauge that will indicate both pressure and vacuum.

Bur 5-4030

Issued 8-06

Printed in U.S.A.

9002-14

PRESSURE-TEMPERATURE CHART AIR LOUVER (BEHIND SEAT) MAXIMUM TEMP. TEMPERATURE PRESSURE INDICATION PRESSURE INDICATION °F (°C) psi (bar) psi (bar) °F (°C) AMBIENT

NORMAL LOW

NORMAL HIGH

80 (27)

9 to 12

145 to 165

(0.62 to 0.83)

(10 to 11.53)

11 to 15

190 to 210

(0.76 to 1.04)

(13.10 to 14.48)

16 to 18

210 to 230

(1.10 to 1.24)

(14.48 to 15.86)

17 to 19

235 to 255

(1.17 to 1.31)

(16.2 to 17.58)

20 to 21

260 to 280

(1.38 to 1.45)

(17.93 to 19.31)

22 to 24

290 to 310

(1.93 to 2.14)

(20 to 21.37)

90 (32) 95 (35) 100 (38) 105 (41) 110 (43)

The pressure-temperature chart is based on the following conditions: NOTE: High humidity will cause higher air louver temperatures and dramatic increase in suction pressure. The table shown represents readings taken in low relative humidity. Adjust the chart according to local conditions.

55 (14) 61 (18) 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

Bur 5-4030

Issued 8-06

Printed in U.S.A.

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 SM104A system to explode.

WARNING: Always wear safety goggles when working with liquid refrigerant. Liquid r e f ri g er a n t i n y o u r ey e s c o u l d c a u s e SM105A blindness.

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.

Bur 5-4030

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 8-06

Printed in U.S.A.

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 possible problems.

Bur 5-4030

Issued 8-06

test for other

Printed in U.S.A.

9002-17

HIGH

HIGH


476L7

Indication of Large Quantity of Air in System: 1. Evacuate and reclaim refrigerant from system. See Section 9003. 2. Replace receiver-drier. Discharge air from evaporator warm

Yes

3. Remove air and moisture from the system. See Section 9003. 4. Charge system with new refrigerant. See Section 9003.

Condenser Malfunctioning - Indications: 1. Check for loose or worn compressor or engine fan belt and proper condenser fan operation. 2. Check to see that condenser is clean and unobstructed and that the fins are straight. 3. Check system for too much refrigerant. Evacuate, reclaim and recharge refrigerant until gauge pressure is normal. See Section 9003. A. Liquid line (between evaporator and condenser) is very hot. B. Discharge air from evaporator warm.

4. Remove and check condenser for restrictions caused by oil or reduced heat transfer. A. Remove refrigerant from the system. See Section 9003. B. Use compressed condenser.

air

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.

Bur 5-4030

Issued 8-06

Printed in U.S.A.

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 ° F (° 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)

Bur 5-4030

Issued 8-06

Printed in U.S.A.

9002-19

PROBLEM: NOT ENOUGH COOLING

NORMAL TO SLIGHTLY HIGH

NORMAL


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.

Bur 5-4030

Issued 8-06

Printed in U.S.A.

9002-20

LOW

LO W


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

Bur 5-4030

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 8-06

Printed in U.S.A.

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.

Bur 5-4030

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 8-06

Printed in U.S.A.

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

Bur 5-4030

1. Replace expansion valve. See Section 9004.

Issued 8-06

Printed in U.S.A.

9002-23

HIGH

HIGH


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.

Bur 5-4030

Issued 8-06

Printed in U.S.A.

9002-24

PROBLEM: INTERMITTENT COOLING

NORMAL

NORMAL


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.

Bur 5-4030

Issued 8-06

Printed in U.S.A.

9002-25

PROBLEM: NOISE IN SYSTEM

NORMAL TO HIGH

HIGH


476L7

Too Much Refrigerant in System - Indications: A. Cool discharge air from heater/evaporator. B. Compressor makes noise.

Bur 5-4030

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 8-06

Printed in U.S.A.

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.

Bur 5-4030

Issued 8-06

Printed in U.S.A.

9003

Section 9003 AIR CONDITIONER SYSTEM SERVICE


Bur 5-3030


9003-2

TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAFETY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRESSURE - TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 5-3030

Issued 8-06

3 3 4 5 7 10

Printed in U.S.A.

9003-3

SPECIFICATIONS Air conditioning system refrigerant capacity ...................................................................................... 1.7 kg (3.75 lbs)

SPECIAL TOOLS

A22094

REFRIGERANT RECOVERY, RECYCLING AND RECHARGING STATION OEM-1415

Bur 5-3030

109L7

SAFETY GOGGLES CAS-10073-3

Issued 8-06

Printed in U.S.A.

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 M171B PERSONAL INJURY OR DEATH. 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 (CFC’s) which are harmful to the Earth’s ozone layer. Safety procedures must be followed when working with refrigerant HFC-134a to prevent possible personal injury. 1. Always wear safety goggles when doing any service work near an air conditioner system. Liquid refrigerant getting into the eyes can cause ser ious injur y. Do the following if you get refrigerant near or in your eyes: A. Flush your eyes with water for 15 minutes.

3. Keep refrigerant containers in the correct upright position. Always keep refrigerant containers away from heat and sunlight. The pressure in a container will increase with heat. 4. Always reclaim refrigerant from the system, if you are going to weld or steam clean near the air conditioner system. 5. Always check the temperature and pressure of the air conditioner system before reclaiming refrigerant and when you test the system. 6. Dangerous gas can form when refrigerant comes in contact with an open flame. Never permit fumes to be inhaled. 7. Never leak test with compressed air or flame testers. Tests have indicated that compressed mixtures of HFC-134a and air can for m a combustible gas. 8. Always reclaim refrigerant from the system before removing any air conditioning component.


Bur 5-3030

Issued 8-06

Printed in U.S.A.

9003-5

AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY Recovered refr igerant passes through an oil separator and a filter-drier before entering the refrigerant tank. The moisture indicator will turn green when dry refrigerant passes over it.

STEP 3

If possible, run the air conditioning system for ten minutes before starting the recovery process. Turn the system off before proceeding.

STEP 1

A22114

Open the high and low valves.

STEP 4

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 por t on the discharge hose. Tur n in valve depressor.

Bur 5-3030

Issued 8-06

Printed in U.S.A.

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.

Bur 5-3030

Issued 8-06

Printed in U.S.A.

9003-7

AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING IMPORTANT: Replace the receiver-drier if one or more of the following conditions occurs before you remove the air and moisture from the system. A. The system has been opened for service before. B. Receiver-drier has operated two or more years. C. Disassembly of compressor shows small particles of moisture removing material (gold or brown particles).

Air and moisture are removed from the system by a va c u u m p u m p. A v a c u u m p u m p i s t h e o n l y equipment made to lower the pressure enough to change the moisture to vapor that can be removed from the system. NOTE: Refer to the vacuum pump manufacturer’s user manual for additional information.

STEP 11

D. Large system leak (broken hose, break in line). E. Too much air or moisture in system. F. Removal of compressor caused the system to be open (uncapped) longer than 5 minutes.

STEP 10 A22113

Connect the main power plug to a 115 volt AC outlet. Move the main power switch to the ON position. If program and vacuum do not appear at the top of the display press the vacuum key. Program a minimum of 45 minutes and press the Enter key. The display will flash once indicating the programmed data has been accepted.

STEP 12 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.

Bur 5-3030

Issued 8-06

Printed in U.S.A.

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 star t. The display will show the amount of time programmed and begin a countdown to zero.

STEP 14

When the programmed time has elapsed, an automatic hold occurs. Check the low pressure gauge to see that the A/C system maintains a 28 to 29-1/2 inches of mercury (Hg). The low pressure gauge must not increase faster than one inch of mercury (Hg) in 10 minutes. A previously charged, l e a k - f r e e s y s t e m w i l l l e a c h r e f r i g e ra n t f r o m compressor oil and raise system pressure under vacuum. If the system will not hold vacuum, a leak exists that must be corrected before recharging can begin. See Section 9002 in the manual for a leak test. A22114

Fully open the low and high pressure valves.

STEP 17

STEP 15

A22113 A22107

Open the red (vapor) and blue (liquid) valves on the tank.

Bur 5-3030

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 8-06

Printed in U.S.A.

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. Bur 5-3030

Issued 8-06

Printed in U.S.A.

9003-10

PRESSURE - TEMPERATURE CHART AMBIENT NORMAL LOW NORMAL HIGH TEMPERATURE PRESSURE INDICATION PRESSURE INDICATION °F (°C) psi (bar) psi (bar)

AIR LOUVER MAXIMUM TEMP. °F (°C)

80 (27)

9 to 12 (0.62 to 0.83)

145 to 165 (10 to 11.5)

55 (14)

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.

Bur 5-3030

Issued 8-06

Printed in U.S.A.

REMOVAL AND INSTALLATION OF AIR CONDITIONING AND HEATER COMPONENTS


Bur 5-3040


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

Bur 5-3040

Issued 8-06

3 4 5 5 6 8 9 14 19 19 20

Printed in U.S.A.

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 M171B PERSONAL INJURY OR DEATH. ATTENTION: Only authorized technicians certified by an approved training and certification organization may service or repair motor vehicle or mobile air conditioning systems. It is mandatory that all refrigerant must be RECOVERED and RECYCLED when removed from a system during servicing. Refrigerant HFC-134a is the most stable, and easiest to work with of the refrigerants now used in air conditioner systems. Refrigerant HFC-134a does not contain any chlorofluorocarbons (CFC’s) which are harmful to the earth’s ozone layer. Safety procedures must be followed when working with Refrigerant HFC-134a to prevent possible personal injury. 1. Always wear safety goggles when doing any service work near an air conditioner system. Liquid refrigerant getting into the eyes can cause ser ious injur y. Do the following if you get refrigerant near or in your eyes: A. Flush your eyes with water for 15 minutes.

3. Keep refrigerant containers in the correct upright position. Always keep refrigerant containers away from heat and sunlight. The pressure in a container will increase with heat. 4. Always reclaim refrigerant from the system if you are going to weld or steam clean near the air conditioner system. 5. Always check the temperature and pressure of the air conditioner system before reclaiming refrigerant and when you test the system. 6. Dangerous gas can form when refrigerant comes in contact with an open flame. Never permit fumes to be inhaled. 7. Never leak test with compressed air or flame testers. Tests have indicated that compressed mixtures of HFC-134a and air can for m a combustible gas. 8. Always reclaim refrigerant from the system before removing any air conditioning component.


Bur 5-3040

Issued 8-06

Printed in U.S.A.

9004-4

SPECIAL TOOLS

A22094

REFRIGERANT RECOVERY, RECYCLING AND CHARGING STATION OEM-1415

Bur 5-3040

BS03H012

SAFETY GOGGLES CAS-10073-3

Issued 8-06

Printed in U.S.A.

9004-5

COMPRESSOR Removal

STEP 4


STEP 2 Discharge the air conditioning system according to the instructions in Section 9003.

STEP 3 BD06F116

Remove the fan belt.

STEP 5

BD06F113

BD06F117

Disconnect the low pressure line from the suction port and the high pressure line from the discharge p o r t o n t h e c o m p r e s s o r. I m m e d i a t e l y i n s t a l l protective caps on the open ports and lines.

BD06F114

Loosen and remove the four bolts holding the protective shield. Remove the shield.

Bur 5-3040

Issued 8-06

Printed in U.S.A.

9004-6

Installation

STEP 6

STEP 9 Place the compressor into position on the machine.

STEP 10

BD06F117

Disconnect the compressor clutch wire from the engine harness assembly.

STEP 7 BD06F117

Install the three bolts to mount the compressor.

STEP 11

BD06F117

Loosen and remove the three compressor mounting bolts.

STEP 8 Remove the compressor from the machine.

Bur 5-3040

BD06F117

Connect the compressor clutch wire to the engine harness assembly.

Issued 8-06

Printed in U.S.A.

9004-7

STEP 12

STEP 13 Carefully remove the protective cap, install a new O-ring, and connect the low pressure line to the suction port on the compressor.

STEP 14 Install the belt.

STEP 15 Install the protective shield.

STEP 16 BD06F117

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.

Bur 5-3040

Issued 8-06

Printed in U.S.A.

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.

Bur 5-3040

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 8-06

Printed in U.S.A.

9004-9

Removal

STEP 23

STEP 17 Park the machine on a level surface and lower the bucket to the floor.

STEP 18 If changing any air conditioning components, discharge the air conditioning system according to the instructions in Section 9003.

STEP 19 BD06G212

Open the cover on the cooler.

STEP 24

BD02N160

If changing the heater core, put a 37 liter (10 gallon) container below radiator drain. Remove radiator cap. Remove cap and drain coolant into container. Install cap after coolant has drained. Install radiator cap.

BD06G213

Remove the four screws securing the air vent, remove the vent cover.

STEP 20 Place the master disconnect in the OFF position.

STEP 25

STEP 21 Disconnect the wiring harness from the operator’s seat (if equipped with air seat option).

STEP 22

BD06G214

Remove the three screws securing the cooler to the cab, remove the cooler.

STEP 26 BD06G202

Fold the rubber mat over to gain access to the upper box mounting bolts.

Remove the four bolts that fasten the operator’s seat to the upper box, remove the seat from the machine. Bur 5-3040

Issued 8-06

Printed in U.S.A.

9004-10

STEP 27

STEP 30

BD06G215

Remove the six bolts securing the upper box.

BD06G217

G o i n g t h r o u g h th e i n s i d e f i l t e r a r e a fe e l th e recirculating vain to make sure is is in the outside air, “closed”, position.

STEP 28

STEP 31

BD06G216

Remove two screws, one on each side of the upper box, securing the upper box to the lower box.

BD06G218

STEP 29

The above photo shows that the recirculating vain is not in the outside air “closed” position.

Place the air selector on the control panel to outside air.

STEP 32

NOTE: In step 30 and 33 the upper box is shown removed for clarity only, these steps must be done prior to removing the upper box.

BD06G240

Use a screw driver and disconnect the linkage.

Bur 5-3040

Issued 8-06

Printed in U.S.A.

9004-11

STEP 33

STEP 36

BD06G219

Close the vain so the upper cover can be removed.

BD06G203

Disconnect the solenoid driver.

STEP 34 Remove the upper box up and rest it against the console.

STEP 37

NOTE: The wiring harness for the HVAC system goes through the upper cover, by resting the cover against the console the wiring harness will not need to be removed.

STEP 35

BD06G236

Remove the upper PPE from the heater and air conditioning cores. NOTE: If testing on the electrical components are required the solenoid driver can be reconnected once the upper PPE is removed.

BD06G220

Pull the wiring harness loose from the upper PPE.

Bur 5-3040

Issued 8-06

Printed in U.S.A.

9004-12 NOTE: If replacing the heater control valve, heater core, air conditioning expansion valve, air conditioning evaporator core do steps 38 through 47, if replacing electrical components go to step 48.

STEP 40

STEP 38

BD06G206

Remove the thermostat probe and clamp from the evaporator core.

STEP 41 BD06G204

Remove the right side cab skirt.

STEP 39

2

3

1

BD06G237

Disconnect the electrical connectors from the thermostat control.

STEP 42 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.

Bur 5-3040

Issued 8-06

Printed in U.S.A.

9004-13

STEP 43

STEP 49

Pull the heater core and evaporator core from the lower box PPE.

STEP 44 Remove the expansion valve from the evaporator core.

STEP 45 Remove and discard the O-rings from the openings in the expansion valve.

STEP 46 Remove the screws from the heater core and remove the control valve.

STEP 47 Remove and discard the O-rings from the heater control valve.

BD06G208

D i s c o n n e c t t h e e l e c t r i c a l c o n n e c t o r fo r t h e recirculating vain motor, disconnect the linkage from the vain. Remove the mounting screws and remove the motor.

STEP 50

STEP 48 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.

Bur 5-3040

1. FAN SPEED AND A/C SWITCH 2. INSIDE/OUTSIDE AIR SELECTOR SWITCH 3. THERMOSTAT

R e m ove t h e sw i t c h p a n e l f r o m t h e c o n s o l e. Disconnect the electrical connectors and remove switches as required.

Issued 8-06

Printed in U.S.A.

9004-14

Installation

STEP 53

STEP 51 1

1 2

3 3 2

BD06G207

BD06G209

1. FAN SPEED SWITCH 2. INSIDE/OUTSIDE AIR SELECTOR SWITCH 3. THERMOSTAT

Re place switches and connect the electr ical connectors as required. Install the switch panel in the console.

1. RESISTORS 2. RESISTOR CONNECTOR 3. BLOWER MOTOR CONNECTOR

Install the resistor, install the two mounting screws and tighten. Install the fans in the lower PPE, connect the electrical connectors.

STEP 54 Install new O-rings on the heater control valve.

STEP 52 STEP 55 Install the control valve, install and tighten the screws to the heater core.

STEP 56 Install new O-rings on the openings of the expansion valve.

STEP 57 Install the heater core and evaporator core into the lower box PPE. BD06G208

STEP 58

Install the motor and install the mounting screws and tighten. Connect the electrical connector for the recirculating vain motor, connect the linkage to the vain.

BD06G236

Connect the electrical connectors to the heater control valve.

Bur 5-3040

Issued 8-06

Printed in U.S.A.

9004-15

STEP 59

STEP 61 3

2

1

BD06G237

Connect the electrical connectors to the thermostat control.

STEP 60

BD06G205


Remove the plugs from the hoses and the caps from the fittings. Install new O-rings in the evaporator fittings, connect the heater and evaporator hoses. Remove and discard identification tags that were used during disassemble.

STEP 62

BD06G206

Install the thermostat probe coil and clamp to the evaporator core “cold” tube.

BD06G204

Install the right side cab skirt.

STEP 63

BD06G238

Install the upper PPE on the heater and air conditioning cores. Bur 5-3040

Issued 8-06

Printed in U.S.A.

9004-16

STEP 64

STEP 67

BD06G210. BD06G203

Connect the solenoid driver.

Make sure that the recirculating vain is in the closed position. IMPORTANT: This photo shows it in the open position and the upper box will not go back into position without damaging the recirculating vain.

STEP 65

STEP 68

BD06G239

Push the wiring harness into the preformed notches in the upper PPE.

BD06G241

STEP 66

Set the upper box into position on the heater and evaporator cores.

Place the air selector on the control panel to outside air.

STEP 69

BD06G216

Install two screws, one on each side of the upper box securing the upper box to the lower box.

Bur 5-3040

Issued 8-06

Printed in U.S.A.

9004-17

STEP 70

STEP 74

BD06G242

BD06G214

Install the insolation panel in the center of the upper box.

Install and tighten the three screws securing the cooler to the cab.

STEP 71

STEP 75

BD06G215

BD06G213

Install and tighten the six bolts securing the upper box.

Install the vent cover, install and tighten the four screws securing the air vent.

STEP 72

STEP 76

BD06G243

Install the right rear floor mat into the cab, if machine is equipped with air ride seat make sure to pull the wiring up above the mat for the seat.

BD06G202

Install and torque the four bolts to 73 to 87 Nm (55 to 65 pound-feet).

STEP 73 Install the remainder of the floor mat.

Bur 5-3040

Issued 8-06

Printed in U.S.A.

9004-18

STEP 77

STEP 79

Connect the wiring connector to the operator’s seat (if equipped with air seat option).

Charge the air conditioning system according to the instructions in Section 9003.

STEP 78 Fill engine coolant system with a solution of 50% Ethylene Glycol and 50% water. Install the radiator cap. Fill the coolant reservoir up to the FULL mark on the reservoir.

Bur 5-3040

Issued 8-06

Printed in U.S.A.

9004-19

CONDENSER AND RECIEVER DRIER Removal

STEP 85

STEP 80 Park the machine on a level surface and lower the bucket to the ground.


STEP 82 Discharge the air conditioning system according to the instructions in Section 9003. BS03A107

Fa s t e n i d e n t i f i c a t i o n t a g s o n t h e h o s e s a n d disconnect the hoses from the condenser.

STEP 83

STEP 86

1

Install plugs in the hoses and caps on the fittings.

2

STEP 87

BD01D142

1. COVER

2. CONDENSER

Open the cover (1) to gain access to the condenser (2).

STEP 84 BS03A109

Loosen the bolts that fasten the condenser to the bracket, pivot the condenser and remove the bolts and condenser.

BD03A109

The condenser is connected to a bracket which pivots on the cooling frame. Pivot the condenser to gain access to the hoses.

Bur 5-3040

Issued 8-06

Printed in U.S.A.

9004-20

Installation

STEP 88

STEP 91 Put the condenser in position on the bracket.

STEP 92

BD06G211

Fa s t e n i d e n t i f i c a t i o n t a g s o n t h e h o s e s a n d disconnect the hoses from the receiver drier.

STEP 89 Install plugs in the hoses and caps on the fittings.

STEP 90 Disconnect the trinary switch, remove the mounting bolt, remove the receiver drier and bracket.

BS03A109

Install the bolts that fasten the condenser to the bracket, pivot the condenser down and tighten the bolts.

STEP 93

BS03A107

Pivot the condenser to gain access to the hoses.

STEP 94 Remove the plugs from the hoses and the caps from the fittings. Install new O-rings and connect the hoses to the fittings. Remove and discard identification tags that were used during disassemble.

STEP 95 Pivot the condenser down and close the cover.

STEP 96 Mount the receiver drier and bracket, install and tighten the mounting bolt.

Bur 5-3040

Issued 8-06

Printed in U.S.A.

9004-21

STEP 97

STEP 98 Charge the air conditioning system according to the instructions in Section 9003.


BD06G211

Remove plugs from the hoses and caps from the fittings, install new O-rings and connect the hoses to the fittings, connect the trinary switch. Remove and discard identification tags that were used during disassemble.

Bur 5-3040

Issued 8-06

Printed in U.S.A.

9004-22

NOTES

Bur 5-3040

Issued 8-06

Printed in U.S.A.

Section 9006

9006

LOADER


Bur 5-3300


9006-2

TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUCKET TEETH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement of the Tooth Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement of the Bucket Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement of the Bucket Corner Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RETURN TO DIG ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE LOADER FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE LOADER FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 5-3300

Issued 8-06

3 3 3 3 3 4 5 7 9

Printed in U.S.A.

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 3 2

6

8

10

1

Replacement of the Bucket Teeth 1. Loosen and remove the nuts (4), hardened washers (5), and bolts (6) from the bucket teeth.

9 7

NOTE: If wear of the bolt or nut makes removal difficult, the bolt or nut can be cut off. 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). Bur 5-3300

Issued 8-06

Printed in U.S.A.

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 to 7.5 Nm (4.5 to 5.5 pound-feet). NOTE: The proximity switch (5) must not protrude past the proximity switch guard (6). 6. Start the engine, position the bucket to the correct digging angle and stop the engine.

7. Loosen the bolts holding the target bar (3) to the target mounting bracket (1). Slide the target bar (3) towards the proximity switch (5) until the face of the proximity switch (5) is completely covered. 8. Align the target bar (3) parallel to the tilt cylinder (2) and tighten the bolts. 9. Turn the ignition switch to the ON position. Do NOT start the engine. 10. Place the bucket control lever in the ROLLBACK position. 11. Loosen the bolts holding the target bar (3) to the target mounting bracket (1). 12. Slide the target bar (3) slowly away from the proximity switch (5), until the control lever returns to the center position. Tighten the bolts holding the target bar (3). 13. Check to make sure that the 3.2 to 5.0 mm (1/8 to 3/16 inch) gap is still maintained. 14. Start the engine. 15. Place the detent switch in the ON position and place the return to travel/float detent switch to the TRAVEL position. 16. Raise the lift arms approximately horizontal, and put the bucket in the fully dumped position. 17. Place the loader control lever in the ROLLBACK position, and verify that the electromagnet holds it in that position until the end of the target bar (3) passes in front of the proximity switch (5). 18. Lower the lift arms and verify that the bucket is at the correct digging angle.

Bur 5-3300

Issued 8-06

Printed in U.S.A.

9006-5

HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT

5 6

4

3 2 1

BS01C081

1. TARGET MOUNTING PLATE 2. HEIGHT CONTROL TARGET

3. PROXIMITY SWITCH 4. LIFT ARM

5. RETURN TO TRAVEL TARGET 6. FRONT CHASSIS (TOP LEFT HAND SIDE)

HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT ILLUSTRATION

1. Park the machine on a level surface. 2. Start the engine and apply the parking brake. 3. Lower the lift arms and place the bucket flat on the ground. 4. Stop the engine.

6. Adjust the proximity switch (3) out towards the return to travel target (5) until an air gap of 3.2 to 5.0 mm (1/8 to 3/16 inch) is obtained. 7. Lock the proximity switch (3) in this position with the jam nut. Torque the jam nut to 6 to 7.5 Nm (4.5 to 5.5 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 compar tment, always suppor t 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). Bur 5-3300

Issued 8-06

Printed in U.S.A.

9006-6

2 A

3 B

1

BS01C082

1. HEIGHT CONTROL TARGET

2. RETURN TO TRAVEL TARGET

MACHINE

A

APPROXIMATE RESULTING RETURN TO TRAVEL HINGE PIN HEIGHT

821E

56 mm (2.2 inches)

414 mm (16.3 inches)

3. TARGET MOUNTING PLATE

B

APPROXIMATE RESULTING HEIGHT CONTROL HINGE PIN HEIGHT

42 mm (1.6 inches)

3302 mm (130 inches)

HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT ILLUSTRATION

8. Refer to the table and the illustration on this page. Position the height control target (1) on the target mounting plate (3) using the table above. NOTE: The higher the height control target (1) is positioned in its slot in the target mounting plate (3), the lower the lift arms will stop as they are raised. 9. Tighten the height control target (1). 10. Position the return to travel target (2) using the table above. NOTE: The higher the return to travel target (2) is positioned in its slot in the target mounting plate (3), the lower the lift arms will stop as they are lowered. 11. Check to make sure the proximity switch (3) and all of the mounting bolts are tight. Refer to the illustration on page 5.

14. Place the loader control lever in the raise position and verify that the electromagnet holds it in that position until the height control target (2) passes in front of the proximity switch (3). Refer to the illustration on page 5. 15. With the lift arms still raised, place the loader control lever in the lower position and verify that the electromagnet holds it in that position until the return to travel target (5) passes in front of the proximity switch (3). Refer to the illustration on page 5. 16. Repeat steps 8 through 15 until the desired heights are reached. 17. Lower the bucket to the ground and stop the engine.

12. Start the engine. 13. Place the detent switch in the ON position, and set the return to travel/float detent switch to the return to travel position.

Bur 5-3300

Issued 8-06

Printed in U.S.A.

9006-7

REMOVING THE LOADER FRAME 1. Park the machine on a level surface and apply the parking brake. Roll the bucket all the way forward and lower the bucket to the floor. Stop the engine. 2. Loosen the filler plug in the reservoir to release the air in the reservoir. 3. Fasten a chain hoist to the cross member (1) of the loader frame (2), refer to the illustration on page 8.

17. Loosen and remove the bolt (19), flat washer (20) and spacer (21) that fasten the pivot pin (9 or 10) to the front frame. 18. Raise the loader frame slightly. Use an acceptable driver and drive the pivot pin (9 or 10) out of the front frame. Do not lose the washers (18) and wipers (22) between the front frame and the loader frame (2).

4. Loosen and remove the bolt (12), flat washer (13), and spacer (14) that fasten the pivot pin (3) to the piston rod yoke of the right lift cylinder (4). 5. Use an acceptable driver and drive the pivot pin (3) out of the piston rod yoke of the right lift cylinder (4). Do not remove the driver. 6. Repeat Steps 4 and 5 for the left lift cylinder (6). 7. Start the engine. Roll the bucket back and lower the bucket so that the bucket is flat on the floor and fasten the chain hoist to a lift cylinder (4 or 6). 8. Raise the lift cylinder (4 or 6) slightly and remove the driver.

BD01G009

19. Remove the proximity switch cover. Left-hand side of the machine only.

9. Repeat steps 7 and 8 for the other lift cylinder (4 or 6). 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).

1 2

12. Use an acceptable driver and drive the pivot pin (7) out of the piston rod eye of the bucket cylinder (8). BD01G010

13. Raise the bucket cylinder (8) and use a chain or other acceptable holding equipment to hold the bucket cylinder (8) in place. 14. If the machine is equipped with auxiliary hydraulics, disconnect the two hoses from the tubes at the bracket on the right side of the loader frame (2). Install caps on the hoses and plugs in the tube fittings. 15. If the machine is equipped with front lamps, loosen and remove the cap screws and lock washers that fasten the lamp brackets to the front frame. Put the lamp brackets on the fenders.

1. ELECTRICAL CONNECTION

2. PROXIMITY SWITCH

20. Disconnect the electrical connector (1), remove the lock nut from the proximity switch (2) and remove the proximity sw itch (2) fr om the machine. Left-hand side of the machine only. 21. Repeat Steps 17 and 18 for the other pivot pin (9 or 10). 22. Raise the loader frame (2) out of the front frame. Carefully move the machine out of the loader frame (2).

16. Connect the chain hoist to the loader frame (2).

Bur 5-3300

Issued 8-06

Printed in U.S.A.

9006-8

10

19

18

22

20 18

8 16 6

9

7

15

17

2 11

1 21

5 4

5

14 5

12 3 13 23

BS01G022

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

CROSS MEMBER LOADER FRAME PIVOT PIN LIFT CYLINDER PIVOT PIN LIFT CYLINDER

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

PIVOT PIN BUCKET CYLINDER PIVOT PIN PIVOT PIN BELL CRANK BOLT

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

WASHER SPACER BOLT WASHER SPACER WASHER

19. 20. 21. 22. 23.

BOLT WASHER SPACER WIPER DUMP LINK

LOADER FRAME ILLUSTRATION

Bur 5-3300

Issued 8-06

Printed in U.S.A.

9006-9

INSTALLING THE LOADER FRAME 1. Apply antiseize compound to the inner bores and outer bores for the pivot pins of the front frame, refer to the illustration on page 8. 2. Move the machine into alignment with the loader frame (2). 3. Lower the loader frame (2) into alignment with the front frame. 4. Apply antiseize compound to the pivot pins (9 and 10) that fasten the loader frame (2) to the front frame. 5. Start the pivot pins (9 and 10) into the front frame. Install the washers (18) and new wipers (22) between the loader frame (2) and the front frame. 6. Install the pivot pins (9 and 10) all the way. 7. Install the bolt (19), washer (20) and spacer (21) that fasten the pivot pins (9 and 10). Tighten the bolt. 8. Install the proximity switch and cover. Left-hand side of the machine only. 9. Disconnect the chain hoist from the loader frame (2). 10. If the machine is equipped with front lamps, hold the front lamps in place and install the cap screws and lock washers that fasten the front lamps to the front frame. Tighten the cap screws. 11. If the machine is equipped with auxiliary hydraulics, remove the plugs from the tube fittings and the caps from the hoses. Connect the hoses to the tubes. 12. Connect the chain hoist to the bucket cylinder (8) and lower the bucket cylinder (8). 13. Start the engine and run the engine at low idle. 14. Have another person help you at this time. Move the bucket control lever as required to align the piston rod eye of the bucket cylinder (8) with the bell crank (11). Stop the engine. IMPORTANT: D o n o t u s e yo 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 (8). 16. Install the bolt (15), washer (16), and spacer (17) that fasten the pivot pin (7). Tighten the bolt.

Bur 5-3300

17. Disconnect the chain hoist from the bucket cylinder (8). 18. Fasten the chain hoist to one of the lift cylinders (4 or 6). 19. Raise the piston rod yoke of the lift cylinder (4 or 6) 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 6). 22. Disconnect the chain hoist from the lift cylinder (4 or 6). 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 6) with the loader frame (2). IMPORTANT: D o n o t u s e yo 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 6). 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 8-06

Printed in U.S.A.

9006-10

NOTES

Bur 5-3300

Issued 8-06

Printed in U.S.A.

Section 9007

9007

ROLLOVER PROTECTIVE STRUCTURE (ROPS) CAB STRUCTURAL FRAME (CSF)


Bur 5-4070


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

Bur 5-4070

Issued 8-06

3 3 4 4 9

Printed in U.S.A.

9007-3

ROLLOVER PROTECTIVE STRUCTURE (ROPS) CAB STRUCTURAL FRAME (CSF) Attention

The Rollover Protective Structure (ROPS) or Cab S t r u c t u r a l Fr a m e ( C S F ) i s a s p e c i a l s a fe t y component of your machine.

After an accident, fire or rollover, the following MUST be performed before returning the machine to field or job site operation: ●

The ROPS or CSF structure MUST be replaced.

●

The ROPS or CSF mounting or suspension, operator seat and suspension, seat belts and mounting components and wiring within the operator’s protective system MUST be carefully inspected for damage.

●

All damaged parts MUST be replaced.

DO NOT attach any device to the ROPS or CSF for pulling purposes. The ROPS or CSF is a certified structural support and any damage, fire, corrosion or modification will weaken the structure and reduce your protection. If this occurs, the ROPS or CSF MUST be replaced so that it will provide the same protection as a new ROPS or CSF.

DO NOT WELD, ATTEMPT TO STRAIGHTEN OR REPAIR THE ROPS OR CAB STRUCTURAL FRAME.

MAINTENANCE AND INSPECTION OF THE (CSF) CAB OR (ROPS) CANOPY After every 500 hours of operation or every six months, whichever comes first, do the following: 1. Check the torque on the CSF cab or ROPS canopy mounting bolts; torque should be 773 to 854 Nm (570 to 630 lb-ft). If necessary, tighten the bolts to the correct torque. 2. Check that seat belt mounting hardware is tight and seat belt is not cut or frayed. Check the torque on operators seat mounting bolts; torque should be 73 to 87 Nm (54 to 64 lb-ft). If necessary, tighten the bolts to the correct torque. Replace parts that are worn or damaged. WARNING: Grade 8 hardware is used to mount and anchor the ROPS. Parts used for replacement must be those shown in the 47-27A parts catalog.

Bur 5-4070

WARNING: Do not install attachments that will make the total weight of the machine more than the weight shown in the maximum gross vehicle weight section of the ROPS 47-26 serial number plate. WARNING: Do not change the ROPS in any way. Changes made to the ROPS which are not authorized, such as welding, drilling or cutting will make the ROPS weaker and decrease your protection. Replace the ROPS if it becomes damaged in any way. DO NOT TRY TO MAKE REPAIRS TO THE 47-25 ROPS.

Issued 8-06

Printed in U.S.A.

9007-4

CSF CAB AND ROPS CANOPY Removal

STEP 5

NOTE: Procedures and photos in following steps cover in detail removal and installation of CSF structure. Removal and installation of ROPS is similar to removal and installation of CSF structure.

STEP 1 Park machine on a level surface and lower bucket to floor. Stop engine. Actuate brake pedal several times to discharge brake accumulators. Put key switch in ON position and move loader control lever back and forth at least 30 times to release any pressure from hydraulic circuit. Put key switch in OFF position.

BD06G191

Remove skirting under each side and front of cab.

STEP 2

STEP 6

BD01F143


BD06G186

Remove the ducts from the machine.

STEP 3

STEP 7

Put battery disconnect switch in OFF position.

STEP 4

BD06G189

BD01F184

At RH rear, bottom of cab, disconnect ground strap from rear chassis.

If machine is equipped with a heater, put a 40 liters (10 Gallons) container below radiator drain. Remove cap and drain coolant into container. Install cap after coolant has drained.

Bur 5-4070

Issued 8-06

Printed in U.S.A.

9007-5

STEP 8

STEP 11

BD06G194

BD06G192

If machine is equipped with windshield washers, identify, tag, and disconnect front and rear windshield washer nozzle hoses from supply hoses.

Identify, tag, and disconnect hoses from steering control valve. Plug hoses and cap steering control valve fittings to prevent entry of foreign matter into hydraulic system.

STEP 9 STEP 12 2

3

1

BD06G205


BD06F207

Unlatch and open the window on the right hand side.

If machine is equipped with a heater disconnect heater hoses (3), if machine is equipped with air conditioning discharge the air conditioning system, see section 9003, and disconnect the air conditioning hoses (2), cap and plug lines and fittings.

STEP 13

STEP 10

BD06F208

Open and remove the access panel.

BD06G193

Disconnect throttle connector and the air duct. Bur 5-4070

Issued 8-06

Printed in U.S.A.

9007-6

STEP 14

STEP 19

BD06F209

Remove the front access panel.

BD06G187

Disconnect the electrical connectors, push connectors out of the bottom of the cab with the rubber gromment

STEP 15

STEP 20

BD06F210

Disconnect the electrical connectors for the remote control valve.

BD06G188

STEP 16

Raise floor mat up and away from brake pedal to gain access to mounting hardware.

Loosen the filler cap on the reservoir to release any air in the reservoir. Connect a vacuum pump to the hydraulic reservoir, turn on the pump.

STEP 21

STEP 17 Put identification tags on each hose and disconnect one at a time from the remote control valve. Install plugs in the hoses and caps on the fittings to prevent entry of foreign matter into hydraulic system.

STEP 18 Push the hoses out of the bottom of the cab with the rubber gromment. BD06G185

Remove hardware securing brake valve to cab floor. Let brake valve rest on the frame.

Bur 5-4070

Issued 8-06

Printed in U.S.A.

9007-7

STEP 22

STEP 25 Slowly raise cab from rear chassis. Check that all tie straps and clamps have been removed and all hoses, tubes, and wires are disconnected and free. Check that brake valve with hoses attached are free and clear of cab. Remove the ROPS or CSF from the machine. Lower ROPS or CSF onto wooden blocks to prevent damaging cab or canopy.

BD06G184

Install lifting eyes in threaded holes at top of the cab.

STEP 23 Connect lifting equipment to cab at lifting eyes. Take up all slack in lifting equipment.

STEP 24 Remove nuts, bolts, and washers securing cab to rear chassis.

Bur 5-4070

Issued 8-06

Printed in U.S.A.

9007-8

1 2

1 2

3

3

4 4 5 5 6 6 BC06G031

1. NUT 2. WASHER 3. RUBBER MOUNT

Bur 5-4070

4. RUBBER MOUNT 5. WASHER 6. BOLT

Issued 8-06

Printed in U.S.A.

9007-9

Installation

STEP 32

STEP 26 Check rubber mounts (3 an 4) for deterioration, tears, defor mation, or other damage; replace rubber mounts as necessary.

STEP 27

BD06G188

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. Bur 5-4070

Issued 8-06

Printed in U.S.A.

9007-10

STEP 35

STEP 38 3

2

1

BD06G186

BD06G205


Install the ducts on the machine.

STEP 36

If machine is equipped with a heater, remove plugs from hoses and caps from fittings, connect heater hoses (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, 12, and 13. BD06G189

At RH rear, bottom of cab, connect ground strap to rear chassis.

STEP 37

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.

Bur 5-4070

Issued 8-06

Printed in U.S.A.

9007-11

3

8 4 6 7

1 5

2

7

8

7

5 2

1 8

3 6

4 BC05M092

1. PILOT TANK HOSE 2. PILOT PRESSURE HOSE 3. YELLOW BLACK GREEN

4. ORANGE BLACK GREEN 5. GREEN BLACK GREEN 6. RED BLACK GREEN

7. GREEN WHITE GREEN 8. RED WHITE GREEN


Bur 5-4070

Issued 8-06

Printed in U.S.A.

9007-12

5

5

7

1

4 3

4 6

3

1

2 7

7

6

3

6

2

7 1

2

4

7

7 1

2

6

3

5

4

5 BC05M091

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



Bur 5-4070

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



Issued 8-06

Printed in U.S.A.

9007-13

1 5 4

5

6

4

6

3

2 1

3 2

1

2

6

3 4

1

2

6

3

5

4

5 BC05M090

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



Bur 5-4070

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


JOYSTICK HOSE COLOR CODING

Issued 8-06

Printed in U.S.A.

9007-14

STEP 40

STEP 43

BD06F210

Connect the electrical connectors for the remote control valve.

BD06F208

Install and close the access panel.

STEP 44 STEP 41

BD06F209

Place the access panel into position, install and tighten the screw.

STEP 42

BD06F207

Close the right hand window.

STEP 45

BD06G187

Connect wiring harness connectors.

Bur 5-4070

BD06G191

Install skirting under each side and front of cab.

Issued 8-06

Printed in U.S.A.

9007-15

STEP 46

STEP 49 Start engine and run engine at low idle. Run engine at operating temperature for approximately five minutes to completely mix Ethylene Glycol and water. When coolant is at operating temperature, stop engine. When engine has cooled, check coolant level at reservoir. WARNING: Hot coolant can spray out if radiator cap is removed. To remove radiator cap: let system cool, turn to first notch, then wait until all pressure is released. Scalding can result from fast removal of radiator cap. BD01F184

If machine is equipped with a heater and coolant was drained, check that coolant drain cap is tight.


STEP 47 Fill engine coolant system with a solution of 50% Ethylene Glycol and 50% water. Cooling system capacity is 36.9 liters (9.75 U.S. Gallons). Install radiator cap. Fill coolant reservoir up to FULL mark on reservoir.

STEP 48 Put battery disconnect switch in ON position.

Bur 5-4070

Issued 8-06

Printed in U.S.A.

9007-16

NOTES

Bur 5-4070

Issued 8-06

Printed in U.S.A.

Section 9010


Bur 6-42710


9010

CAB GLASS INSTALLATION

9010-2

TABLE OF CONTENTS PREPARATION FOR GLASS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 GLASS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SILICONE SEALANT APPLICATION - FRONT WINDOWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Bur 6-42710

Issued 4-03

Printed in U.S.A.

9010-3

PREPARATION FOR GLASS REPLACEMENT 1. Remove all of the damaged glass section and the silicone sealant from the window frame 2. Remove all the adhesive from the window frame. 3. The window frame recesses must be free of oil and dust. Clean the frame with rubbing alcohol with a clean rag. Do not reuse the rag.

5. Clean the new glass section. Apply a 25 mm (1 inch) wide band of glass primer (349-110) to the black ceramic painted edges of the window. 6. When replacing a front window section, a silicone forming tool is needed, refer to Figure 2. Use the template and instructions provided to make the tool.

4. Apply a 25 mm (1 inch) wide band of metal primer (349-108) to the window recesses.

GLASS INSTALLATION NOTE: Once the adhesive is applied, the glass must be installed within 5 minutes. If the glass is not installed within the 5 minute period, the adhesive must be removed and applied again. 1. Apply a 10 mm (3/8 inch) diameter bead of adhesive (345-135) to the pr imed surface approximately 12 mm (1/2 inch) from edge. 2. The adhesive may be applied either to the primed glass or to the primed metal frame. DO NOT apply the adhesive to both the glass and the frame.

3. For front glass installations install a glass spacer 12 mm (1/2 inch) from each corner on bottom edge of each glass section, refer to Figure 3. 4. Install the glass. The glass edges must not contact the metal frame at any point. 5. For front glass installations position the glass to maintain a uniform 3 mm (1/8 inch) gap between front and front side glass sections.

NOTE: When replacing two or more sections of the front glass apply extra adhesive in corners, refer to Figure 3.

SILICONE SEALANT APPLICATION - FRONT WINDOWS 1. Clean the edges of the front center and front side windows. Use glass cleaning primer. 2. Apply masking tape to the inside edge of each glass section next to the gap. 3. Apply the polyester tape on top of the masking tape across the inside side gap. Do not push the tape into the gap. 4. Apply masking tape to the outside edge of each glass section. Align the edge of the tape with edge of glass on both sections. 5. The tape must be smooth to get the best result when using the silicone forming tool.

Bur 6-42710

6. Fill the joint with the clear silicone sealant (114328A1), refer to Figure 1. The silicone must completely penetrate and fill the gap between the glass sections. The sealant must extend at least 1.5 mm (1/16 inch) above the outside surface of the glass section for the length of the gap. Be sure the sealant fills against the adhesive at each end of the joint. 7. Remove the polyester tape from the inside joint. 8. Remove the extra silicone from the outside joint by carefully sliding the forming tool down the length of the joint. The tool must remain in contact with the glass sections during this process. Refer to Figure 2 for for ming tool template.

Issued 4-03

Printed in U.S.A.

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 Bur 6-42710

Issued 4-03

Printed in U.S.A.

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 completting the installation, DO NOT slam the cab door. The increased air pressure may break the seal on newly installed glass. DO NOT operate the machine for a period of 12 hours, allowing the adhesive and silicone to properly set. Bur 6-42710

Issued 4-03

Printed in U.S.A.

9010-6

NOTES

Bur 6-42710

Issued 4-03

Printed in U.S.A.

Vended Schematic 5-3310

CNH AMERICA LLC 700 STATE STREET RACINE, WI 53404 U.S.A.

English Part Number 84299244 Printed in U.S.A. • Rac © 2009 CNH America LLC. All Rights Reserved. Case is a registered trademark of CNH America

CASE 821E Service Manual

Recommend Documents