case 821e service manual

SERVICE MANUAL

WHEEL LOADER

821ETIER 3

84299244(Replaces 87364100)

Revised December 2009Issued September 2006

Copyright © 2006 CNH Ameica LLC.All rights reserved.

Printed in U.S.A.Issued August, 2006

CASE, LLC.700 State StreetRacine, WI 53404 U.S.A. Bur 5-3090

SECTION INDEX

GENERAL

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

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

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

Section Title Section Number

Section1001

1001

Copyright © 2004 CNH America LLC.All rights reserved.

Printed in U.S.A.Issued April, 2003 Revised July, 2005


GENERAL TORQUE SPECIFICATIONS

1001-2

Bur 8-71603 Revised 7-05 Printed in U.S.A.

TABLE OF CONTENTS

TORQUE SPECIFICATIONS - DECIMAL HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TORQUE SPECIFICATIONS - METRIC HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1001-3


TORQUE SPECIFICATIONS - DECIMAL HARDWAREUse the torques in this chart when special torquesare not given. These torques apply to fasteners withboth UNC and UNF threads as received fromsuppliers dry, or when lubricated with engine oil. Notapplicable if special graphities, Molydisulf idegreases, or other extreme pressure lubricants areused.

Grade 5 Bolts, Nuts, and Studs

SizePound-Inches

Newtonmetres

1/4 inch 108 to 132 12 to 15

5/16 inch 204 to 252 23 to 28

3/8 inch 420 to 504 48 to 57

SizePound-

FeetNewtonmetres

7/16 inch 54 to 64 73 to 87

1/2 inch 80 to 96 109 to 130

9/16 inch 110 to 132 149 to 179

5/8 inch 150 to 180 203 to 244

3/4 inch 270 to 324 366 to 439

7/8 inch 400 to 480 542 to 651

1.0 inch 580 to 696 787 to 944

1-1/8 inch 800 to 880 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

Grade 8 Bolts, Nuts, and Studs

SizePound-Inches

Newtonmetres

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

SizePound-

FeetNewtonmetres

7/16 inch 70 to 84 95 to 114

1/2 inch 110 to 132 149 to 179

9/16 inch 160 to 192 217 to 260

5/8 inch 220 to 264 298 to 358

3/4 inch 380 to 456 515 to 618

7/8 inch 600 to 720 814 to 976

1.0 inch 900 to 1080 1220 to 1465

1-1/8 inch 1280 to 1440 1736 to 1953

1-1/4 inch 1820 to 2000 2468 to 2712

1-3/8 inch 2380 to 2720 3227 to 3688

1-1/2 inch 3160 to 3560 4285 to 4827

NOTE: Use thick nuts with Grade 8 bolts.

1001-4


TORQUE SPECIFICATIONS - METRIC HARDWAREUse the following torques when specifications are notgiven.

These values apply to fasteners with coarse threadsas received from supplier, plated or unplated, orwhen lubricated with engine oil. These values do notapply if graphite or Molydisulfide grease or oil isused.

Grade 12.9 Bolts, Nuts, and Studs

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


SizePound-Inches

Newtonmetres

M4 24 to 36 3 to 4

M5 60 to 72 7 to 8

M6 96 to 108 11 to 12

M8 228 to 276 26 to 31

M10 456 to 540 52 to 61

SizePound-

FeetNewtonmetres

M12 66 to 79 90 to 107

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

8.8


SizePound-Inches

Newtonmetres

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

SizePound-

FeetNewtonmetres

M10 54 to 64 73 to 87

M12 93 to 112 125 to 150

M14 149 to 179 200 to 245

M16 230 to 280 310 to 380

M20 450 to 540 610 to 730

M24 780 to 940 1050 to 1275

M30 1470 to 1770 2000 to 2400

M36 2580 to 3090 3500 to 4200

10.9

12.9

1001-5


TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS

37 Degree Flare Fitting

Tube ODHose ID

ThreadSize

Pound-Inches

Newtonmetres

1/4 inch6.4 mm

7/16-20 72 to 144 8 to 16

5/16 inch7.9 mm

1/2-20 96 to 192 11 to 22

3/8 inch9.5 mm

9/16-18 120 to 300 14 to 34

1/2 inch12.7 mm

3/4-16 180 to 504 20 to 57

5/8 inch15.9 mm

7/8-14 300 to 696 34 to 79

Tube ODHose ID

ThreadSize

Pound-Feet

Newtonmetres

3/4 inch19.0 mm

1-1/16-12 40 to 80 54 to 108

7/8 inch22.2 mm

1-3/16-12 60 to 100 81 to 135

1.0 inch25.4 mm

1-5/16-12 75 to 117 102 to 158

1-1/4 inch31.8 mm

1-5/8-12 125 to 165 169 to 223

1-1/2 inch38.1 mm

1-7/8-12 210 to 250 285 to 338

Split Flange Mounting Bolts

SizePound-Inches

Newtonmetres

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

SizePound-

FeetNewtonmetres

1/2-13 55 to 65 74 to 88

5/8-11 140 to 150 190 to 203

Straight Threads with O-ring

Tube ODHose ID

ThreadSize

Pound-Inches

Newtonmetres

1/4 inch6.4 mm

7/16-20 144 to 228 16 to 26

5/16 inch7.9 mm

1/2-20 192 to 300 22 to 34

3/8 inch9.5 mm

9/16-18 300 to 480 34 to 54

1/2 inch12.7 mm

3/4-16 540 to 804 57 to 91

Tube ODHose ID

ThreadSize

Pound-Feet

Newtonmetres

5/8 inch15.9 mm

7/8-14 58 to 92 79 to 124

3/4 inch19.0 mm

1-1/16-12 80 to 128 108 to 174

7/8 inch22.2 mm

1-3/16-12 100 to 160 136 to 216

1.0 inch25.4 mm

1-5/16-12 117 to 187 159 to 253

1-1/4 inch31.8 mm

1-5/8-12 165 to 264 224 to 357

1-1/2 inch38.1 mm

1-7/8-12 250 to 400 339 to 542

1001-6


TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS

O-ring Face Seal EndO-ring Boss End

Fitting or Lock NutNom.SAEDashSize Tube OD

ThreadSize

Pound-Inches

Newtonmetres

ThreadSize

Pound-Inches

Newtonmetres

-4 1/4 inch6.4 mm

9/16-18 120 to 144 14 to 16 7/16-20 204 to 240 23 to 27

-6 3/8 inch9.5 mm

11/16-16 216 to 240 24 to 27 9/16-18 300 to 360 34 to 41

-8 1/2 inch12.7 mm

13/16-16 384 to 480 43 to 54 3/4-16 540 to 600 61 to 68

ThreadSize

Pound-Feet

Newtonmetres

-10 5/8 inch15.9 mm

1-14 552 to 672 62 to 76 7/8-14 60 to 65 81 to 88

Nom.SAEDashSize Tube OD

ThreadSize

Pound-Feet

Newtonmetres

1-1/16-12 85 to 90 115 to 122

1-3/16-12 95 to 100 129 to 136

-12 3/4 inch19.0 mm

1-3/16-12 65 to 80 90 to 110 1-5/16-12 115 to 125 156 to 169

-14 7/8 inch22.2 mm

1-3/16-12 65 to 80 90 to 110 1-5/8-12 150 to 160 203 to 217

-16 1.0 inch25.4 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 inch31.8 mm

1-11/16-12 125 to 140 170 to 190

-24 1-1/2 inch38.1 mm

2-12 150 to 180 200 to 254

Section1002 10

02



CNH America LLC.700 State StreetRacine, WI 53404 U.S.A. Bur 5-3100

FLUIDS AND LUBRICANTS

1002-2

Bur 5-3100 Issued 8-06 Printed in U.S.A.

TABLE OF CONTENTS

CAPACITIES AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3ENGINE OIL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4TRANSMISSION TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5DIESEL FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Fuel Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Specifications for Acceptable No. 2 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Model 821E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

MAINTENANCE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Model 821E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1002-3


CAPACITIES AND LUBRICANTSEngine 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 SystemCapacity...................................................................................................................40.9 liters (10.8 U.S. Gallons)Type of Coolant ............................................................................................50% water and 50% Ethylene Glycol

Fuel TankCapacity ...................................................................................................................... 288 liters (76 U.S. Gallons)Type of Fuel............................................................................................. See Diesel fuel specifications on page 5

Hydraulic SystemHydraulic 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®

TransmissionRefill Capacity with Filter Change ............................................................................39.7 litres (10.5 U.S. Gallons)Type of Oil ................................................................................................................ Case AKCELA No. 1 15W-40

AxlesCapacity

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 resultof using an alternate oil. Machines are shipped from the factory with break-in oil.

Brake SystemType of Fluid (Same as Hydraulic System)................................................................Case AKCELA Hy-Tran Ultra®

1002-4


ENGINE OIL RECOMMENDATIONSCase AKCELA No. 1 Engine oil is recommendedfor use in your Case engine. Case AKCELA No. 1Engine Oil will lubricate your engine correctlyunder all operating conditions.

If Case AKCELA No. 1 Multi-Viscosity Oil is notavailable, use only oil meeting API engine oil servicecategory CH-4 (preferred) or CG-4.

S e e t h e c h a r t b e l ow fo rrecommended v iscos i ty a ta m b i e n t a i r t e m p e ra t u r eranges.

NOTE: Do not put performanceadditives or other oil additiveproducts in the enginecrankcase. The oil changeintervals given in this manualare according to tests with CaseAKCELA lubricants.

BD03A102

BC02N250

RH99K130

1002-5


TRANSMISSION TEMPERATURE CHART

BC04F193

DIESEL FUEL SYSTEMUse No. 2 diesel fuel in the engine of this machine.The use of other fuels can cause the loss of enginepower and high fuel consumption.

In very cold temperatures, a mixture of No. 1 and No.2 diesel fuels is temporarily permitted. See thefollowing Note.

NOTE: See your fuel dealer for winter fuelrequirements in your area. If the temperature of thefuel lowers below the cloud point (wax appearancepoint), wax crystals in the fuel will restrict the fuelfilter and cause the engine to lose power or not start.

The diesel fuel used in this machine must meet thespecifications as shown below in, “Specifications forAcceptable No. 2 Diesel Fuel”, or “SpecificationD975-81” of the American Society for Testing andMaterials.

Fuel StorageIf you keep fuel in storage for a period of time, youcan get foreign material or water in the fuel storagetank. Many engine problems are caused by water inthe fuel.

Keep the fuel storage tank outside and keep the fuelas cool as possible. Remove water from the storagecontainer at regular periods of time.

Fill the fuel tank at the end of the daily operatingperiod to prevent condensation in the fuel tank.

Specifications for Acceptable No. 2 Diesel Fuel API gravity, minimum ............................................................................................................................................. 34Flash point, minimum ............................................................................................................................60°C (140°F)Cloud point (wax appearance point), maximum ...........................................................-20°C (-5°F) See Note abovePour point, maximum ..................................................................................................-26°C (-15°F) See Note aboveDistillation temperature, 90% point ................................................................................282 to 338°C (540 to 640°F)Viscosity, at 38°C (100°F)

Centistokes ......................................................................................................................................... 2.0 to 4.3Cetane number, minimum .......................................................................... 43 (45 to 55 for winter or high altitudes)Water and sediment, by volume, maximum ..................................................................................................... 0.05%

1002-6


MAINTENANCE SCHEDULE

Model 821E

SERVICE INTERVAL

ITE

MN

UM

BE

R SERVICE POINTS

Initi

al S

ervi

ce

FREQUENCY IN HOURS

CH

EC

K

CLE

AN

CH

AN

GE

DR

AIN

LUB

RIC

ATE

RE

PLA

CE

AD

JUS

T

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

Every 50 Hours

2 Check Engine Coolant Level 50

3 Check Transmission Oil Level 50

4 Check Hydraulic Oil Level 50

5 & 6 Grease Bucket Mounting Fittings 50

18 Bleed Fuel Filter of Condensation 50

First 100 Hours

17 Change Engine Oil and Filters 100

18 & 26 Replace Fuel Filters 100

19 Change Hydraulic Filter 100

21 Change Oil in Axles 100

Every 100 Hours

8Lubricate The Steering Cylinder Pivots - Rod And Closed End (4 Fittings)

100

9 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

Every 250 Hours

12 & 23 Check Cab Air Filter 250

13 Check Radiator Coolant Level 250

14 Check Tire Pressure & Wheel Torque 4 250

22 Check Drive Belt 250

XX Trans Clutch Calibration (See Section 6002) 250 1000

Every 500 Hours

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 500

26 Replace Fuel Filter 500

Every 1000 Hours

19 Replace Hydraulic Oil filter 1000

20 Grease Articulation Fittings 1000

21 Change Front & Rear Axle Oil 1000

22 Replace Drive Belt 1000

23 Replace Cab Air Filter 1000

25 Change Transmission Oil and Filter 1000

XX Check Injector Calibration 1000

XX Check Valve Adjustment (Engine Manual) 1000

XX Trans Clutch Calibration (See Section 6002) 1000

Every 2000 Hours

27 Change Hydraulic Oil 2000

28 Change Coolant 2000

29 Replace Engine Air Cleaner 2000

XX Valve Clearance (Engine Manual) 2000

Every 6000 hours

XX Engine Injectors (Engine Manual) 6000

XX Fuel Pump (Engine Manual) 6000 6000

1002-7


MAINTENANCE POINTS

Model 821E

BC06F531

See your Operators manual for maintenance ofsafety related items and for detailed information ofthe service items on this char t. Operators andservice manuals are available for this machine fromyour dealer.

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

1 29 1712 23

10 11

5

11

5

22162134810

26

1814

21 15 19 25 24 8 21 15 6

17

6 9 8 20 3 18 17 28 27

1002-8


NOTES

Section1003

1003


Printed in U.S.A.Issued April, 2003


METRIC CONVERSION CHART

1003-2


TABLE OF CONTENTS

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

1003-3


CONVERSION FACTORS

Metric to U.S.

MULTIPLY BY TO OBTAIN

Area: sq. meterhectare

10.763 912.471 05

square footacre

Force: newtonnewton

3.596 9420.224 809

ounce forcepound force

Length: millimetermeterkilometer

0.039 3703.280 8400.621 371

inchfootmile

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: kilopascalbar

0.145 03814.50385

lb/sq. inchlb/sq. inch

Temperature: degree C 1.8 x C +32 degree F

Torque: newton meternewton meter

8.850 7480.737 562

lb/inchlb/foot

Velocity: kilometer/hr. 0.621 371 miles/hr.

Volume: cubic centimetercubic metercubic metermilliliterlitrelitrelitrelitre

0.061 02435.314 661.307 9500.033 8141.056 8140.879 8770.264 1720.219 969

cubic inchcubic footcubic yd.ounce (US fluid)quart (US liquid)quart (Imperial)gallon (US liquid)gallon (Imperial)

Volume/Time: litre/min.litre/min.

0.264 1720.219 969

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

1003-4


U.S. to Metric

* = exact

MULTIPLY BY TO OBTAIN

Area: square footacre

0.092 9030.404 686

square meterhectare

Force: ounce forcepound force

0.278 0144.448 222

newtonnewton

Length: inchfootmile

25.4 *0.304 8 *1.609 344 *

millimetermeterkilometer

Mass: poundounce

0.453 59228.35

kilogramgram

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 7570.0690.070 303

kilopascalbarkg/sq. cm

Temperature: degree F 1.8 F - 32 degree C

Torque: pound/inchpound/foot

0.112 9851.355 818

newton meternewton meter

Velocity: miles/hr. 1.609 344 * kilometer/hr.

Volume: cubic inchcubic footcubic yardounce (US fluid)quart (US liquid)quart (Imperial)gallon (US)gallons (Imperial)

16.387 060.028 3170.764.55529.573 530.946 3531.136 5233.785 4124.546 092

cubic centimetercubic metercubic metermilliliterlitrelitrelitrelitre

Volume/Time: gallon/min. 3.785 412 litre/min.




SECTION INDEX

ENGINES

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

Stall Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2002

After Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2003

FOR ENGINE REPAIR, SEE THE ENGINE SERVICE MANUAL87519803


Section2000

2000




ENGINE AND RADIATOR REMOVAL AND INSTALLATION

2000-2


TABLE OF CONTENTS

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2000-3


ENGINE

Removal

STEP 1

BD03A040

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

STEP 2Stop engine. Actuate brake pedal several times todischarge brake accumulators. Put key switch in ONposition and move loader control lever back and forthat least 30 times to release any pressure fromhydraulic circuit. Put key switch in OFF position.

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

STEP 4

BD06F108

The master and hood raise switch are located in theright batter box. Raise the hood with the hood liftmotor. Put master disconnect switch in OFF position.Remove both battery covers and disconnectbatteries from the machine.

STEP 5

BD02N160

Put a 37 liter (10 gallon) container below radiatordrain. Remove radiator cap. Remove cap and draincoolant into container. Install cap after coolant hasdrained. Install radiator cap.

STEP 6

BD02N160

Put a 14.2 liter (15 U.S. quarts) container belowengine oil drain. Remove cap and drain oil intocontainer. Install cap after oil has drained.

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

2000-4


STEP 7

BD03A231

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

STEP 8

BD03A230

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

STEP 9

BD03A228

Remove the pin from the top of the lifting motor.

STEP 10

BD06F109

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

STEP 11

BD03A227

BD03A226

Remove mount bolt (1) and backup alarm wiringharness clamp from cooler housing. Have anotherperson balance the hood and remove the hood hingemounting bolts (2) from the cooler frame.

1

2

1

2

2

2000-5


STEP 12

BD03A232

Carefully raise and remove hood from loader. Lowerhood onto suitable platform and disconnect liftingequipment.

STEP 13

BD03A224

Tag and disconnect engine wiring harness connectorfrom air filter restriction switch.

STEP 14

BD03A225

Loosen clamp on air cleaner intake hose and removethe crankcase ventilation hose.

STEP 15

BD06F110

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

STEP 16

BD06F110

Loosen the clamp on the turbocharger for the aftercooler inlet hose.

STEP 17

BD03A115

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

2000-6


STEP 18

BD06F111

Loosen the clamp on the intake manifold for the aftercooler output hose.

STEP 19

BD03A118

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

STEP 20

BD06F110

Loosen the exhaust clamp from the turbocharger.

STEP 21

BD06F112

Remove the air cleaner and muffler from the bracket.

STEP 22

BD06F113

BD06F114

Remove the four mounting bolts from the belt cover,remove the cover.

NOTE: After removing the belt cover remove thecover mounting brackets from the machine frame.

2000-7


STEP 23

BD06F115

Remove the drive belt from the engine.

STEP 24

BD06F116

Loosen clamps and remove lower cooler hose fromthe engine.

STEP 25

BD06F117

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

STEP 26

BD06F118

Tag and disconnect the wiring from the alternator.

STEP 27

BD06F119

Remove bolt securing wiring harness clamp toengine.

STEP 28

BD06F120

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

1

2

1

2

2000-8


STEP 29

BD06F121

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

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

STEP 30

BD06F146

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

STEP 31

BD06F122

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

STEP 32

BD06F111

Tag and remove the grid heater cable.

STEP 33

BD03A142

Disconnect the wiring harness from the EDC 7controller.

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

STEP 34

BD06F123

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

3

1

2

2

1

3

2000-9


STEP 35

BD06F124

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

STEP 36

BD06F125

Remove bolt and clamp.

STEP 37

BD06F126

Connect and turn on vacuum pump to hydraulicreservoir. Tag and remove the hydraulic lines fromthe brake system pump, plug the lines and cap thefittings.

STEP 38

BD06F127

Remove the lower cover for the drive shaft.

STEP 39

BD03A172

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

STEP 40Connect suitable lifting equipment to engine liftingbrackets. Take up all slack in lifting equipment.Remove the engine mounting bolts and lift the engineenough to gain access to the drain hose, pull thedrain hose with the engine.

STEP 41Slowly raise engine from rear chassis. Be sure allharness connect ions and hoses have beendisconnected and are clear of the engine. Removeengine from machine.

1

2

2000-10


Installation

BS03B035

STEP 42

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

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

STEP 44Tighten engine mounting bolts to a torque of 244 to298 Nm (180 to 220 lb-ft).

STEP 45Disconnect lifting equipment from engine liftingbrackets.

STEP 46Connect engine oil drain hose to frame bracket.

STEP 47

BD03A172

At front of engine, position drive shaft on enginecoupling. Install six bolts to secure drive shaft toengine coupling. Tighten the six bolts to a torque of53 to 62 Nm (39 to 46 lb-ft).

1. ENGINE MOUNT BOLT 3. INSOLATOR UPPER 5. WASHER 7. NUT2. WASHER 4. INSOLATOR LOWER 6. WASHER 8. REMOTE OIL DRAIN HOSE

1

4

3

2

7

6

5

4

3

2

1

1

7

8

7

6

5

2

3

4

5

6

2000-11


STEP 48

BD06F127

Install the lower cover for the drive shaft.

STEP 49

BD06F126

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

STEP 50

BD06F125

Install bolt and clamp for fuel return hose.

STEP 51

BD06F124

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

STEP 52

BD06F123

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

STEP 53

BD03A142

Connect wiring harness to EDC 7 controller.

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

1

2

2000-12


STEP 54

BD06F111

Connect grid heater cable to grid heater. Removeand discard tag.

STEP 55

BD06F122

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

STEP 56

BD06F146

Connect the engine coolant vent hose.

STEP 57

BD06F121

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

STEP 58

BD06F120

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

STEP 59

BD06F119

Install bolt securing wiring harness clamp to engine.

2

1

3

3

1

2

1

2

2000-13


STEP 60

BD06F118

Connect the wiring to the alternator. Remove anddiscard tags.

STEP 61

BD06F117

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

STEP 62

BD06F116

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

STEP 63

BD06F115

Install the drive belt.

STEP 64

BD06F113

BD06F114

Install the cover mounting brackets to the machineframe. Install the belt cover, install the four mountingbolts for the belt cover.

1

2

2000-14


STEP 65

BD06F112

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 leaveloose at this time.

STEP 66

BD06F110

Instal l and t ighten the exhaust clamp on theturbocharger, tighten the muffler mounting bolts.

STEP 67

BD03A118

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

STEP 68

BD06F111

Tighten the clamp on the intake manifold for the aftercooler output hose.

STEP 69

BD03A115

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

STEP 70

BD06F110

Tighten the clamp on the turbocharger for the aftercooler inlet hose.

2000-15


STEP 71

BD06F110

Install the intake hose and tighten the clamps onturbocharger and air cleaner.

STEP 72

BD03A225

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

STEP 73

BD03A224

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

STEP 74

BD03A232

Carefully raise and place hood over loader.

NOTE: Refer to step 7 and 8 of removal for liftingprocedure.

STEP 75

BD03A227

BD03A226

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

1

2

2

2000-16


STEP 76

BD03A228

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

STEP 77

BD06F109

Connect hood wiring harness connector to rearchassis wiring harness connector. Remove anddiscard tag.

STEP 78

BD03A221

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

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

Hood Adjustment Table

Y (MM)

X (MM)

Y (MM)

X (MM)

Y (MM)

X (MM)

Y (MM)

X (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

2

1

2000-17


STEP 79

BD02N160

Check and make sure that drain caps are tight.

STEP 80Install a new oil filter on engine. Fill engine with 14.2liters (15 quarts) of Case AKCELA No. 1 Engine Oil(SAE 15W-40).

STEP 81If hydraulic reservoir was drained, fill reservoir with105.7 liters (27.9 gallons) of Case AKCELA Hy-TranUltra® fluid.

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

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

STEP 84Start engine and run the engine at low idle. Run theengine at operating temperature for approximatelyfive minutes to completely mix the Ethylene Glycoland water. When the coolant is at operat ingtemperature, stop the engine. When engine hascooled, check the coolant level at the reservoir.

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

STEP 85

BD06F108

Lower the hood with the hood lift motor.

STEP 86Put articulation lock in OPERATING position.

2000-18


RADIATOR

Removal

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

STEP 2

BD03A040

Put articulation lock in LOCKED position.

STEP 3Put master disconnect switch in OFF position.

STEP 4

BD03A120

Have another person raise and hold the side panelup into the raised position. Remove the two mountingscrews for the side panel, remove the panel.

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

STEP 5

BD06F128

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

STEP 6

BD02N160

Put a 37 liter (10 gallon) container below radiatordrain. Remove radiator cap then remove cap anddrain coolant into container. Install cap after coolanthas drained. Install radiator cap.

STEP 7

BD03A109

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

2000-19


STEP 8

BD03A108

Loosen the upper radiator hose clamps, remove thehose.

STEP 9

BD06F129

Loose and remove the lower radiator hose from theradiator.

STEP 10

BD03A113

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

STEP 11

BD03A106

Remove screws and install lifting eyes (1). Attachsuitable lifting equipment to lifting eyes. Remove fourmounting bolts (2), remove radiator from machine.

1

22

2000-20


Installation

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

STEP 13

BD03A106

Install four lock washers and bolts (2) to secureradiator to cool ing f rame. Disconnect l i f t ingequipment from lifting eyes. Remove lifting eyes andinstall screws (1).

STEP 14

BD03A113

Connect connector to coolant level sender, connectoverflow hose to radiator.

STEP 15

BD06F129

At bottom of radiator, install bottom radiator hose.Position and tighten two hose clamps to a torque of10.1 to 11.3 Nm (90 to 100 lb-inch).

STEP 16

BD03A108

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

STEP 17

BD06F130

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

1

22

2000-21


STEP 18

BD06F131

Align the whole in the fender on the bolt.

STEP 19

BD06F132

Align the slots in the fender with the tabs on the bodyof the machine.

STEP 20

DSC00105.TIF

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

STEP 21

BD03A120

Have another person raise and hold the side panelup into position. Apply Loctite 242 to the threads,install the two mounting screws for the side paneland to rque to 6 .5 ± 3 .0 Nm (57 .5 ± 26 .5pound-inches).

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

STEP 22

BD02N160

Check that coolant drain cap is tight.

STEP 23Fill engine coolant system with a solution of 50%Ethylene Glycol and 50% water. Cooling systemcapacity is 36.9 liter (9.75 gallon). Install the radiatorcap. Fill the coolant reservoir up to the FULL mark onthe reservoir.

2000-22


STEP 24Put master disconnect switch in ON position.

STEP 25Start engine and run the engine at low idle. Run theengine at operating temperature for approximatelyfive minutes to completely mix the Ethylene Glycoland water. When the coolant is at operat ingtemperature, stop the engine. When engine hascooled, check the coolant level at the reservoir.

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


Section2002 20

02




STALL TEST

2002-2


TABLE OF CONTENTS

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Stall Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

STALL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3INSTRUMENT CLUSTER DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3PROCEDURE TO HEAT THE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

POWER MODE SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6PERFORMING STALL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Test No. 1 - Torque Converter and Hydraulic Stall Together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Understanding the Results of Test No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Test No. 2 - Torque Converter Stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Understanding the Results of Test No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Test No. 3 - Hydraulic Stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Understanding the Results of Test No. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2002-3


SPECIFICATIONSLow idle ..............................................................................................................................................875 to 925 rpmAlternate low idle .................................................................................................................................575 to 625 rpmCold low idle ....................................................................................................................................1175 to 1225 rpmIn gear low idle when in boost or auto power modes (see note) .....................................................1050 to 1150 rpmFull throttle (no load)........................................................................................................................2090 to 2225 rpmTemperature 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 thisaccelerated level until the transmission is placed back into neutral for two seconds.

Stall SpeedsTorque converter..............................................................................................................................1750 to 1895 rpmHydraulic system .............................................................................................................................1860 to 2175 rpmTorque converter and hydraulic system together.............................................................................1500 to 1800 rpm

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

INSTRUMENT CLUSTER DISPLAYS1. With the engine running, press the up or down

key and scroll through the information screensand trip screens. The following sequence isusing the down key only.

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

BD06F188

2. From the driving screen push the down arrow, asshown.

BD06F183

3. Info 1 is the first information screen using thedown arrow from the driving screen. It displaysengine RPM’s, speed, fuel level, and the voltagelevel.

2002-4


BD06F027

4. Info 2 will be displayed next. The Info 2 screenwill display coolant temperature, turbocharger airtemperature, engine oil temperature in eitherFahrenheit or Celsius, as well as oil pressurePSI.

BD06F184

5. Push the down button again and the Info 3screen. This screen displays the temperature inFahrenheit or Celsius of the transmission oil,hydraulic oil, sump oil, and radiator coolanttemperature.

BD06F169

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

BD06F170

7. By continuing to scroll down, the fifth screen willdisplay the Trip 2 screen. Trip 1 and Trip 2screens can be reset independently. Theprevious screen can be accessed by using theup arrow key.

2002-5


PROCEDURE TO HEAT THE OIL

Torque Converter1. Sit in the seat.

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

3. To measure the oil temperature with theinstrument cluster:

A. Press the up or down arrow key.

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

4. Place the declutch switch in the OFF position.

5. Place the automatic switch in the manual modeposition. Push down and hold the brake pedal forthe remainder of this procedure.

6. Release the parking brake.

7. Move the transmission control lever to Forwardand turn the transmission control lever to 3rdgear.

8. Increase the engine speed to full throttle and runthe engine at this speed for 30 seconds.

9. Decrease the engine speed to low idle and movethe transmission control lever to the Neutralposition for 15 seconds.

10. Repeat steps 7, 8, and 9 until the temperature ofthe torque converter oil is 82° to 104°C (180° to220°F).

Hydraulic System1. Apply the parking brake.

2. Start the engine and run at full throttle.

3. To measure the oil temperature with theinstrument cluster:


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

4. Hold the bucket control lever in the ROLLBACKposition while raising and lowering the lift armsfrom ground level to full height.

5. Continue this procedure until the temperature ofthe hydraulic oil is 54° to 57°C (129° to 134°F).

2002-6


POWER MODE SELECTION1. After the oil temperatures have been raised to

operating temperatures the power mode must beset to “Auto”.

BD06H038

2. Press and hold the confirmation “enter” button fortwo seconds to arrive at the above servicescreen.

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 normaldriving screen.

2002-7


PERFORMING STALL TESTS

Test No. 1 - Torque Converter and Hydraulic Stall Together

1. Sit in the seat.


3. Press the brake pedal, release the park brake,shift into Forward.

4. Run engine at low idle. Push the clutch cutoutswitch to OFF. Put the transmission in manualmode. Push down and hold the brake pedal forthe remainder of this procedure.

5. Turn the transmission control lever to third gear.

6. Increase the engine speed to full throttle.

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

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

8. Check the engine speed.

9. Release the bucket control lever.

10. Decrease the engine speed to low idle.

11. Lower the bucket to the ground, place thetransmission in neutral and apply the parkingbrake.

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 hydraulicsystem are probably good.

2. If the engine speed was not as specified, do TestNo. 2 and 3.

Test No. 2 - Torque Converter Stall1. Sit in the seat.


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 theremainder of this test.

6. Turn the transmission control lever to third gear.




10. Place the transmission in neutral and apply theparking brake.



1. If the engine speed was as specified, the engine,torque converter and transmission are probablygood.

2. If the engine speed was more than specified, theproblem can be in the torque converter or thet ransmiss ion . See Sec t ion 6002 fo rtroubleshooting information.

3. If the engine speed was less than specified, doTest No. 3.

2002-8


Test No. 3 - Hydraulic Stall1. Sit in the seat.



4. Hold the bucket control lever in the ROLLBACKposition and raise the lift arms.

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


6. Release the bucket control lever.


8. Lower the bucket to the ground.

9. Stop the engine.


1. If the engine speed was as specified, the engineand hydraulic system are good.

2. If the engine speed was more or less thanspecified the main relieef setting may be too lowor too high. See Section 8002 for troubleshootinginformation.

3. If the engine speed was less than specified in alltests, the engine is probably the cause.

Section2003

2003


Printed in U.S.A.Issued February, 2004


AFTER COOLER

2003-2


TABLE OF CONTENTS

TROUBLESHOOTING AFTER COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3AFTERCOOLER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2003-3


TROUBLESHOOTING AFTER COOLER

STEP 1Park machine on level ground, lower the bucket. Puttransmission in neutral, apply the parking brake. Turnoff engine.

STEP 2Raise hood. Install ‘T’ fitting in waste gate valve hose.Attach pressure gauge. Install another pressuregauge into the intake manifold port.

STEP 3Have assistant start engine and run at 2000 r/min(rpm). Record pressure readings for both gauges. Ifthe pressure difference is greater than 60 mBar (0.87 psi), inspect cooler components for damagedor missing parts.

STEP 4

BD03A116

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

STEP 5

BD03A115

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

BD03A118

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

STEP 6

BD03A119

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

STEP 7

BD03A109

Visually inspect top of after cooler for damage orleaks

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

2003-4


AFTERCOOLER REMOVAL

Removal

STEP 1

BD03A116

Loosen clamps and remove turbocharger outletcomponents.

STEP 2

BD03A115

Loosen clamps and remove air cooler inlet hose.

STEP 3

BD03A119

Loosen clamps and remove Intake hose.

STEP 4

BD03A118

Loosen clamps and remove air cooler outlet hose.

STEP 5

BD03112

Raise air conditioning/air cooler cover. Support coverwith appropriate lifting device. Remove cover supportlatch.

STEP 6

BD03A111

Remove three cover mounting bolts and lift cover off.

2003-5


STEP 7

BD03A109

Unlatch air conditioning condenser clamp.

STEP 8

BD03A107

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

STEP 9

BD03A117

Remove the two bolts at the rear of the after coolermounting frame.

STEP 10

BD03A113

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

STEP 11Li f t a i r cooler and f rame f rom machine wi thappropriate lifting devise.

STEP 12

BD03A111

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

2003-6


Leak Test

BS03B028

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

NOTE: If leakage is detected replace the aftercooler.

Installation

STEP 1

BD03A111

Install after cooler in its frame. Install four mountingbolts. Support after cooler with appropriate liftingdevice. Install the after cooler and frame in themachine.

STEP 2

BD03A113

Install two side mounting bolts

STEP 3

BD03A117

Install two bolts at the rear of the after coolermounting frame.

2003-7


STEP 4

BD03A107

Position air conditioner condenser and installmounting bolts. Rotate the condenser down andlatch.

STEP 5

BD03112

Support cover with appropriate lifting device. Raiseair conditioning/air cooler cover over machine. Installcover support latch.

STEP 6

BD03A111

Install three cover mounting bolts.

STEP 7

BD03A116

Install air cooler inlet hose. Tighten clamps atturbocharger outlet.

STEP 8

BD03A115

Tighten clamps at air cooler inlet.

STEP 9

BD03A119

Install air cooler outlet hose and tighten clamps atengine intake.

2003-8


STEP 10

BD03A118

Tighten clamps at air cooler outlet.

STEP 11Install ‘T’ fitting in waste gate valve hose. Attachpressure gauge. Install another pressure gauge intothe intake manifold port.

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




SECTION INDEX

FUEL SYSTEM

FOR FUEL SYSTEM REPAIR, SEE THE ENGINE SERVICE MANUAL87519803


Section4001

4001




REMOVAL AND INSTALLATION OF STARTER AND ALTERNATOR

4001-2


TABLE OF CONTENTS

STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

BELT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8With Out Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8With Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4001-3


STARTER

Removal

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

STEP 2

BD06F133

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

STEP 3

BD06F134

Place identification tags on the positive cables andremove the positive cables from the starter.

STEP 4

BD06F135

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

4001-4


Installation

STEP 5

BC05G0471. STUDS2. NUTS

Apply Loctite 747 primer to studs and holes, apply 2drops of Loct i te 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 20minutes before installing starter.

STEP 6

BD06F135

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

STEP 7

BD06F134

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

STEP 8Place the master disconnect switch in the ONposition. Lower the engine compartment with liftingmotor.

1

2

2

1

4001-5


ALTERNATOR

Removal

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

STEP 2

BD06F133

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

STEP 3

BD06F136

Disconnect wires from the alternator.

STEP 4

BD06F137

BD06F138

Remove four belt cover mounting bolts, removecover.

STEP 5

BD06F139

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

4001-6


STEP 6

BD06F140

Remove mounting bolts for alternator, removealternator.

Installation

STEP 7

BD06F140

Place alternator onto engine, install mounting boltsfor alternator and tighten.

STEP 8

BD06F139

Use a wrench to move the belt tensioner, install thebelt.

NOTE: Belt routing instructions are on belt cover.

4001-7


STEP 9

BD06F137

BD06F138

Install belt cover, install four belt cover mountingbolts and tighten.

STEP 10

BD06F136

Connect wires to the alternator, place rubber bootover positive post.

STEP 11

BD06F133

Place the master disconnect switch in the ONposition. Lower the engine compartment with liftingmotor.

4001-8


BELT INSTALLATION

BC05G045

WITH OUT AIR CONDITIONING

BC05G046

WITH AIR CONDITIONING

Section4002 40

02




ELECTRICAL SPECIFICATIONS AND TROUBLESHOOTING

4002-2


TABLE OF CONTENTS

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7ELECTRICAL WIRE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8UNDERSTANDING THE TROUBLESHOOTING TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38LOCATING COMPONENTS ON THE SCHEMATIC POSTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38STARTING AND CHARGING SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Starting Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Crank Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Crank Request Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Time Delay Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Master Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Neutral Start Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Voltmeter Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

POWER RELAY MODULES AND COLD STARTING SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Power Relay Module A, Ignition Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Power Relay Module B, Ignition Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Power Relay Module C, For Fuel Filter Heater and Water Separator Heater . . . . . . . . . . . . . . . . . . . . . . . . . 46Grid Heater Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Grid Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Circuit breaker Cab B+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Water Separator Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Fuel Filter Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Power Relay Module D, Accessory Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

ENGINE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Water In Fuel Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Throttle Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Electronic Diesel Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

RETURN TO TRAVEL - RETURN TO DIG - PIN ENGAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Return-To-Travel/Float Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Height Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53Electromagnetic Detents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Return-To-Dig Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Pilot Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55Height Control/Return-To-Travel Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Return to Dig Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55Pin Engage Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56Pilot Pressure Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56Pin Engage Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

PILOT CONTROL - RIDE CONTROL - FAN CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57Ride Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Ride Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Fan Reversing Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Fan Reverse Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Pilot Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Ride Control Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Rollback Pressure Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Rollback Jumper (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Fan PWM Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Fan Reversing Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

4002-3


TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Output Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Transmission Solenoid Valve and Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Filter Maintenance Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Torque Converter Output Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Engine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Intermediate Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Turbine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Transmission Shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Transmission Electronic Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Transmission Enable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63FNR Switch for Joystick Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Transmission Kick-down Switch (Located In Hydraulic Controller for Joystick Option; Next to Hydraulic Levers for Single Axis Controls) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63FNR Switch for Single Axis Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Transmission Auto Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Brake Declutch Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Declutch Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Diagnostic Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

WARNING BUZZER, INSTRUMENT CLUSTER 1, PARK BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Instrument Cluster Connector 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65Warning Buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Parking Brake Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Air Filter Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Parking Brake Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Radiator Coolant Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Brake Warning Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

SWITCH PAD, INSTRUMENT CLUSTER 2, PARK BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69Switch Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70Instrument Cluster Connector 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71Hydraulic Filter Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72Hydraulic Oil Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73Redundant Brake Pressure Switch 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73Redundant Brake Pressure Switch 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73Coolant Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

BACK UP ALARM CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75Back-up Alarm Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76Back-up Alarm Disable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

LIGHTS - 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77Work Lamps Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78Door Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78Rotating Beacon (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79Beacon Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79Left Hand Front Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79Right Hand Front Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80Left Hand Rear Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80Right Hand Rear Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80Lights Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

LIGHTS - 02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82Brake Lamp Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Brake Lamps Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Flasher Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84Hazard Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

4002-4


Turn Signal, High-Low Beam, and Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85Driving Lamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

LIGHTS - 03 AND HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87Left Hand Front Combination Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88Right Hand Front Combination Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89Horn Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

LIGHTS - 04 AND BACK UP ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91Right Hand Rear Combination Lamp (North America Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92Right Hand Rear Combination Lamp (Europe Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93Left Hand Rear Combination Lamp (North America Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94Left Hand Rear Combination Lamp (Europe Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95License Plate Lamp (North America Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95License Plate Lamp (Europe Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96Back-up Alarm (North America Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96Back-up Alarm (Europe Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

CAB WINDOW WASHER AND WIPER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97Front Wiper High Speed Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98Front Wiper Cut Out Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98Front Wiper Low Speed Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99Rear Wiper and Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99Front Wiper and Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100Front Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101Rear Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102Rear Washer Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102Front Washer Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102Wiper Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

SECONDARY STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104Secondary Steering Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105Secondary Steering Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105Secondary Steering Module (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106Secondary Steering Motor (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107Secondary Steering Pressure Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

CAN COMMUNICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108CAN Communication Diagnostics Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

RADIO AND POWER CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110Power Relay Module E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111Power Converter 24 volts to 12 volts (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111Power Outlet (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11112 Volt Radio Ready (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112Right Speaker (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112Left Speaker (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

AIR SEAT - CIGAR LIGHTER - AIR CONDITIONING COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113Seat Compressor and Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114Cigar Lighter (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114Compressor Clutch Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114A/C High/Low Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115Compressor Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

CLIMATE CONTROL - AUTOMATIC TEMPERATURE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116Electronic Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117External Air Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117Internal Air Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117Sun Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117Blower Motor Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117Blower Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117Thermocouple Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

4002-5


Mixed Air Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117Compressor Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118Recycling Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118Electronic Water Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11824 to 12 Volt Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

STANDARD CLIMATE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119Air Recirculation Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120Electronic Water Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120Blower Motor Speed Resistors with Thermal Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121Blower Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121Air Conditioning Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121Control Panel Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121Water Valve Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121Air Recirculating Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

HOOD RAISE AND LOWER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123Hood Up Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124Hood Down Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124Hood Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124Hood Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

4002-6


NOTES

4002-7


SPECIFICATIONS

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

BatteriesGroup Size ..........................................................................................................................................................31Reserve Capacity................................................................................................................................ 170 minutesCold Cranking Capacity At -17° C (0° F) for 60 Seconds At 6.0 Volts................................................700 amperesLoad of Capacity (Load) Test .............................................................................................................400 amperes

Alternator ..................................................................................................................................... 24 volt, 65 amperesVoltage Regulator ............................................................................................................. Solid State, Not AdjustableStarter................................................................................................................................ 24 volt, Solenoid ActuatedBucket Control Valve (Joystick) Detent Electromagnets Resistance at 20° C (68° F) (Nominal)................ 68.2 ohmsBucket Control Valve (Single Axis) Detent Electromagnets Resistance at 20° C (68° F) (Nominal) ........... 305 ohmsFuel Level Sender............................................................................................................................... 33 to 240 ohmsCoolant, Torque Converter, and Hydraulic Temperature Sender 20° C (68° F) ......................................... 3521 ohmsTransmission 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 ohmsParking Brake Solenoid DC Resistance At 20° C (68° F) (Nominal) .......................................................... 40.3 ohmsPilot Pressure Solenoid (Joystick) DC Resistance At 20° C (68° F) (Nominal) .......................................... 29.9 ohmsPilot Pressure Solenoid (Single Axis) DC Resistance At 20° C (68° F) (Nominal) ..................................... 27.4 ohmsRide Control Solenoid DC Resistance At 20° C (68° F) (Nominal)............................................................. 22.7 ohmsPin Engage Solenoid DC Resistance At 20° C (68° F) (Nominal) .............................................................. 28.8 ohmsSecondary Steering Solenoid DC Resistance At 20° C (68° F) (Nominal) ................................................. 39.3 ohmsFan Reversing Solenoid DC Resistance At 20° C (68° F) (Nominal).......................................................... 39.3 ohmsFan PWM Solenoid DC Resistance At 20° C (68° F) (Nominal) ..................................................................xx.x ohmsRollback Pressure Switch (Normally Closed) Opening Set point ....................................................... 6.2 Bar (90 psi)Fuel Temperature Sensor At 20° C (68° F) (Nominal) ............................................................................... 2500 ohmsGrid Heater .................................................................................................................................................. 500 ohmsEngine Control Unit ............................................................................................... Electronic Diesel Control (EDC 7)Analog Throttle ..................................................................................Idle Validation Switch Closes At 0.775V ± 0.1VThrottle Position Potentiometer.................................................................................................. 5V Reference ± 0.2V

Low Idle Position ..............................................................................................................................0.4V ± 0.025VHigh Idle Position .................................................................................................................................4.0V ± 0.1V

4002-8


ELECTRICAL WIRE IDENTIFICATION

Wire Identification From Connector To Connector

Wire CircuitColor, Size, and Material

Connector Cavity Connector Cavity

14 Alternator D+ Lg 1.0 SXL AD, Alternator D+ 1 ENG, Engine Cab 26

42 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 FRONT, Cab Front Chassis 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 FRONT, Cab Front Chassis 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 Proximity Switch Grnd Bk 1.0 SXL SPL-A2, Ultrasonic A GND-FC, Ground A 1

0 AC Proximity Switch Grnd Bk 1.0 SXL PXF, RTD B SPL-A2, Ultrasonic A

0 AD Ride Control Ground Bk 1.0 SXL YRC, Ride Control Option 2 SPL-A1, Ultrasonic A

0 AE Pin Engage Ground Bk 1.0 SXL SPL-A1, Ultrasonic A YPE, Pin Engage 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 FRONT, Cab Front Chassis 9 HOT-FA, Front Axle Oil Temp 2

0 B 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

21C Bk - 1.0

Wire Identification Codes

Wire Color

Wire Name

Wire Size (mm2)

Bk = Black DU = Dark Blue S = Gray LG = Light Green K = Pink

T = Tan W = White N = Brown G = Green U = Blue

LU = Light Blue Or = Orange R = Red P = Purple Y = Yellow

0.8 mm 1.0 mm 2.0 mm 5.0 mm

4002-9


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

C

0 B4 Back Light Ground Bk 0.8 GXL SRTD, Detent Switch 7 SPL-BCK-LT-GD2, Spl Bk Lt Grnd

D

0 B5 Back Light Ground Bk 0.8 GXL SPE, Pin Engage Switch 9 SPL-BCK-LT-GD2, Spl Bk Lt Grnd

E

0 B6 Cab2 Ground Bk 1.0 GXL GND-CAB2, Ground A 1 SPL-BCK-LT-GD2, Spl Bk Lt Grnd

F

0 B7 Back Light Ground Bk 0.8 GXL SFC, Fan Control Switch 7 SPL-BCK-LT-GD2, Spl Bk Lt Grnd

M

0 B8 Front Wiper Motor Ground Bk 0.8 GXLSPL-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 GXLSPL-HOOD-GRND, Hood Grnd 6 Pck

E GND-CAB2, Ground A 1

0 B11 Back Light Ground Bk 0.8 GXLSPL-BCK-LT-GD2, Spl Bk Lt Grnd

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

F

0 B12 Hood Down Relay Ground Bk 1.0 GXLSPL-HOOD-GRND, Hood Grnd 6 Pck

A ECC, Work Lights C4

0 B13 Back Light Ground Bk 1.0 GXLSPL-BCK-LT-GD, Spl Bk Lt Grnd

A GND-CAB2, Ground A 1

0 B14 Back Light Ground Bk 0.8 GXL SWL, Work Lights Switch 7 SPL-BCK-LT-GD, Spl Bk Lt Grnd B

0 B15 Back Light Ground Bk 0.8 GXL SBE, Beacon Switch 7 SPL-BCK-LT-GD, Spl Bk Lt Grnd C

0 B16 Hood Down Control Ground Bk 1.0 GXLSPL-HOOD-GRND, Hood Grnd 6 Pck

B ECC, Work Lights B4

0 B17 Back Light Ground Bk 0.8 GXL STA, Trans Auto Switch 7 SPL-BCK-LT-GD, Spl Bk Lt Grnd E

0 B18 Back Light Ground Bk 0.8 GXL SDC, Declutch Switch 7 SPL-BCK-LT-GD, Spl Bk Lt Grnd F

0 B19 Back Light Ground Bk 0.8 GXL SDR, Driving Lights Switch 7 SPL-BCK-LT-GD, Spl Bk Lt Grnd G

0 B20 Back Light Ground Bk 0.8 GXL SRC, Ride Control Switch 7 SPL-BCK-LT-GD2, Spl Bk Lt Grnd

J

0 B21 Back Light Ground Bk 1.0 GXL SBU, Backup Alarm Disc Sw 7 SPL-BCK-LT-GD, Spl Bk Lt Grnd J

0 B22 Hood Up Relay Ground Bk 1.0 GXLSPL-HOOD-GRND, Hood Gnd 6 Pck

C ECC, Work Lights C2




21C Bk - 1.0


Wire Color

Wire Name

Wire Size (mm2)




0.8 mm 1.0 mm 2.0 mm 5.0 mm

4002-10


0 B23 Back Light Ground Bk 0.8 GXL SRWP, Rear Wiper Switch 7 SPL-BCK-LT-GD, Spl Bk Lt Grnd L

0 B24 Back Light Ground Bk 0.8 GXL SHZ, Hazard Switch 7 SPL-PED-BL-GD, Spl Bk Lt Grnd 6 Pck

C

0 B25 Hood Up Control Ground Bk 1.0 GXLSPL-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 SPL-BCK-LT-GD2, Spl Bk Lt Grnd

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

E

0 B30 Back Light Ground Bk 0.8 GXL SETHR, Ether Switch 7 SPL-PED-BL-GD, Spl Bk Lt Grnd 6 Pck

D

0 BA Pedestal Gnd Strap 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 GND-ENG7, Tranny, Cool Temp 1

0 BAG Hood Grounds (EURO) Bk 1.0 SXL GND-ENG4, Rear Lighting 1 E-HD, Trans Hood c

0 BAG N Hood Grounds (NA) Bk 1.0 SXL ENG-H, Engine to Hood 1 GND-ENG4, Rear Lighting 1

0 BAH QSM11 Ground Bk 0.8 GXL SPL-EDC1, Ultrasonic A QSM11, Engine Controller 29

0 BAI QSM11 Ground Bk 0.8 GXL SPL-EDC1, Ultrasonic A QSM11, Engine Controller 30

0 BAJ QSM11 Ground Bk 0.8 GXL SPL-EDC1, Ultrasonic A QSM11, Engine Controller 39

0 BAK QSM11 Ground Bk 0.8 GXL SPL-EDC1, Ultrasonic A QSM11, Engine Controller 40

0 BAL QSM11 Ground Bk 0.8 GXL SPL-EDC1, Ultrasonic A QSM11, Engine Controller 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 SPL-EDC1, Ultrasonic A QSM11, Engine Controller 50

0 BAR WIF Body Ground Bk 1.0 SXLGND-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 GND-ENG7, Tranny, Cool Temp 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 SPL-EDC1, Ultrasonic A EDC7, Engine Controller 11




21C Bk - 1.0


Wire Color

Wire Name

Wire Size (mm2)




0.8 mm 1.0 mm 2.0 mm 5.0 mm

4002-11


0 BD EDC7 Grnd Bk 1.0 GXL SPL-EDC1, Ultrasonic A EDC7, Engine Controller 10

0 BE EDC7 Grnd Bk 1.0 GXL SPL-EDC1, Ultrasonic A EDC7, Engine Controller 5

0 BF EDC7 Grnd Bk 1.0 GXL SPL-EDC1, Ultrasonic A EDC7, Engine Controller 6

0 BG AIC Power Ground Bk 0.8 GXL ENG, Engine Cab 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 GND-ENG7, Tranny, Cool Temp 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 SXLSPL-ENG-GRD, Grd Spl 6 Pck

A GND-ENG3, SPLC-PK, Washer Motor

1

0 BN Filter Heater Control Bk 0.8 GXL PRM-C2, PRM Signal B EDC7, Engine Controller 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 GND-ENG4, Rear Lighting 1

0 BR N LH Rear Light Ground (NA) Bk 1.0 SXL LLR-N, LH Rear Comb Lamp D SPL-J1, Ultrasonic A

0 BS Fan Control Ground Bk 1.0 SXL SPL-FAN, Ultrasonic A SPL-ENG-GRD, Grd Spl 6 Pck D

0 BT LH Rear Light Ground (EURO) Bk 1.0 SXL LLR-E, LH Rear Comb Lamp 5 GND-ENG4, Rear Lighting 1

0 BT N RH Rear Light Ground (NA) Bk 1.0 SXL LRR-N, RH Rear Comb Lamp D SPL-J1, Ultrasonic A

0 BU Fuel Level Sender Ground Bk 1.0 SXL RFLG, Fuel Send Ground 1 GND-ENG7, Tranny, Cool Temp 1

0 BV Grid Heater Control Grnd Bk 0.8 TXL GHC, Grid Heater Relay 2 EDC7, Engine Controller 75

0 BW Water Separator Htr Ground Bk 2.0 SXLGND-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 SXLSPL-ENG-GRD, Grd Spl 6 Pck

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 Sec. Steering Signal Ground Bk 1.0 SXL SSM, Sec. Steering Mod 12 SPL-SEC-STR, Sec. Steer 6 Pck A

0 CC Sec. Steering Press Sw Ground Bk 1.0 SXLPSS, Sec. Steer Press Switch

B SPL-SEC-STR, Sec. Steer 6 Pck C

0 CD Sec. Steering Splice Ground Bk 1.0 SXLSPL-SEC-STR, Sec. Steer 6 Pck

F SS-TR, SS Mod Trans D




21C Bk - 1.0


Wire Color

Wire Name

Wire Size (mm2)




0.8 mm 1.0 mm 2.0 mm 5.0 mm

4002-12


0 CE Sec. Steering Chassis Ground Bk 1.0 SXL SSM, Sec. Steering Mod 4 GND-SSMOD, Sec. Str Chas Gnd 1

0 CF Sec. Steering Sol Ground Bk 1.0 SXL YSS, Sec. Strg Sol 2 SPL-SEC-STR, Sec. Steer 6 Pck 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 AIC Power Ground Red 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 GXLGND-CAB-SPL2, Spl Back Light Ground

A TDM, Time Delay Module 3

0 DD Voltmeter Relay Control Ground Bk 0.8 GXLGND-CAB-SPL2, Spl Back Light Ground

E ECB, Elect Center B B2

0 DE Neutral Start Relay Control Grd Bk 0.8 GXLGND-CAB-SPL2, Spl Back Light Ground

G ECB, Elect Center B B4

0 DF Crank Request Relay Control Ground

Bk 0.8 GXLGND-CAB-SPL2, Spl Back Light Ground

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 GND-CAB-SPL, Cab Grd Spl M DIA, Diagnostic A

0 DJ AC Relay Control Ground Bk 0.8 GXL GND-CAB-SPL, Cab Grd Spl K ECD, Elect Center D B10

0 DK Seat Compressor Motor Ground Bk 0.8 GXL GND-CAB-SPL, Cab Grd Spl I SC, Seat Comp Motor B

0 DL Power Converter Relay Control Ground

Bk 0.8 GXL GND-CAB-SPL, Cab Grd Spl 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 CAB-T, Cab Transmission 28 TECM, Trans 4

0 DP DIAG TECM Ground Bk 0.8 TXL GND-CAB3D, Ground A 1 TECM, Trans 1

0 DQ DIAG TECM Ground Bk 0.8 TXL GND-CAB3D, Ground A 1 TECM, Trans 2

0 DR Roof Splice Grounds Bk 1.0 GXL CAB-RF, Cab to Roof Conn. F GND-CAB1, Ground A 1

0 DS Roof Splice Grounds Bk 1.0 GXL CAB-RF, Cab to Roof Conn. G GND-CAB1, Ground A 1

0 DT Front Wiper/Washer Sw Grd Bk 0.8 GXL GND-CAB-SPL, Cab Grd Spl G SFWW, Front Wiper/Washer 2

0 DU Pilot Pressure Sol Grd Bk 0.8 GXL GND-CAB-SPL, Cab Grd Spl L YPP, Pilot Press Sol B

0 DV Cigar Lighter Ground Bk 3.0 SXL CL, Cigar Lighter 2 GND-CAB3, Ground C 1

0 DW AIC Power Ground Bk 0.8 TXL CAB-E, Cab Engine 19 AIC-1, Adv Instr Cluster 1 12

0 DX AIC Sensor Ground Bk 0.8 TXL CAB-E, Cab Engine 17 AIC-1, Adv Instr Cluster 1 6

0 DY Front Axle Temp Sensor Grnd Bk 1.0 GXL CAB-F, Cab Front Chassis 9 GND-CAB3D, Ground A 1




21C Bk - 1.0


Wire Color

Wire Name

Wire Size (mm2)




0.8 mm 1.0 mm 2.0 mm 5.0 mm

4002-13


0 EA Time Delay relay Control Grnd Bk 0.8 GXLGND-CAB-SPL2, Spl Back Light Ground

B PRM-B2, PRM Signal B

0 EB Ignition Relay Control Ground Bk 0.8 GXLGND-CAB-SPL2, Spl Back Light Ground

C PRM-A1, PRM Signal B

0 EC ACC Relay Control Ground Bk 0.8 GXLGND-CAB-SPL2, Spl Back Light Ground

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 GXLGND-CAB-SPL, Cab Grnd Spl

A 140M, DIODE Module C

0 EF Brake Lights Relay Ctrl Grnd Bk 0.8 GXLGND-CAB-SPL2, Spl Back Light Ground

M ECC, Work Lights B6

0 EG Flasher Module Ground Bk 0.8 GXL FLSHR, Flasher Module 4 GND-CAB-SPL2, Spl Back Light Ground

L

0 EH Flasher Module Ground Bk 0.8 GXL FLSHR, Flasher Module 3 GND-CAB-SPL2, Spl Back Light Ground

K

0 EJ Power Converter Ground Bk 1.0 GXLCNV, 24V to 12V Pwr Convert

3 GND-CAB4, Ground C 1

0 EK AUX Power Outlet 1 Grnd Bk 1.0 GXL PO1, Power Outlet C GND-CAB5, Ground C 1

0 EL AUX Power Outlet 2 Grnd Bk 1.0 GXL PO2, Power Outlet C GND-CAB5, Ground C 1

0 EM Radio Ground Bk 0.8 GXL CAB-RF, Cab to Roof Conn. M GND-CAB-SPL, Cab Grnd Spl B

0 EN Radio Ground Bk 0.8 GXL ROOF, Roof to Cab Conn. M RAD, Radio Power 8

0 EP Horn Switch Ground Bk 0.8 GXL GND-CAB-SPL, Cab Grd Spl C SRHSTLK, RH Stalk Switch 31

0 EQ Splice Pack GND-CAB-SPL2 Grnd

Bk 0.8 GXLGND-CAB-SPL2, Spl Back Light Ground

H GND-CAB6, Start, FFH, Water Sep Htr

1

0 ER Power Converter Grnd Bk 1.0 GXL CNV, 24V to 12V Pwr Conv 6 GND-CAB4, Ground C 1

0 ES Grid Heater Ground Bk 19.0 SXL GH-1, Grid Heater 1 GND-GH1, STRT, FFH, Water Sep Htr

1

0 GB Starter Relay Control Ground Bk 1.0 SXL SRC-1, Relay 2 GND-ENG1, STRT, FFH, Water Sep Htr

1

0 HC Trans Splice Grounds Bk 1.0 SXLSPL-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 TRANS, Cab Transmission 28 OSS, Out Speed Sensor 1

0 HF Engine Speed Sensor GrndBk 0.8 GXL Twist

ESS, Engine Speed Sensor 2 SPL-H2, Ultrasonic A




21C Bk - 1.0


Wire Color

Wire Name

Wire Size (mm2)




0.8 mm 1.0 mm 2.0 mm 5.0 mm

4002-14


0 HG Inter Speed Sensor GrndBk 0.8 GXL Twist

ISS, Inter Speed Sensor 2 SPL-H2, Ultrasonic A

0 HH Turbine Speed Sensor GrndBk 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 SPL-TRN-GRD, Spl Trans Grd F

0 HP Sec. Steering Splice Grnd Bk 1.0 SXL TRAN-E, Trans to Engine 1 TR-SS, Sec. Steering Module Opt D

0 HV Coolant Level Sender Grnd Bk 1.0 SXL CLS, Cool Jump Cool Sender B SPL-TRN-GRD, Spl Trans Grd D

0 HW Hot Ground Bk 1.0 SXLHOT, Hydraulic Oil Temp Send

B SPL-TRN-GRD, Spl Trans Grd C

0 JA Hood Grounds (EURO) Bk 1.0 SXL HD-E, Hood Trans C SPL-J1, Ultrasonic A

0 JA N Hood Grounds (NA) Bk 1.0 SXL HD-N, Hood to Engine 1 SPL-J1, Ultrasonic A

0 JB Backup Alarm Grnd Bk 1.0 SXL BU1, Backup Alarm Grnd 1 SPL-J1, Ultrasonic A

0 JC License Plate Light Grnd Bk 1.0 SXL LPL, Lic Plate Light B SPL-J1, Ultrasonic A

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 SPL-ROOF, Spl Rood Grnd B

0 MC Beacon Light Grnd Bk 1.0 GXL LBEGRD, Light Beacon Grnd 1 SPL-ROOF, Spl Rood Grnd A

0 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 SPL-ROOF, Spl Rood Grnd D

0 MF RH Rear Work Light Grnd Bk 1.0 GXL LRRW, RH Rear Work Light B SPL-ROOF, Spl Rood Grnd E

0 MJ RH Front Work Light Grnd Bk 1.0 GXL LRFW, RH Front Work Light B SPL-ROOF, Spl Rood Grnd J

0 MK Roof Grounds Bk 1.0 GXL ROOF, Roof to Cab Conn. G SPL-ROOF, Spl Rood Grnd M

0 MN Roof Grounds Bk 1.0 GXL ROOF, Roof to Cab Conn. F SPL-ROOF, Spl Rood Grnd L

0 MU LH Front Work Light Grnd Bk 1.0 GXL LLFW, LH Front Work Light B SPL-ROOF, Spl Rood Grnd 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 SGR242F, Chassis Grnd Sec. Strg Motor

1 GND-SSCHAS, SSM Ground Cable

1




21C Bk - 1.0


Wire Color

Wire Name

Wire Size (mm2)




0.8 mm 1.0 mm 2.0 mm 5.0 mm

4002-15


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

12ACCB ACC PRM control Power W 0.8 GXL SPL-ACC, Ultrasonic A PRM-D1, PRM Signal A

12ACCC

Power Converter PRM Control Power

W 0.8 GXL SPL-ACC, Ultrasonic A PRM-E2, PRM Signal A

12V 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 CAB-RF, Cab to Roof Conn. 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 ROOF, Roof to Cab Conn. N SPL-RAD, Ultrasonic A

12V HA 12V Fused Power to Radio Or 0.8 GXL SPL-RAD, Ultrasonic A RAD, Radio Power 7

12V HB 12V Fused Power to Radio Or 0.8 GXL SPL-RAD, Ultrasonic A RAD, Radio Power 4

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 TDM, Time Delay Module 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 SPL-DLY-RL, Ultrasonic A ECD, Elect Center D A3

13H C Trans ECM Time Delay Power Or 0.8 GXL SPL-DLY-RL, Ultrasonic A ECD, Elect Center D A1

13H D Engine ECM Time Delay Power Or 3.0 GXL SPL-DLY-RL, Ultrasonic A ECD, Elect Center D A2

13K Ignition Switch Pwr Or 1.0 GXL S-KEY, Ignition Switch 3 SPL-PK1, Slice 3-4 Way E

13K A Ignition Switch Pwr Or 1.0 GXL TDM, Time Delay Module 5 SPL-PK1, Slice 3-4 Way G

13K B Ignition Switch Pwr Or 1.0 GXL SPL-PK1, Slice 3-4 Way F PRM-A1, PRM Signal A

13K C Ignition Switch Pwr Or 1.0 GXL SPL-PK1, Slice 3-4 Way H ECB, Elect Center B D1




21C Bk - 1.0


Wire Color

Wire Name

Wire Size (mm2)




0.8 mm 1.0 mm 2.0 mm 5.0 mm

4002-16


13M Fuel Shutoff Fused Power 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 EDC7, Engine Controller 40

13M B Key Switch Power Disc Sw Or 1.0 GXL ENG-D, Disconnect Harness B QSM11, Engine Controller 38

13V Voltmeter Input ANALOG Or 0.8 TXL AIC-1, Adv Instr Cluster 1 1 ECB, Elect Center B D2

14 A Alternator D+ LG 0.8 GXL CAB-E, Cab Engine 26 215F, Alternator Resistor 1

17P A Switch Pad Power From AIC Pwr Or 0.8 TXL SW-PD, Switch Pad 9 AIC-1, Advanced Instr Cluster 25

18B LH High Beam Fused Power Or 1.0 SXL FRONT, Cab Front Chassis 7 LLF, Lights LH 3

18B A LH High Beam Fused Power Or 0.8 GXL CAB-F, Cab Front Chassis 7 ECB, Elect Center B AA3

18C RH High Beam Fused Power Or 1.0 SXL FRONT, Cab Front Chassis 16 LRF, Lights RH 3

18C A RH High Beam Fused Power Or 0.8 GXL CAB-F, Cab Front Chassis 16 ECB, Elect Center B AA4

18D LH Low Beam Fused Power Or 1.0 SXL FRONT, Cab Front Chassis 14 LLF, Lights LH 2

18D A LH Low Beam Fused Power Or 0.8 GXL CAB-F, Cab Front Chassis 14 ECB, Elect Center B AA6

18E RH Low Beam Fused Power Or 1.0 SXL FRONT, Cab Front Chassis 15 LRF, Lights RH 2

18E A RH Low Beam Fused Power Or 0.8 GXL CAB-F, Cab Front Chassis 15 ECB, Elect Center B AA5

18F LH Position/Tail Fused Power Or 1.0 SXL FRONT, Cab Front Chassis 6 LLF, Lights LH 4

18F A LH Position/Tail Fused Power Or 0.8 GXL CAB-E, Cab Engine 5 SPL-POS-L, Ultrasonic

18F AN LH Position/Tail Fused Power Or 1.0 SXL ENG, Engine Cab 5 ENG-H, Engine to Hood 6

18F B LH Position/Tail Fused Power Or 1.0 SXL ENG, Engine Cab 5 LLR-E, LH Rear Comb Light 3

18F BN LH Position/Tail Fused Power Or 1.0 SXL HD-N, Hood to Engine 6 LLR-N LH Rear Combination

LightB

18F C LH Position/Tail Fused Power Or 1.0 GXL SPL-POS-L, Ultrasonic ECB, Electric Center B AA7

18F E LH Position/Tail Fused Power Or 0.8 GXL CAB-F, Cab Front Chassis 6 SPL-POS-L, Ultrasonic

18F F LH Position/Tail Fused Power Or 1.0 SXL HD-9, Hoof to Engine 6 LLR-9, LH Rear Comb Light 3

18G RH Position/Tail Fused Power Or 1.0 GXL SPL-POS-R, Ultrasonic ECB, Elect Center B AA8

18G A RH Position/Tail Fused Power Or 1.0 SXL FRONT, Cab Front Chassis 5 LRF, Lights RH 4

18G CN RH Position/Tail Fused Power Or 1.0 SXL SPL-POS-NA, Ultrasonic A LRR-N, RH Rear Combination

LightB

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

18G EN Licence Plate Light Fused Pwr Or 1.0 SXL LPL, Licence Plate Light A SPL-POS-NA, Ultrasonic A




21C Bk - 1.0


Wire Color

Wire Name

Wire Size (mm2)




0.8 mm 1.0 mm 2.0 mm 5.0 mm

4002-17


18G F RH Position/Tail Fused Power Or 0.8 GXL CAB-E, Cab Engine 9 SPL-POS-R, Ultrasonic

18G G RH Position/Tail Fused Power Or 0.8 GXL CAB-F, Cab Front Chassis A SPL-POS-R, Ultrasonic

18G H RH Position/Tail Fused Power Or 1.0 SXL ENG, Engine Cab 9 SPL-POS, Ultrasonic A

18G HN RH Position/Tail Fused Power Or 1.0 SXL ENG, Engine Cab 9 ENG-H, Engine to Hood 5

18G J RH Position/Tail Fused Power Or 1.0 SXLLRR-E, RH Rear Combination Light

3 SPL-POS, Ultrasonic A

18G JN RH Position/Tail Fused Power Or 1.0 SXL HD-N, Hood to Engine 5 SPL-POS-NA, Ultrasonic A

18G K RH Position/Tail Fused Power Or 1.0 SXL HD-N, Hood to Engine 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

18J 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 SPL-EDC2, Ultrasonic A

18J B EDC7 Time Delay Fused Power Or 1.0 GXL SPL-EDC2, Ultrasonic A EDC7, Engine Controller 3

18J C EDC7 Time Delay Fused Power Or 1.0 GXL SPL-EDC2, Ultrasonic A EDC7, Engine Controller 2

18J D EDC7 Time Delay Fused Power Or 1.0 GXL SPL-EDC4, Ultrasonic A EDC7, Engine Controller 8

18J E EDC7 Time Delay Fused Power Or 1.0 GXL SPL-EDC4, Ultrasonic A EDC7, Engine Controller 9

18J F EDC7 Time Delay Fused Power Or 2.0 SXL ENG, Engine Cab 14 SPL-EDC4, Ultrasonic 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 SPL-EDC4, Ultrasonic A WIF, Water In Fuel Sensor 3

18J K EDC7 Time Delay Fused Power Or 3.0 GXL SPL-D2, Ultrasonic A ECD, Elect Center D AA2

18J L QSM11 Time Delay Power Or 0.8 GXL SPL-EDC4, Ultrasonic A QSM11, Engine controller 17

18J M QSM11 Time Delay Power Or 0.8 GXL SPL-EDC2, Ultrasonic A QSM11, Engine controller 7

18J N QSM11 Time Delay Power Or 0.8 GXL SPL-EDC2, Ultrasonic A QSM11, Engine controller 8

18J P QSM11 Time Delay Power Or 0.8 GXL SPL-EDC4, Ultrasonic A QSM11, Engine controller 18

18J Q QSM11 Time Delay Power Or 0.8 GXL SPL-EDC4, Ultrasonic A QSM11, Engine controller 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 SPL-CSTR, Ultrasonic A ECC, Work Lights D9

18L C Comfort Steer Fused Power Or 0.8 GXL SPL-CSTR, Ultrasonic A ECC, Work Lights B9




21C Bk - 1.0


Wire Color

Wire Name

Wire Size (mm2)




0.8 mm 1.0 mm 2.0 mm 5.0 mm

4002-18


18L D Comfort Steer Fused Power Or 0.8 GXL SCS, Comfort Steer Switch 2 SPL-CSTR, Ultrasonic 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 SPL-BLWR, Ultrasonic A HVAC1, HVAC1 2

18N B Blower Motor Fused Power Or 3.0 GXL SPL-BLWR, Ultrasonic A HVAC2, HVAC2 1

18R 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

19A Output Speed Sensor Fused Pwr Or 1.0 SXL TRANS, Cab Transmission 29 OSS, Out Speed Sensor 3

19A A Brake Declutch Sw Fused Pwr Or 1.0 SXL FRONT, Cab Front Chassis 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 STE, Trans Enable Switch 2 SPL-D15, Ultrasonic A

19A E Trans Enable Switch Fused Pwr Or 0.8 GXL STE, Trans Enable Switch 10 SPL-D15, Ultrasonic A

19A F Trans Enable Switch Fused Pwr Or 0.8 GXL SPL-TRNS-PWR, Trans Pwr B SPL-D15, Ultrasonic A

19A G FNR Sw Fused Power Or 0.8 GXL SPL-FNR, Ultrasonic A SFNR, FNR Switch 8

19A H Trans Shifter Fused Power Or 0.8 GXL TS1, Transmission Shifter A SPL-TRNS-PWR, Trans Pwr M

19A J Pilot Control Switched Fused Pwr

Or 0.8 GXL SPC, Pilot Control Switch 2 SPL-PB1, Ultrasonic A

19A K TECM Fused Power Or 0.8 TXLSPL-TRANS-PWR, Trans Pwr

J TECM, Trans 45

19A L Park Brake Switched Fused Pwr Or 0.8 GXL SPB, Parking Brake Switch 2 SPL-PB1, Ultrasonic A

19A M Output Speed Sensor Fused Pwr Or 0.8 TXL CAB-T, Cab Transmission 29 SPL-TRNS-PWR, Trans Power K

19A N Trans Fused Power Or 1.0 GXLSPL-TRANS-PWR, Trans Pwr

A ECA, Elect Center A A1

19A P Backup Alarm Relay Control Fused Power

Bk 1.0 GXLSPL-TRANS-PWR, Trans Pwr

G ECD, Elect Center D AA10

19A Q Trans/Auto Switch Fused Power Or 0.8 GXL STA, Trans Auto Switch 2 SPL-TRANS-PWR, Trans Pwr C

19A R Declutch Switch Fused Power Or 0.8 GXL SDC, Declutch Switch 2 SPL-TRANS-PWR, Trans Pwr H

19A S Trans Fused Power Or 0.8 GXLSPL-TRANS-PWR, Trans Pwr

L SPL-PB1, Ultrasonic A

19A T Brake Declutch Switch Fused Power

Or 0.8 GXL CAB-F, Cab Front Chassis 27 SPL-TRANS-PWR, Trans Pwr D




21C Bk - 1.0


Wire Color

Wire Name

Wire Size (mm2)




0.8 mm 1.0 mm 2.0 mm 5.0 mm

4002-19


19A U Trans Dick Down Switch Fused Power

Or 0.8 GXL SPL-FNR, Ultrasonic A 20M, Trans Kick Down 1

19A V FNR Switch Fused Power Or 0.8 GXL SFNR, FNR Switch 5 SPL-FNR, Ultrasonic A

19A W Diagnostic Conn. Fused Power Or 0.8 GXL 108F, Diagnostic Connector 1 SPL-TRANS-PWR, Trans Pwr E

19B Turn Signal Fused Power Or 0.8 GXL SRHSTLK, RH Stalk Switch 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 SRC, Ride Control Switch 2 SPL-D24, Ultrasonic A

19D A Parking Brake Relay Fused Pwr Or 1.0 GXL SPL-PBS, Ultrasonic A ECA, Elect Center A A6

19D B Parking Brake Relay Fused Pwr Or 0.8 GXL SPL-PBS, Ultrasonic A ECB, Elect Center B D9

19D C Parking Brake Relay Fused Pwr Or 1.0 GXL SPL-PBS, Ultrasonic A ECB, Elect Center B B9

19E A AIC Wake Up Ignition Or 0.8 TXL AIC-2, Adv Instr Cluster 2 21 ECA, Elect Center A A3

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 SPL-PK3, Splice 3-4 Way M FWM, Front Wiper Motor C

19J B Front Wip Wash Sw Fused Pwr Or 0.8 GXL SFWW, Front Wiper/Washer 5 SPL-PK3, Splice 3-4 Way J

19J C Front Wiper Relay Fused Power Or 0.8 GXL SPL-PK3, Splice 3-4 Way 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

19J F Front Wiper Relay LS Control Fused Power

Or 0.8 GXL SPL-FW, Ultrasonic A ECD, Elect Center D D3

19J G Wiper Cutout Relay Fused Pwr Or 0.8 GXL SPL-FW, Ultrasonic A K-WCO, Wiper Cutout 86

19K Rear Wiper Fused Pwr 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 GXLCAB-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

19L 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 CNV, 24V to 12V Pwr Conver 1 SPL-CNV, Ultrasonic A




21C Bk - 1.0


Wire Color

Wire Name

Wire Size (mm2)




0.8 mm 1.0 mm 2.0 mm 5.0 mm

4002-20


19L B Pwr Converter Fused Power Or 2.0 GXL CNV, 24V to 12V Pwr Conver 2 SPL-CNV, Ultrasonic A

19M Sec. Steering Accessory Fused Pwr

Or 0.8 GXL CAB-T, Cab Transmission 3 ECA, Elect Center A C7

19M A Sec. Steering Accessory Fused Pwr

Or 1.0 SXL TRANS, Cab Transmission 3 TR-SS, Sec. Steering Module Opt A

19M C Sec. Steering Accessory Fused Pwr

Or 1.0 SXL SSM, Sec. Steering Module 7 SS-TR, Sec. Steering Mod Trans A

19N Seat Compressor Fused Pwr Or 1.0 GXL SC, Seat Compressor Motor A ECA, Elect Center A C6

19P Pin Engage/Fan Fused Pwr Or 0.8 GXL SPL-PIN, Spl Back Lgt Pwr B ECA, Elect Center A A7

19P A Pin Engage Sw Fused Pwr Or 0.8 GXL SPE, Pin Engage Sw 2 SPL-PIN, Spl Back Lgt Pwr A

19P C Fan Rev Sw Fused Pwr Or 0.8 GXL SFC, Fan Control Switch 5 SPL-PIN, Spl Back Lgt Pwr C

19P D Fan Rev Relay Fused Pwr Or 0.8 GXL SPL-PIN, Spl Back Lgt Pwr E ECB, Elect Center B D7

19P E Fan Rev Relay Fused Pwr Or 0.8 GXL SPL-PIN, Spl Back Lgt Pwr F ECB, Elect Center B B7

19R Sec. Steering Ign Fused Pwr Or 0.8 GXL DM, Diode OR C SPL-2 Ultrasonic A

19RR Sec. Steering Ign Fused Pwr Or 0.8 GXL DM, Diode OR A ECA, Elect Center A A4

19R A Sec. Steering Ign Fused Pwr Or 1.0 SXL TRANS, Cab Transmission 4 TR-SS, Sec. Steering Module Opt B

19R C Sec. Steering Ign Fused Pwr Or 1.0 SXL SSM, Sec. Steering Module 1 SS-TR, Sec. Steering Mod Trans B

19R D Alternator Resistor Fused Pwr Or 0.8 GXL SPL-2, Ultrasonic A 216F, Alternator Resistor 1

19R E Sec. Steering Ign Fused Pwr Or 0.8 GXL SPL-2, Ultrasonic A CAB-T, Cab Transmission 4

19S1 Sec. Steering Fused Pwr Or 1.0 GXL SS, Sec. Steering Fused Pwr 1 CAB-T, Cab Transmission 26

19S1 E Sec. Steering Fused Pwr Or 1.0 SXL TRANS, Cab Transmission 26 TR-SS, Sec. Steering Module Opt E

19S1 X Sec. Steering Fused Pwr R 1.0 SXL SSM, Sec. Steering Module 3 SS-TR, Sec. Steering Module Trans

E

19S B AIC Delay Fused Power Or 0.8 GXL SPL-DKY3, Ultrasonic A ECD, Elect Center D AA3

19S C AIC Delay Fused Power Or 0.8 TXL SPL-DKY3, Ultrasonic A AIC-2, Advanced Instr Cluster 2 20

19S D AIC Delay Fused Power Or 0.8 TXL SPL-DKY3, Ultrasonic 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

19U 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 GXLROOF, Roof to Cab Connection

D LDM1, Dome Light B+ 1




21C Bk - 1.0


Wire Color

Wire Name

Wire Size (mm2)




0.8 mm 1.0 mm 2.0 mm 5.0 mm

4002-21


19U D Dome Lt Fused Pwr Or 0.8 GXLCAB-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 GXLROOF, Roof to Cab Connection

S DS, Door Switch A

19U G Door Sw Fused Power Or 0.8 GXLCAB-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 SPL-HOOD, Ultrasonic A ECC, Work Lights D2

19Y B Hood Down Relay Fused Power Or 1.0 GXL SPL-HOOD, Ultrasonic A ECC, Work Lights D4

19Y C Hood Switch Fused Power Or 1.0 GXL CAB-E, Cab Engine 35 SPL-HOOD, Ultrasonic A

19Y D Hood Switch Fused Power Or 1.0 GXL ENG, Engine Cab 35 HD, Hood Switch B

19Z Driving Lights Sw Fused Power Or 1.0 GXL SPL-PK2, Splice 3-4 Way G ECC, Work Lights A3

19Z A Driving Lights Sw Fused Power Or 1.0 GXL SDR, Driving Lights Sw 2 SPL-PK2, Splice 3-4 Way E

19Z B Driving Lights Sw Fused Power Or 1.0 GXL SDR, Driving Lights Sw 5 SPL-PK2, Splice 3-4 Way F

19Z C High Beam Flash Fused Power Or 1.0 GXL SRHSTLK, RH Stalk Switch 56d SPL-PK2, Splice 3-4 Way H

1A Ign Switch Fused Power R 1.0 GXL S-KEY, Ignition Switch 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 TDM, Time Delay Module 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 FRONT, Cab Front Chassis 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

1 C ECC Bat Power R 8.0 GXL P-A1, B+ Power 1 L1-ECC, ECC Battery Power cs01

1 DR Brake Light Switch Power R 1.0 GXL CAB-F, Cab Front Chassis 22 SPL-FLSHR-PWR, Ultrasonic A




21C Bk - 1.0


Wire Color

Wire Name

Wire Size (mm2)




0.8 mm 1.0 mm 2.0 mm 5.0 mm

4002-22


1 DU Flasher Module Pwr R 1.0 GXL FLSHR, Flasher Module 1 SPL-FLSHR-PWR, Ultrasonic A

1 DV Brake Lights/Flasher Bat Pwr R 2.0 GXLSPL-FLSHR-PWR, Ultrasonic

A ECC, Work Lights A4

1 DW Brake Lt Relay Bat Pwr R 1.0 GXLSPL-FLSHR-PWR, Ultrasonic

A ECC, Work Lights B5

1 E 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 SPL-FLSHR-PWR, Ultrasonic A

1 NA Battery Crossover R 62.0 SGR BT3, Starter Battery 1 BT2, Disconnect Battery 1

1 NB Battery Starter R 62.0 SGR BT1, Battery Starter 1 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

1 Y Grid Heater Fused Power R 19.0 SXL GHF3, Grid heater Fuse 1 GHF4, Grid Heater 1

1 Z 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 EDC7, Engine Controller 89

20G B EDC7 ESO-K Interface W 0.8 GXL CAB-E, Cab Engine 31 DIA, Diagnostic E

21C 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

21D 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 AA9

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

21E 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 EDC7, Engine Controller 32

21F 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 SPL-EDC3, Ultrasonic A




21C Bk - 1.0


Wire Color

Wire Name

Wire Size (mm2)




0.8 mm 1.0 mm 2.0 mm 5.0 mm

4002-23


21F B EDC7 Digital Ground W 0.8 TXL SPL-EDC3, Ultrasonic A EDC7, Engine Controller 29

21F C EDC7 Digital Ground W 0.8 TXL RTHP, Throttle Pedal 1 SPL-EDC3, Ultrasonic A

21G EDC7 Crank Control relay W 0.8 GXL CAB-E, Cab Engine 3 ECB, Elect Center B AA10

21G A EDC7 Crank Control relay W 0.8 TXL ENG, Engine Cab 3 EDC7, Engine Controller 37

21H 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 EDC7, Engine Controller 17

21K Ign Sw Start Signal W 0.8 GXL S-KEY, Ignition Switch 2 SPL-CRK, Ultrasonic A

21K A Ign Sw Start Signal W 0.8 TXL SPL-CRK, Ultrasonic A AIC-2, Adv Instrument Cluster 2 17

21K B Ign Sw Start Signal W 0.8 GXL SPL-CRK, Ultrasonic A ECB, Elect Center B B3

24B Throttle Signal W 0.8 TXL RTHP, Throttle Pedal 3 EDC7, Engine Controller 79

24B A Throttle Signal W 0.8 TXL RTHP, Throttle Pedal 3 QSM11, Engine Controller 47

24L Low Idle Sw W 0.8 TXL RTHP, Throttle Pedal 6 EDC7, Engine Controller 48

24R Throttle Pos Sens Grnd W 0.8 TXL RTHP, Throttle Pedal 4 EDC7, Engine Controller 78

24R A Throttle Pos Sens Grnd W 0.8 TXL RTHP, Throttle Pedal 4 QSM11, Engine Controller 49

24S Throttle Supply W 0.8 TXL RTHP, Throttle Pedal 5 EDC7, Engine Controller 77

24S A Throttle Supply W 0.8 TXL RTHP, Throttle Pedal 5 QSM11, Engine Controller 48

25A Eng Speed SigW 0.8 GXL Twist

TRANS, Cab Transmission 7 ESS, Engine speed Sensor 1

25A A Eng Speed Sig LU 0.8 TXL CAB-T, Cab Transmission 7 TECM, Trans 19

25B Int Speed SigW 0.8 GXL Twist

TRANS, Cab Transmission 9 ISS, Int Speed Sensor 1

25B A Int Speed Sig LU 0.8 TXL CAB-T, Cab Transmission 9 TECM, Trans 42

25C Turbine Speed SigW 0.8 GXL Twist

TRANS, Cab Transmission 8 TSS, Turbine Speed Sensor 1

25C A Turbine Speed Sig LU 0.8 TXL CAB-T, Cab Transmission 8 TECM, Trans 41

25D Output Speed Sig LU 1.0 SXL TRANS, Cab Transmission 10 OSS, Output Speed Sensor 2

25D A Output Speed Sig LU 0.8 TXL CAB-T, Cab Transmission 10 TECM, Trans 62

25F Forward Signal LU 0.8 TXL TS1, Transmission Shifter B TECM, Trans 43

25G Brake Declutch Switch LU 1.0 SXL FRONT, Cab Front Chassis 28 PBD, Declutch Pressure Switch B

25G A Brake Declutch Switch LU 0.8 GXL CAB-F, Cab Front Chassis 28 SPL-DC, Ultrasonic A

25G B Brake Declutch Switch LU 0.8 GXL SDC, Declutch Switch 1 SPL-DC, Ultrasonic A

25G C Brake Declutch Switch LU 0.8 TXL SPL-DC, Ultrasonic A TECM, Trans 66




21C Bk - 1.0


Wire Color

Wire Name

Wire Size (mm2)




0.8 mm 1.0 mm 2.0 mm 5.0 mm

4002-24


25H Trans Auto Signal LU 0.8 TXL STA, Trans Auto Switch 3 TECM, Trans 29

25J Trans Sol Valve Y6 LU 0.8 TXL TRANS, Cab Transmission 21 TRC, Trans Control 6

25J A Trans Sol Valve Y6 LU 0.8 TXL CAB-T, Cab Transmission 21 TECM, Trans 51

25K Trans Sol Valve Y1 LU 0.8 TXL TRANS, Cab Transmission 16 TRC, Trans Control 1

25K 9 Trans Sol Valve Y2 LU 0.8 TXL TRANS, Cab Transmission 16 TRC, Trans Control 2

25K A Trans Sol Valve Y1 LU 0.8 TXL CAB-T, Cab Transmission 16 TECM, Trans 56

25L Trans Sol Valve Y2 LU 0.8 TXL TRANS, Cab Transmission 17 TRC, Trans Control 2

25L 9 Trans Sol Valve Y1 LU 0.8 TXL TRANS, Cab Transmission 17 TRC, Trans Control 1

25L A Trans Sol Valve Y2 LU 0.8 TXL CAB-T, Cab Transmission 17 TECM, Trans 10

25M Trans Sol Valve Y3 LU 0.8 TXL TRANS, Cab Transmission 18 TRC, Trans Control 3

25M A Trans Sol Valve Y3 LU 0.8 TXL CAB-T, Cab Transmission 18 TECM, Trans 32

25N Trans Sol Valve Y4 LU 0.8 TXL TRANS, Cab Transmission 19 TRC, Trans Control 4

25N A Trans Sol Valve Y4 LU 0.8 TXL CAB-T, Cab Transmission 19 TECM, Trans 55

25P Trans Sol Valve Y5 LU 0.8 TXL TRANS, Cab Transmission 20 TRC, Trans Control 5

25P A Trans Sol Valve Y5 LU 0.8 TXL CAB-T, Cab Transmission 20 TECM, Trans 9

25R Reverse Signal LU 0.8 TXL TS1, Transmission Shifter C TECM, Trans 64

25S Output Sw Power VPS1 LU 0.8 TXL TRANS, Cab Transmission 22 TRC, Transmission Control 7

25S A Output Sw Power VPS1 LU 0.8 TXL CAB-T, Cab Transmission 22 SPL D12, Ultrasonic A

25S B Output Sw Power VPS1 LU 0.8 TXL SPL D12 Ultrasonic A TECM, Trans 12

25S C Output Sw Power VPS1 LU 0.8 TXL SPL D12 Ultrasonic A TECM, Trans 13

25T Neutral Signal LU 0.8 GXL SPL-NEU, Ultrasonic A ECB, Elect Center B D3

25T B Neutral Signal LU 0.8 GXL TS1, Transmission Shifter D SPL-NEU, Ultrasonic A

25T C Neutral Signal LU 0.8 TXL SPL-NEU, Ultrasonic A TECM, Trans 67

25W 3rd And 4th Gear Signal LU 0.8 TXL TS2, Transmission Shifter B TECM, Trans 65

25Y Trans Kick Down Signal LU 0.8 GXL TS2, Transmission Shifter D SPL D11, Ultrasonic A

25Y A Trans Kick Down Signal LU 0.8 TXL SPL D11, Ultrasonic A TECM, Trans 22

25Y B Trans Kick Down Signal LU 0.8 GXL 197F, Main Cab FNR 6 SPL D11, Ultrasonic A

25Y C Trans Kick Down Signal LU 0.8 GXL 20M, Trans Kick Down 2 197M, FNR Main Cab 6

25Z 1st And 4th Gear Signal LU 0.8 TXL TS2, Transmission Shifter C TECM, Trans 63

26E Trans Enable Signal LU 0.8 TXL STE, Trans Enable Switch 3 TECM, Trans 31

26F A FNR Forward Signal LU 0.8 GXL 197M, FNR Main Cab 2 SFNR, FNR Switch 6




21C Bk - 1.0


Wire Color

Wire Name

Wire Size (mm2)




0.8 mm 1.0 mm 2.0 mm 5.0 mm

4002-25


26F B FNR Forward Signal LU 0.8 TXL 197F, Main Cab FNR 2 TECM, Trans 20

26J 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

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 EDC7, Engine Controller 36

28G Grid Heater Source Dr. W 1.0 GXL GHC, Grid Htr Relay 1 EDC7, Engine Controller 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 AIC-1, Adv Instrument Cluster 1 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 TRANS, Cab Transmission 2 CLS, Cool Jump-Cool Send A

31D A Coolant Level Signal Y 0.8 TXL CAB-T, Cab Transmission 2 AIC-2, Adv Instrument Cluster 2 26

31D B Coolant Level Sender Eng Trans Y 1.0 SXL TRANS, Cab Transmission 2 TRAN-E, Trans to Engine 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

31H Hyd Filter Rest Sw Signal Y 1.0 SXL TRANS, Cab Transmission 23 PHF, Hyd Oil Filter Rest Sw 1

31H A Hyd Filter Rest Sw Signal Y 0.8 GXL SW-PD, Switch Pad 4 CAB-T, Cab Transmission 23

31L Pilot Control Switch High Y 0.8 TXL SPC, Pilot Control Switch 3 AIC-2, Advance Instr Cluster 2 18

32F Trans Filter Maint Sw Y 1.0 SXL TRANS, Cab Transmission 31 FM, Filter Maint Sw 1

32F A Trans Filter Maint Sw Y 0.8 TXL CAB-T, Cab Transmission 31 TECM, Trans 17

32J A Trans Enable Indiction Y 0.8 GXL SFNR, FNR Switch 7 197M FNR Main Cab 5

32J C Trans Enable Indiction Y 0.8 GXL STE, Trans Enable Switch 9 SPL-D16, Ultrasonic A

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

33P Brake Warning Press Low Y 1.0 SXL FRONT, Cab Front Chassis 26 PBW, Brake Warning Press Sw 1

33P A Brake Warning Press Low Y 0.8 TXL CAB-F, Cab Front Chassis 26 AIC-2, Advance Instr Cluster 2 5

33R Redundant Brake Accumulator Pressure Low

Y 0.8 TXL CAB-T, Cab Transmission 1 AIC-2, Advance Instr Cluster 2 4




21C Bk - 1.0


Wire Color

Wire Name

Wire Size (mm2)




0.8 mm 1.0 mm 2.0 mm 5.0 mm

4002-26


33R A Redundant Brake Accumulator Pressure Low

Y 1.0 SXL TRANS, Cab Transmission 1 SPL-RD, Ultrasonic A

33R B Redundant Brake Accumulator Pressure Low

Y 1.0 SXL SPL-RD, Ultrasonic A PRB2, Redundant Brake Switch A

33R C Redundant Brake Accumulator Pressure Low

Y 1.0 SXL SPL-RD, Ultrasonic A PRB1, Redundant Brake Switch A

33U Parking Brake Switch Y 0.8 TXL SPB, Parking Brake Switch 3 AIC-2, Advance Instr Cluster 2 6

35A 9 Backup Alarm Power Y 1.0 SXL HD-9, Hood to Engine 7 E-HD9, Transmission-Hood B

35A A Backup Alarm Relay Out Y 0.8 GXL SPL-PK1, Splice 3-4 Way L ECD, Elect Control D AA9

35A B Backup Alarm Disable Switch Y 0.8 GXL SBU, Backup Alarm Dis Sw 2 SPL-PK1, Splice 3-4 Way K

35A C Backup Alarm Relay Out Y 0.8 GXL CAB-E, Cab Engine 7 SPL-PK1, Splice 3-4 Way M

35A D Backup Alarm Relay Out Y 0.8 GXL209M, Backup Alarm Dis Jump

A SPL-PK1, Splice 3-4 Way J

35A E Backup Alarm Relay Out Y 0.8 SXL209F, 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 SPL-D8-C1, Ultrasonic A

35A G Backup Alarm Relay Out Y 0.8 SXL ENG, Engine Cab 40 E-HD, Trans Hood B

35A GN Backup Alarm Relay Out Y 1.0 SXL ENG, Engine Cab 40 ENG-H, Engine to Hood 7

35A H Backup Alarm Relay Out Y 1.0 SXL HD-E, Hood Trans B BU2, Backup Alarm 1

35A HN Backup Alarm Relay Out Y 1.0 SXL HD-N, Hood to Engine 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 HD-9, Hood to Engine 8

35A N Revers Light K 1.0 SXL SPL-REV, Ultrasonic A LLR-9, LH Rear Comb Light 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 ENG-H, Engine to Hood 8

35B AIC Buzzer HSD W 0.8 TXL BUZ, AIC Buzzer 1 AIC-1, Advance Instr Cluster 1 13

35C Backup Alarm Relay Control Y 0.8 TXL TECM, Trans 7 ECD, Elect Center D A9

35R C Backup Alarm Sw Y 0.8 GXL SBU, Backup Alarm Dis Sw 1 SPL-D8-C1, Ultrasonic A

35W Water In Fuel Indicator W 0.8 TXL WIF, Water In Fuel Sensor 1 EDC7, Engine Controller 42




21C Bk - 1.0


Wire Color

Wire Name

Wire Size (mm2)




0.8 mm 1.0 mm 2.0 mm 5.0 mm

4002-27


35X Sec. Str Low Press Sig Y 0.8 TXL CAB-T, Cab Transmission 6 AIC-2, Advance Instr Cluster 2 11

35X A Sec. Str Low Press Sig Y 1.0 SXL SPL-C3, Ultrasonic A PSS, Sec. Steering Press Sw C

35X B Sec. Str Low Press Sig Y 1.0 SXL TRANS, Cab Transmission 6 TR-SS, Sec. Steering Mod Option C

35X C Sec. Str Low Press Sig Y 1.0 SXL SPL-C3, Ultrasonic A SS-TR, SS Module Trans C

35X D Sec. Str Low Press Sig Y 1.0 SXL SSM, Sec. Steering Module 8 SPL-C3, Ultrasonic A

36A Rear Axle Temp P 0.8 TXL CAB-E, Cab Engine 32 AIC-1, Advance Instr Cluster 1 5

36A A Rear Axle Temp P 1.0 SXL ENG, Engine Cab 32 HOT-RA, Rear Axle Oil Temp 1

36B Front Axle Temp P 0.8 TXL AIC-1, Adv Instr Cluster 1 8 CAB-F, Cab Front Chassis 8

36B A Front Axle Temp P 1.0 SXL FRONT, Cab Front Chassis 8 HOT-FA, Front Axle Oil Temp 1

36C 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 AIC-1, Advance Instr Cluster 1 11

36F 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 AIC-1, Advance Instr Cluster 1 2

36G Torque Conv Output Temp Signal

P 1.0 SXL TRANS, Cab Transmission 13 TCOT, TCO Sender 1

36G A Torque Conv Output Temp Signal

P 0.8 TXL CAB-T, Cab Transmission 13 TECM, Trans 49

36H Hydraulic Oil Temp Signal P 1.0 SXL TRANS, Cab Transmission 30 HOT, Hydraulic Oil Temp Sender A

36H A Hydraulic Oil Temp P 0.8 TXL CAB-T, Cab Transmission 30 AIC-1, Advance Instr Cluster 1 9

36R A Trans Temps/Filter Return P 1.0 SXL TRANS, Cab Transmission 12 SPL H1, Ultrasonic A

36R B Trans Filter Maint Sw Return P 1.0 SXL SPL H1, Ultrasonic A FM, Filter Maint Switch 2

36R C Valve Body Temp Return P 0.8 TXL SPL H1, Ultrasonic A TRC, Trans Control 9

36R D TCO Temp Return P 1.0 SXL SPL H1, Ultrasonic A TCOT, TCO Sender 2

36R E Trans Temps/Filter Return P 0.8 TXL CAB-T, Cab Transmission 12 TECM, Trans 46

36T Valve Body Temp Sig P 0.8 TXL TRANS, Cab Transmission 5 TRC, Trans Control 8

36T A Valve Body Temp Sig P 0.8 TXL CAB-T, Cab Transmission 5 TECM, Trans 39

37D A Diagnostic Signal P 0.8 TXL 108F, Diagnostic Connector 2 TECM, Trans 15

37E Diagnostic Signal Switched P 0.8 TXL 108F, Diagnostic Connector 4 TECM, Trans 18

41H A High Beam Pwr Or 1.0 GXL SRHSTLK, RH Stalk Switch 56a SPL-PK2, Splice 3-4 Way L

41H B High Beam LH Pwr Or 0.8 GXL SPL-PK2, Splice 3-4 Way K ECB, Elect Center B A3

41H C High Beam RH Pwr Or 0.8 GXL SPL-PK2, Splice 3-4 Way J ECB, Elect Center B A4




21C Bk - 1.0


Wire Color

Wire Name

Wire Size (mm2)




0.8 mm 1.0 mm 2.0 mm 5.0 mm

4002-28


41H D High Beam Pwr Or 0.8 TXL SW-PD, Switch Pad 1 SPL-PK2, Splice 3-4 Way M

41J Driving Light Power Or 1.0 GXL SDR, Driving Lights Switch 6 SRHSTLK, RH Stalk Switch 56

41L A Low Beam Power Or 1.0 GXL SRHSTLK, RH Stalk Switch 56b SPL-LB, Ultrasonic

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

41T Position Lights Switched Pwr K 1.0 GXL SDR, Driving Lights Switch 3 SPL-PK2, Splice 3-4 Way C

41T A Position Lights RH Switched Pwr K 1.0 GXL SPL-PK2, Splice 3-4 Way D ECB, Elect Center B A8

41T B Position Lights LH Switched Pwr K 1.0 GXL SPL-PK2, Splice 3-4 Way 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 SPL-PK2, Splice 3-4 Way B SPL-D, Ultrasonic

42C A Front Work Lights Fused Pwr DU 1.0 GXL CAB-RF, Cab to Roof Conn. C SPL-PK1, Splice 3-4 Way A

42C C Front Work Lights Fused Pwr DU 1.0 GXL SPL-PK1, Splice 3-4 Way D ECB, Elect Center B AA1

42C D Front Work Lights Fused Pwr DU 1.0 GXL SPL-PK1, Splice 3-4 Way C D-OR, Diode OR A

42C E Front Work Lights Fused Pwr DU 0.8 TXL SW-PD, Switch Pad 3 SPL-PK1, Splice 3-4 Way B

42C F Front Work Lights Fused Pwr DU 1.0 GXL ROOF, Roof to Cab Conn. C SPL-WRKF, Ultrasonic A

42C G RH Front Work Lights Fused Pwr DU 1.0 SXL SPL-WRKF, Ultrasonic A LRFW, RH Front Work Light A

42C H LH Front Work Lights Fused Pwr DU 1.0 SXL SPL-WRKF, Ultrasonic A LLFW, LH Front Work Light A

42FS Front Work Lights Switched Pwr DU 1.0 GXL SWL, Work Lights Switch 3 ECB, Elect Center B A1

42RS Rear Work Light Switched Pwr DU 1.0 GXL SWL, Work Lights Switch 6 ECB, Elect Center B A2

42R C Rear Work Lights Fused Pwr DU 1.0 GXL CAB-RF, Cab to Roof Conn. B ECB, Elect Center B AA2

42R F Rear Work Lights Fused Pwr DU 1.0 GXL ROOF, Roof to Cab Conn. B SPL-WRKR, Ultrasonic A

42R G RH Rear Work Lt Fused Pwr DU 1.0 SXL SPL-WRKR, Ultrasonic A LRRW, RH Rear Work Light A

42R H LH Rear Work Lt Fused Pwr DU 1.0 SXL SPL-WRKR, Ultrasonic A LLRW, LH Rear Work Light A

42 A Work Lights Fused Power R 2.0 GXL SWL, Work Lights Switch 2 SPL-WL, Ultrasonic A

42 B Work Lights Fused Power R 2.0 GXL SWL, Work Lights Switch 5 SPL-WL, Ultrasonic A

43S A Door Open Signal W 0.8 GXL CAB-RF, Cab to Roof Conn. R SPL-DS, Ultrasonic A

43S B Door Open Signal W 0.8 GXL ROOF, Roof to Cab Conn. R DS, Door Switch B

43S C Door Open Signal W 0.8 TXL SPL-DS, Ultrasonic A AIC-2, Adv Instrument Cluster 2 2

43S D Time Delay Mod Door Sw Reset W 0.8 TXL TDM, Time Delay Module 4 SPL-DS, Ultrasonic A

43 A Dome Light Auto Mode DU 0.8 TXL CAB-RF, Cab to Roof Conn. A AIC-1, Adv Instrument Cluster 1 7




21C Bk - 1.0


Wire Color

Wire Name

Wire Size (mm2)




0.8 mm 1.0 mm 2.0 mm 5.0 mm

4002-29


43 B Dome Light Auto Mode DU 0.8 GXL ROOF, Roof to Cab Conn. A LDM2, Dome Light Auto 1

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 AIC-1, Adv Instrument Cluster 1 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

44A DN Brake Light Relay Out T 1.0 SXL ENG, Engine Cab 8 ENG-H, Engine to Hood 2

44A E Brake Light Relay Out T 1.0 SXL LLR-E, LH Rear Comb Light 1 SPL-B8, Ultrasonic A

44A EN Brake Light Relay Out T 1.0 SXL HD-N, Hood to Engine 2 SPL-J2-N, Ultrasonic A

44A F Brake Light Relay Out T 1.0 SXL LRR-E, RH Rear Comb Light 1 SPL-B8, Ultrasonic A

44A FN Brake Light Relay Out T 1.0 SXL LLR-N, LH Rear Comb Light A SPL-J2-N, Ultrasonic A

44A GN Brake Light Relay Out T 1.0 SXL LRR-N, RH Rear Comb Light A SPL-J2-N, Ultrasonic A

44A J Brake Light Power T 1.0 SXL SPL-L1, Ultrasonic A HD-9, Hood to Engine 2

44A K Brake Light Power T 1.0 SXL SPL-L1, Ultrasonic A LRR-9, RH Rear Comb Light 1

44A L Brake Light Power T 1.0 SXL LLR-9, LH Rear Comb Light 1 SPL-L1, Ultrasonic A

44 A Brake Light Control Power T 0.8 GXL CAB-F, Cab Front Chassis 23 ECC, Work Lights D5

45A A Left Turn Switch Power N 0.8 GXL FLSHR, Flasher Module 9 SRHSTLK, RH Stalk Switch L

45B A Right Turn Switch Power N 0.8 GXL FLSHR, Flasher Module 10 SRHSTLK, RH Stalk Switch R

45H Hazard Switch Power N 0.8 GXL FLSHR, Flasher Module 11 SHZ, Hazard Switch 3

45L Left Turn Signal N 1.0 SXL FRONT, Cab Front Chassis 1 LLF, Lights LH 5

45L 9 Left Turn Signal N 1.0 SXL HD-9, Hood to Engine 3 LLR-9, LH Rear Comb Light 2

45L A Left Turn Signal N 1.0 SXL ENG, Engine Cab 10 LLR-E, LH Rear Comb Light 2

45L AN Left Turn Signal N 1.0 SXL ENG, Engine Cab 10 ENG-H, Engine to Hood 3

45L B Left Turn Signal N 0.8 GXL CAB-E, Cab Engine 10 SPL-PK3, Splice 3-4 Way D

45L BN Left Turn Signal N 1.0 SXL HD-N, Hood to Engine 3 LLR-N, LH Rear Comb Light C

45L C Left Turn Signal N 0.8 GXL CAB-F, Cab Front Chassis 1 SPL-PK3, Splice 3-4 Way C

45L D Left Turn Signal N 0.8 GXL FLSHR, Flasher Module 8 SPL-PK3, Splice 3-4 Way B

45L E Left Turn Signal N 0.8 TXL SPL-PK3, Splice 3-4 Way A AIC-2, Adv Instrument Cluster 2 9

45N A Flasher OPP Side Control N 0.8 GXL FLSHR, Flasher Module 2 64F, Flasher Connector 1




21C Bk - 1.0


Wire Color

Wire Name

Wire Size (mm2)




0.8 mm 1.0 mm 2.0 mm 5.0 mm

4002-30


45N B Flasher OPP Side Control N 0.8 GXL FLSHR, Flasher Module 12 64M, Flasher Connector 1

45R Right Turn Signal N 1.0 SXL FRONT, Cab Front Chassis 3 LRF, Lights RH 5

45R 9 Right Turn Signal N 1.0 SXL HD-9, Hood to Engine 4 LRR-9, RH Rear Comb Light 2

45R A Right Turn Signal N 1.0 SXL ENG, Engine Cab 12 LRR-E, RH Rear Comb Light 2

45R AN Right Turn Signal N 1.0 SXL ENG, Engine Cab 12 ENG-H, Engine to Hood 4

45R B Right Turn Signal N 0.8 GXL CAB-E, Cab Engine 12 SPL-PK3, Splice 3-4 Way H

45R BN Right Turn Signal N 1.0 SXL HD-N, Hood to Engine 4 LRR-N, RH Rear Comb Light C

45R C Right Turn Signal N 0.8 TXL SPL-PK3, Splice 3-4 Way E AIC-2, Adv Instrument Cluster 2 10

45R D Right Turn Signal N 0.8 GXL CAB-F, Cab Front Chassis 3 SPL-PK3, Splice 3-4 Way G

45R E Right Turn Signal N 0.8 GXL FLSHR, Flasher Module 7 SPL-PK3, Splice 3-4 Way F

46 C Beacon Switched Power K 1.0 GXL CAB-RF, Cab to Roof Conn. E SBE, Beacon Switch 3

46 D Beacon Switched Power K 1.0 GXL ROOF, Roof to Cab Conn. E LBEPWR, Light Beacon power 1

46 E Beacon Switched Power 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 SPL-BCK-LGT, Spl Back Lgt Pwr F

49S Back Light Power S 0.8 GXL STA, Trans Auto Switch 8 SPL-BCK-LGT, Spl Back Lgt Pwr J

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 SWL, Work Lights Switch 8 SPL-BCK-LGT, Spl Back Lgt Pwr M

49 B Back Light Power S 0.8 GXL SBE, Beacon Switch 8 SPL-BCK-LGT, Spl Back Lgt Pwr L

49 C Back Light Power S 0.8 GXL SRWP, Rear Wiper Switch 8 SPL-BCK-LGT, Spl Back Lgt Pwr C

49 D Back Light Power S 0.8 GXL SHZ, Hazard SWitch 8 SPL-PED-BL, Spl Back Lgt Pwr 6 Pck

C

49 E Back Light Power S 0.8 GXLSPL-BCK-LGT2, Spl Back Lgt Pwr

A SPL-BCK-LGT, Spl Back Lgt Pwr K

49 F Back Light Power S 0.8 GXL SPE, Pin Engage Switch 10 SPL-BCK-LGT2, Spl Back Lgt Pwr

F

49 G Back Light Power S 0.8 GXL SRC, Ride control Switch 8 SPL-BCK-LGT2, Spl Back Lgt Pwr

K

49 H Back Light Power S 0.8 GXL STE, Trans Enable Switch 8 SPL-BCK-LGT, Spl Back Lgt Pwr D

49 J Back Light Power S 0.8 GXL SRTD, Detent Switch 8 SPL-BCK-LGT2, Spl Back Lgt Pwr

C




21C Bk - 1.0


Wire Color

Wire Name

Wire Size (mm2)




0.8 mm 1.0 mm 2.0 mm 5.0 mm

4002-31


49 K Back Light Power S 0.8 GXL SFL, Return to Travel Switch 8 SPL-BCK-LGT2, Spl Back Lgt Pwr

E

49 L Back Light Power S 0.8 GXL SBU, Back Up Alarm Dis Sw 8 SPL-BCK-LGT, Spl Back Lgt Pwr E

49 M Back Light Power S 0.8 GXL SHC, Height Control Switch 8 SPL-BCK-LGT2, Spl Back Lgt Pwr

D

49 N Back Light Power S 0.8 GXL SPC, Pilot Control Switch 8 SPL-PED-BL, Spl Back Lgt Pwr 6 Pck

B

49 P Back Light Power S 0.8 GXL SDR, Driving Lights Switch 8 SPL-BCK-LGT, Spl Back Lgt Pwr G

49 Q Back Light Power S 0.8 GXL SFC, Fan Control Switch 8 SPL-BCK-LGT2, Spl Back Lgt Pwr

G

49 R Back Light Power S 0.8 GXL SDC, Declutch Switch 8 SPL-BCK-LGT, Spl Back Lgt Pwr H

49 S Back Light Power S 0.8 GXLSPL-PED-BL, Spl Back Lgt Pwr 6 Pck

F SPL-BCK-LGT2, Spl Back Lgt Pwr

M

49 T Back Light Power S 0.8 GXL SFWW, Front Wiper/Washer 8 SPL-BCK-LGT2, Spl Back Lgt Pwr

H

49 U Back Light Power S 0.8 GXL SCS, Comfort Steer Switch 8 SPL-PED-BL, Spl Back Lgt Pwr 6 Pck

A

49 V Back Light Power S 0.8 GXL SPB, Parking Brake Switch 8 SPL-PED-BL, Spl Back Lgt Pwr 6 Pck

E

51B A Comfort Steer Solenoid Power W 0.8 GXL SCS, Comfort Steer Switch 6 SPL-CSS, Ultrasonic A

51B B Comfort Steer Solenoid Power W 0.8 GXL SPL-CSS, Ultrasonic A ECC, Work Lights D10

51B C Comfort Steer Solenoid Power W 0.8 GXL SPL-CSS, Ultrasonic A CAB-F, Cab Front Chassis 2

51B D Comfort Steer Solenoid Power W 1.0 SXL FRONT, Cab Front Chassis 2 YCS, Comfort Steer Solenoid A

51C Comfort Steer control W 0.8 TXLAIC-1, Adv Instrument Cluster 1

21 ECC, Work Lights B10

51CS Comfort Steer Switch W 0.8 TXL SCS, Comfort Steer Switch 3 AIC-1, Adv Instrument Cluster 1 17

51P A Sec. Str High Press W 1.0 SXL SSM, Sec. Steer Module 9 PSS, Sec. Steer Pressure Switch A

51S Standard Steering Signal W 0.8 TXL SCS, Comfort Steer Switch 1 AIC-1, Adv Instrument Cluster 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 SFC, Fan Control Switch 3 AIC-2, Adv Instrument Cluster 2 8

52A A Fan Reverse Relay Out W 1.0 GXL CAB-E, Cab Engine 22 ECB, Elect Center B D8

52A B Fan Reverse Relay Out W 1.0 SXL ENG, Engine Cab 22 YFR, Fan Rev Solenoid Option 1




21C Bk - 1.0


Wire Color

Wire Name

Wire Size (mm2)




0.8 mm 1.0 mm 2.0 mm 5.0 mm

4002-32


52C Parking Brake Solenoid LSD W 0.8 TXLAIC-1, Adv Instrument Cluster 1

14 ECB, Elect Center B B10

52J Fan Control Switch Jumper W 0.8 GXL SFC, Fan Control Switch 4 SFC, Fan Control Switch 2

52M Fan Reverse Manual W 0.8 TXL SFC, Fan Control Switch 6 AIC-2, Adv Instrument Cluster 2 7

52P Parking Brk Relay Out W 1.0 SXL FRONT, Cab Front Chassis 24 YPB, Park Brake Solenoid 1

52P A Parking Brk Relay Out W 0.8 GXL CAB-F, Cab Front Chassis 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

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 FRONT, Cab Front Chassis 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 EM, RTD Height Control RTT 4 CAB-F, Cab Front Chassis 12

53C A Pilot Control Solenoid LSD W 0.8 TXLAIC-1, Adv Instrument Cluster 1

20 ECD, Elect Center D B6

53P A Pilot Control Relay Out W 0.8 GXL SPL-D25, Ultrasonic A YPP, Pilot Pressure Solenoid A

53P B Pilot Control Relay Out W 0.8 GXL SFL, Return to Travel Switch 2 SPL-D25, Ultrasonic A

53P C Pilot Control Relay Out W 1.0 GXL SPL-D25, Ultrasonic A ECD, Elect Center D D6

53P D Pilot Control Relay Out W 0.8 GXL SHC, Height Control Switch 2 SPL-D25, Ultrasonic A

53P E Pilot Control Relay Out W 0.8 GXL SRTD, Detent Switch 2 SPL-D25, Ultrasonic A

53P F Pilot Control Relay Out W 0.8 GXL CAB-F, Cab Front Chassis 19 SPL-D25, Ultrasonic A

53P G Pilot Control Relay Out W 1.0 SXL FRONT, Cab Front Chassis 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 PXH, Height Control RTT C

54A Height Control Switch Power W 0.8 GXL SHC, Height Control Switch 6 EM, RTD Height Control RTT 2

54B Height RTT Control Signal W 1.0 SXL FRONT, Cab Front Chassis 11 PXH, Height Control RTT A

54B A Height RTT Control Signal W 0.8 GXL CAB-F, Cab Front Chassis 11 SPL-D1, Ultrasonic A

54B B Height RTT Control Signal W 0.8 GXL EM, RTD Height Control RTT 5 SPL-D1, Ultrasonic A

54B C Height RTT Control Signal W 0.8 GXL SFL, Return to Travel Switch 6 SPL-D1, Ultrasonic A

55A A RTT Float Sw Power W 0.8 GXL EM, RTD Height Control RTT 1 SPL-RTT, Ultrasonic A

55A B RTT Float Sw Power W 0.8 GXL SFL, Return to Travel Switch 1 SPL-RTT, Ultrasonic A




21C Bk - 1.0


Wire Color

Wire Name

Wire Size (mm2)




0.8 mm 1.0 mm 2.0 mm 5.0 mm

4002-33


55A C RTT Float Sw Power W 0.8 GXL SFL, Return to Travel Switch 3 SPL-RTT, Ultrasonic A

55B RTT Float Switch Control W 0.8 GXL SFL, Return to Travel Switch 5 EM, RTD Height Control RTT 6

56 A Fan Control PWM W 1.0 SXL ENG, Engine Cab 23 YFN, Fan PWM Solenoid A

57 A Pin Engage Sol Pwr W 0.8 GXL CAB-F, Cab Front Chassis 20 SPL-PINE, Ultrasonic A

57 B Pin Engage Sol Pwr W 0.8 GXL SPE, Pin Engage Switch 1 SPL-PINE, Ultrasonic A

57 C Pin Engage Sol Pwr W 0.8 TXL SPL-PINE, Ultrasonic A AIC-2, Adv Instrument Cluster 2 16

58C Ride Control Switch Jumper W 0.8 GXL SRC, Ride Control Switch 5 SRC, Ride Control Switch 3

58H A Ride Control Sw Pwr VPS2 W 0.8 TXL TECM, Trans 8 ECD, Elect Center D D7

58L Ride Control Relay LSD Bk 0.8 TXL TECM, Trans 57 ECD, Elect Center D B8

58S E Ride Control Sol to Front Cab W 1.0 SXL FRONT, Cab Front Chassis 21 YRC, Ride Control Option 1

58T Ride Control Relay Sw Pwr W 0.8 GXL SRC, Ride Control Switch 4 ECD, Elect Center D B7

58 A Ride Control Sol Pwr W 1.0 SXL 202M, Rollback Jumper A 202M, Rollback Jumper B

58 B Ride Control Sol Pwr W 1.0 SXL FRONT, Cab Front Chassis 21 PRBF, Rollback Pressure Switch B

58 C Ride Control Sol Pwr W 0.8 GXL CAB-F, Cab Front Chassis 21 SPL-D26, Ultrasonic A

58 D Ride Control Sol Pwr W 0.8 GXL 140M, Diode Module D SPL-D26, Ultrasonic A

58 E Ride Control Sol Pwr W 0.8 GXL SPL-D26, Ultrasonic A ECD, Elect Center D D8

58 F Ride Control Sol Pwr W 0.8 GXL SRC, Ride Control Switch 6 SPL-D26, Ultrasonic A

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

59U 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

60D 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

60U 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

61A 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

61C AC Relay Out Or 0.8 GXL CAB-E, Cab Engine 2 ECD, Elect Center D D10

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

61R AC Relay Control W 1.0 SXL ENG, Engine Cab 29 PR, Trinary Press Sw B




21C Bk - 1.0


Wire Color

Wire Name

Wire Size (mm2)




0.8 mm 1.0 mm 2.0 mm 5.0 mm

4002-34


61R B AC Relay Control 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 Front Wiper Park Control W 0.8 GXL ECD, Elect Center D D4 ECD, Elect Center D C2

63C3 Front Wiper Park Control W 0.8 GXL K-WCO, Wiper Cutout 87a ECD, Elect Center D B3

63HC Front Wiper High Speed Rly Ctrl W 0.8 GXL SFWW, Front Wiper/Washer 9 SPL-HC, Ultrasonic A

63HC A Wiper Cutout Relay Control W 0.8 GXL SPL-HC, Ultrasonic A K-WCO, Wiper Cutout 85

63HC B Front Wiper High Speed Rly Ctrl W 0.8 GXL 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 SFWW, Front Wiper/Washer 3 ECD, Elect Center D B4

63L A Front Wiper Low Speed Rly Out W 0.8 GXL FMW, Front Wiper Motor B SPL-WLS, Ultrasonic A

63L B Front Wiper Low Speed Rly Out W 0.8 GXL K-WCO, Wiper Cutout 30 SPL-WLS, Ultrasonic A

63L C Front Wiper Low Speed Rly Out W 0.8 GXL 140M, Diode Module B SPL-WLS, Ultrasonic A

63W Front Washer Pump W 0.8 GXL CAB-E, Cab Engine 25 SFWW, Front Wiper/Washer 7

63W A Front Washer Pump W 1.0 SXL ENG, Engine Cab 25 FWW, Front Washer 1

64C Horn Relay Control Or 0.8 GXL SRHSTLK, RH Stalk Switch 31b ECC, Work Lights B8

64 A Horn Power Or 0.8 GXL CAB-F, Cab Front Chassis 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 CAB-RF, Cab to Roof Conn. K SRWP, Rear Wiper Switch 1

68C A Rear Wiper Park Control Or 1.0 GXL ROOF, Roof to Cab Conn. K RWM, Rear Wiper Motor D

68L Rear Wiper Switch Power Or 1.0 GXL SRWP, Rear Wiper Switch 2 SPL-3, Ultrasonic A

68L A Rear Wiper Switch Power Or 1.0 GXL ROOF, Roof to Cab Conn. L RWM, Rear Wiper Motor B

68L B Rear Wiper Switch Power Or 1.0 GXL CAB-RF, Cab to Roof Conn. L SPL-3, Ultrasonic A

68L C Rear Wiper Switch Power Or 1.0 GXL 140M, Diode Module F SPL-3, Ultrasonic A

68W Rear Washer Pump W 0.8 GXL CAB-E, Cab Engine 24 SRWP, Rear Wiper Switch 6

68W A Rear Washer Pump W 1.0 SXL ENG, Engine Cab 24 RWW, Rear Washer 1

CAN H CAN HighY 0.8 TXL TWIST

CAN2, CAN Bulk Head A EDC7, Engine Controller 35




21C Bk - 1.0


Wire Color

Wire Name

Wire Size (mm2)




0.8 mm 1.0 mm 2.0 mm 5.0 mm

4002-35


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 SPL-CAN-DIAG, Ultrasonic A

CAN HD CAN High

Y 0.8 TXL TWIST

SPL-CAN-TRANS, Ultrasonic A TECM, Trans 25

CAN HE CAN High

Y 0.8 TXL TWIST

SPL-CAN, Ultrasonic A SPL-CAN-TRANS, Ultrasonic A

CAN HF CAN High

Y 0.8 TXL TWIST

SW-PD, Switch Pad 7 SPL-CAN, Ultrasonic A

CAN HG CAN High

Y 0.8 TXL TWIST

SPL-CAN, Ultrasonic A AIC-1, Adv Instrument Cluster 1 3

CAN HJ CAN High From Engine

Y 0.8 TXL TWIST

CAN2, CAN Bulk Head A QSM11, Engine controller 46

CAN HK CAN High

Y 0.8 TXL TWIST

SPL-CAN-HVAC, Ultrasonic A HVAC-CAN1, CAN HVAC AIC A

CAN HM CAN High

Y 0.8 TXL TWIST

SPL-CAN-HVAC, Ultrasonic A SPL-CAN-DIAG, Ultrasonic A

CAN L CAN LowG 0.8 TXL TWIST

CAN2, CAN Bulk Head B EDC7, Engine Controller 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 SPL-CAN-DIAG-L, Ultrasonic A

CAN LD CAN Low

G 0.8 TXL TWIST

SPL-D5, Ultrasonic A SPL-CAN-TRANS-L, Ultrasonic A

CAN LE CAN Low

G 0.8 TXL TWIST

SPL-CAN-L, Ultrasonic A SPL-CAN-TRANS-L, Ultrasonic A

CAN LF CAN Low

G 0.8 TXL TWIST

SW-PD, Switch Pad 8 SPL-CAN-L, Ultrasonic A

CAN LG CAN Low

G 0.8 TXL TWIST

SPL-CAN-L, Ultrasonic A AIC-1, Adv Instrument Cluster 1 4




21C Bk - 1.0


Wire Color

Wire Name

Wire Size (mm2)




0.8 mm 1.0 mm 2.0 mm 5.0 mm

4002-36


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 QSM11, Engine Controller 37

CAN LN CAN Low

G 0.8 TXL TWIST


A SPL-CAN-DIAG-L, Ultrasonic A

ECC L1 Beacon/Dome Light L1 ECC BUSS L1-ECC, ECC Batt Power cs01 ECC, Work Lights L1-1

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




21C Bk - 1.0


Wire Color

Wire Name

Wire Size (mm2)




0.8 mm 1.0 mm 2.0 mm 5.0 mm

4002-37


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-A, Power Relay Mod A

PRM B Time Delay Fuse Ignition Pwr Fuse

BUSS PRM-A, Power Relay Mod A

PRM D Accessory Pwr Fuse Spare BUSS PRM-D, Power Relay Mod D PRM-D, Power Relay Mod D

PRM PWR

Ignition Power Fuse Accessory Power Fuse

BUSS PRM-A, Power Relay Mod A PRM-D, Power Relay Mod D

RAD1 Radio Ground W 0.8 GXL RAD-J3, Radio Jumper 5 RAD-J1, Radio Power 8

RAD2 12V Fused Power to Radio W 0.8 GXL RAD-J3, Radio Jumper 12 RAD-J1, Radio Power 7

RAD3 12V Fused Power to Radio W 0.8 GXL RAD-J3, Radio Jumper 7 RAD-J1, Radio Power 4

RAD4 Left Speaker Ground W 0.8 GXL RAD-J3, Radio Jumper 3 RAD-J2, Speaker 8

RAD5 Left Speaker W 0.8 GXL RAD-J3, Radio Jumper 10 RAD-J2, Speaker 7

RAD6 Not Used W 0.8 GXL RAD-J3, Radio Jumper 4 RAD-J2, Speaker 6




RAD10 Right Speaker Ground W 0.8 GXL RAD-J3, Radio Jumper 1 RAD-J2, Speaker 2

RAD11 Right Speaker W 0.8 GXL RAD-J3, Radio Jumper 8 RAD-J2, Speaker 1




21C Bk - 1.0


Wire Color

Wire Name

Wire Size (mm2)




0.8 mm 1.0 mm 2.0 mm 5.0 mm

4002-38


UNDERSTANDING THE TROUBLESHOOTING TABLES

LOCATING COMPONENTS ON THE SCHEMATIC POSTERSNOTE: For the System Electrical Schematic refer to the Schematic Posters located at the rear of this manual.

Components can be located on the Electr icalSchematic posters (rear pocket) by item numberusing the key at the bottom of the posters.

1. This title is the number and component name on the Electrical Schematic.

2. This column shows the location of the check point.

3. This column shows the indication of the check.

4. This column shows the possible cause of a bad test indication.

5. The numbers in the parentheses show the number of the component on the Electrical Schematic.

6. This statement assumes that all other problems are solved at this point in the test.

1 – Alternator

Check PointsCorrect Reading

Possible Cause of Bad Reading

Check the 10 ampere fuse atlocation 3 and 4C in the fuse block. Good Bad fuse.

Terminal for wire 1A to ground 12 voltsCheck wire 1A between the starter terminal (21) and thealternator (1).

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

1

6

5

32 4

4002-39


STARTING AND CHARGING SYSTEMS

BS06H241 / BS06H242

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

1. STARTING RELAY 7. TIME DELAY MODULE2. RESISTOR 75 OHM 8. MASTER DISCONNECT SWITCH3. ALTERNATOR 9. STARTER 4. CRANK CONTROL RELAY 10. IGNITION SWITCH5. BATTERIES 11. NEUTRAL START RELAY6. CRANK REQUEST RELAY 12. VOLT METER RELAY

5

12

3

8

10

2

9

46

1 711

4002-40


1 – Starting Relay

Located in the right side of the engine compartment on cooling fan housing, open engine compartment to gain access.



Terminal for wire 0-GB to ground Continuity 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.



Between terminals of resistor 75 ohms Bad resistor.

3 – Alternator

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



Between housing of alternator and ground

Continuity Bad ground connection.


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

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

4002-41


4 – Crank Control Relay




Terminal for wire 21H to ground Continuity Bad ground circuit or bad EDC7 (24).

NOTE: Put the master disconnect switch in the ON position. Put the transmission in NEUTRAL. Have anotherperson 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




Terminal for wire 0-DF to ground Continuity Bad ground circuit.

NOTE: Put the master disconnect switch in the ON position. Have another person hold the ignition switch in theSTART 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.

4002-42


7 – Time Delay Module

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



Terminal for wire 0-DC to ground Continuity Bad ground circuit.


Terminal for wire 1DN to ground 24 volts Bad 10 ampere fuse in ECC F5. Check wire 1DN to SPL-DLY and wire 1DM to fuse ECC F5.


Terminal for wire 13K-A to ground 24 volts 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 timedelay 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 voltsKey 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.



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

Between terminals of master disconnect switch

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

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

Between terminals of master disconnect switch

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

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

4002-43


9 – Starter Motor

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



Between housing of starter and ground

Continuity Bad ground connection.


Starter B+ stud to ground 24 volts Check circuit to batteries.

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

Terminal S to ground 24 volts Bad starting relay (1). Also check wire 1-BB between starter and starting relay (1).

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

10 – Ignition Switch

Located on steering column.




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 Bad ignition switch.

NOTE: Hold the ignition switch in the START position.

Between Bat and Starter Continuity Bad ignition switch.

Between Bat and Ign Continuity Bad ignition switch.

NOTE: Put the switch in the Accessory position.

Between Bat and Accessory Continuity Bad ignition switch.

4002-44


11 – Neutral Start Relay




Terminal for wire 0-DE to ground Continuity Bad ground circuit.

NOTE: Put master disconnect switch and ignition switch in ON position. Make sure transmission is in NEUTRAL.

Terminal for wire 25T to ground 24 volts Check circuit 25T, check FNR switch (55).

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

Terminal for wire 21K-B to ground 24 volts Check circuit 21K-B and ignition switch (10).

Terminal for wire 21C to ground 24 volts Bad neutral start relay.

12 – Voltmeter Relay




Terminal for wire 0-DB to ground Continuity Bad ground circuit.


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.

4002-45


POWER RELAY MODULES AND COLD STARTING SYSTEMS

BS06H241 / BS06H242


13. POWER RLEAY MODULE A 18. POWER RELAY MODULE D14. POWER RELAY MODULE B 19. CIRCUIT BREAKER CAB +15. POWER RELAY MODULE C 20. WATER SEPARATOR HEATER16. GRID HEATER RELAY 21. FUEL FILTER HEATER17. GRID HEATER

17 1920

21 1418

15

1613

4002-46


13 – Power Relay Module A, Ignition Power




Terminal for wire 0-EB to ground Continuity Bad ground circuit.

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

Terminal for wire 1CB-A to ground 24 volts Check circuit 1CB to 105 Amp circuit breaker in engine compartment, check circuit breaker.

Terminal for wire 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




Terminal for wire 0-EA to ground Continuity Bad ground circuit.

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

Terminal for wire PRM-B BUSS to ground

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

Terminal for wire 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




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.


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.

4002-47


16 – Grid Heater Relay




Terminal for wire 0-BV to ground Continuity 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 sureengine 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.



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+




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.



Terminal for wire 0-BW to ground Continuity Bad ground circuit.

NOTE: Disconnect connector WSH from water separator heater.

Between terminals A and B of heater 1.9 ohms Bad heater.

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

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.



Terminal for wire 0-BX to ground Continuity Bad ground circuit.

NOTE: Disconnect connector FFH from fuel filter heater.

Between terminals A and B of heater 1.9 ohms Bad heater.

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

21 – Power Relay Module D, Accessory Power




Terminal for wire 0-EC to ground Continuity Bad ground circuit.

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

Terminal for wire PRM-D BUSS to ground


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.

4002-49


ENGINE CONTROLLER

BS06H241 / BS06H242


22. WATER IN FUEL SENSOR23. THROTTLE POTENTIOMETER24. ENGINE CONTROLLER

22

24

23

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.



Terminal for wire 0-BP to ground Continuity Bad ground circuit.

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

Terminal for wire 18J-H to ground 24 volts Check fuse ECD-F2, power relay module B (14), also check circuit 18J.

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

Terminal for wire 35W to ground 24 volts Bad water separator sensor.

23 – Throttle Potentiometer

Located below cab under throttle pedal.



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

Terminal for wire 24S to 24R 5 volts Bad EDC7 (24). Also check wire 24S.

Terminal for wire 24R to ground Continuity Bad EDC7 (24). Also check wire 24R.

NOTE: Throttle pedal in low idle position.

Terminal for wire 24B to 24R0.4 ± 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. Disconnectconnector 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 pedal1000 ± 400

ohms at 20° C (68° F)

Bad potentiometer.

NOTE: Throttle pedal in any position.

Between pin 4 and 5 at pedal1200 ± 400

ohms at 20° C (68° F)

Bad potentiometer.

4002-51


24 – Electronic Diesel Control

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



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


Terminal for wire 0-BD pin 10 to ground


Terminal for wire 0-BC pin 11 to ground


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


Terminal for wire 18J-D pin 8 to ground


Terminal for wire 18J-E pin 9 to ground


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

4002-52


RETURN TO TRAVEL - RETURN TO DIG - PIN ENGAGE

BS06H241 / BS06H242


25. RETURN TO TRAVEL FLOAT SWITCH 30. HEIGHT CONTROL/RETURN TO TRAVEL PROXIMITY SWITCH26. HEIGHT CONTROL SWITCH 31. RETRUN TO DIG SWITCH 27. ELETROMAGNETIC DETENTS 32. PIN ENGAGE SWITCH (OPTION)28. RETURN TO DIG PROXIMITY SWITCH 33. PILOT PRESSURE SOLENOID29. PILOT CONTROL RELAY ECD-K3 34. PIN ENGAGE SOLENOID (OPTION)

30

31

27

33

26

28

32

34

29

25

4002-53


25 – Return-To-Travel/Float Switch

Located on right side console.



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-to-travel/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. Putignition switch in ON position. Put driving lamp switch (95) in position 3.

Terminal for wire 49-K to ground 24 voltsBad 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.

26 – Height Control Switch




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 controlswitch to the ON position.

Terminal for wire 53P-D to ground. 24 volts Bad pilot control relay (29), check fuse ECA-F5.

NOTE: Turn the height control switch to the ON position.

Terminal for wire 54A to ground. 24 volts Bad height control switch.

4002-54


27 – Electromagnetic Detents

Located under right side console.



NOTE: For joystick controller.

Between pins 3 and 474 ohms @

20° C (68° F) Bad electromagnetic detent





NOTE: For single axis controller.

Between pins 3 and 4328 ohms @ 20° C (68° F) Bad electromagnetic detent



NOTE: Put the master disconnect switch and ignition switch in ON position. Put pilot control switch (39) in OFFposition 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.


24 volts Bad height control switch. Also check wires 54A.

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


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

28 – Return-To-Dig Proximity Switch

Located on bucket cylinder.



NOTE: Disconnect the connector from the return-to-dig proximity switch. Put the master disconnect switch andthe ignition switch in the ON position. Put the pilot control switch (39) in the OFF position and the return to digswitch in the ON position.

Terminal B for wire 0-AC to ground Continuity Bad ground circuit.

Terminal A for wire 53B to ground 24 volts Bad bucket control valve detent electromagnets (27) or return to dig switch. Also check circuit 53B.

Terminal C for wire 53P-H to ground 24 volts Bad pilot relay (29), also check circuit 53P.

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

4002-55


29 – Pilot Control Relay




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

Terminal for wire 53C-A to ground 0 volt Bad instrument cluster (62). Also check circuit 53C.

Terminal for wire 53P-A to ground 24 volts 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.



NOTE: Disconnect the connector from the height control/return-to-travel proximity switch. Put the masterdisconnect switch and the ignition switch in the ON position. Put the pilot control switch (39) in the OFF positionand the return to travel switch in the ON position.

Terminal B for wire 0-AA to ground Continuity Bad ground circuit.

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.

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

31 – Return to Dig Switch




Terminals for wire 0-B4 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 controlswitch to the ON position.

Terminal for wire 53P-E to ground. 24 volts Bad pilot control relay (29), check fuse ECA-F5.

NOTE: Turn the height control switch to the ON position.

Terminal for wire 53A to ground. 24 volts Bad return to dig switch.

4002-56


32 – Pin Engage Switch (Option)





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

Terminal for wire 19P-A to ground 24 volts Bad fuse ECA-F7 or power relay module A. Also check circuit 19P.

Terminal for wire 57-B to ground 0 volt 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 voltsCheck 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.

33 – Pilot Pressure Solenoid

Located on bottom side of pilot controls.



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 controlswitch (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.



Terminal for wire 0-AE to ground Continuity Bad ground circuit.

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the pin engage switch(32) in the ON position.

Terminal for wire 57 to ground 24 volts Bad pin engage switch (32), also check circuit 57.

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

4002-57


PILOT CONTROL - RIDE CONTROL - FAN CONTROL

BS06H241 / BS06H242


35. RIDE CONTROL SWITCH (OPTION) 40. RIDE CONTROL SOLENOID (OPTION)36. RIDE CONTROL RELAY (OPTION) 41. ROLLBACK PRESSURE SWITCH (OPTION)37. FAN CONTROL SWITCH (OPTION) 42. ROLLBACK JUMPER38. FAN REVERSE RELAY (OPTION) 43. FAN PWM SOLENOID39. PILOT CONTROL SWITCH 44. FAN REVERSE SOLENOID (OPTION)

44

39

41

42

37

43

40

38

36

35

4002-58


35 – Ride Control Switch




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 ONposition. Put ride control switch in OFF position.

Terminal for wire 19C-D to ground 24 volts Check fuse ECA-F5 and power relay module A. Also check circuit 19C.

Terminal for wire 58C to ground 0 volt 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 voltsCheck 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




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.

4002-59


37 – Fan Reversing Switch (Option)






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 voltsCheck 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




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

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

24 volts Check fuse ECA-F7 and circuit 19P.

NOTE: Put the fan reverse switch in the manual reverse position.

Terminals for wire 52A-A to ground 24 volts Bad fan reverse solenoid, bad fan reverse switch (37), bad advanced instrument cluster (62).

4002-60


39 – Pilot Control Switch

Located on steering column pedestal.



Terminal for wire 0B1 to ground Continuity Bad ground circuit.


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.



NOTE: Disconnect connector YRC from ride control solenoid.

Connector YRC pin 2 to ground Continuity Bad ground circuit.

Between terminals 1 and 2 of ride control solenoid

20 to 26 ohms Bad ride control solenoid.

41 – Rollback Pressure Switch (Option)

Located inside of front frame.



NOTE: Switch opens at 6.2 bar (90 psi). Release all hydraulic pressure from the system, disconnect the wiringharness from the rollback pressure switch.

Between terminals A and B on switch

Continuity Bad rollback pressure switch.

Terminal for wire 58S to ground 37 to 43 ohms Bad ride control solenoid (40).

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

Terminal for wire 58-B to ground24 volts at5 km/hr

(3 m.p.h.)

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

4002-61


42 – Rollback Jumper (Option)

Located inside of front frame.



Between terminals A and B on switch

Continuity Bad rollback jumper.

43 – Fan PWM Solenoid (Option)

Located on fan control valve.



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

Between pins 1and 2 of fan PWM solenoid

26 to 32 ohms Bad fan reversing solenoid.

Pin 2 of wiring harness connector YFN to ground


NOTE: In the options menu of the instrument cluster select auto for the fan. Stall the transmission to raisetransmission 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.



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

Between pins 1and 2 of fan reversing solenoid

36 to 42 ohms Bad fan reversing solenoid.

Pin 2 of wiring harness connector YFR to ground


NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put fan reversing switch in ONposition (hold rocker in momentary position).

Pin 1 of wiring harness connector YFR to ground

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

4002-62


TRANSMISSION

BS06H241 / BS06H242


45. OUTPUT SPEED SENSOR 54. TRANSMISSION ENABLE SWITCH 46. TRANSMISSION SOLENOID VALVE AND TEMPERATURE SENSORS 55. FNR SWITCH FOR JOYSTICK CONTROLS47. FILTER MAINTENANCE SWITCH 56. TRANSMISSION KICK-DOWN SWITCH 48. TORQUE CONVERTER OUTPUT TEMPERATURE SENDER 57. FNR SWITCH FOR SINGLE AXIS CONTROLS 49. ENGINE SPEED SENSOR 58. TRANSMISSION AUTO SWITCH 50. INTERMEDIATE SPEED SENSOR 59. BRAKE DECLUTCH PRESSURE SWITCH51. TURBINE SPEED SENSOR 60. DECLUTCH SWITCH52. TRANSMISSION SHIFTER 61. DIAGNOSTIC CONNECTOR53. TRANSMISSION ELECTRONIC CONTROL MODULE

5255

46

455049

51 47

48

53 54

56 57

58

60

61

4002-63


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

45 – Output Speed Sensor

46 – Transmission Solenoid Valve and Temperature Sensors

47 – Filter Maintenance Switch

48 – Torque Converter Output Temperature Sender

49 – Engine Speed Sensor

50 – Intermediate Speed Sensor

51 – Turbine Speed Sensor

52 – Transmission Shifter

53 – Transmission Electronic Control Module

54 – Transmission Enable Switch

55 – FNR Switch for Joystick Controls

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

57 – FNR Switch for Single Axis Controls

58 – Transmission Auto Switch

59 – Brake Declutch Pressure Switch

60 – Declutch Switch

61 – Diagnostic Connector

4002-64


WARNING BUZZER, INSTRUMENT CLUSTER 1, PARK BRAKE

BS06H241 / BS06H242


62. INSTRUMENT CLUSTER CONNECTOR 1 66. AIR FILTER RESTRICTION SWITCH63. WARNING BUZZER 67. PARKING BRAKE SOLENOID64. PARKING BRAKE RELAY 68. RADIATOR COOLANT TEMPERATURE SENDER65. FUEL LEVEL SENDER 69. BRAKE PRESSURE WARNING SWITCH

6663

6867

65

69

62

64

4002-65


62 – Instrument Cluster Connector 1

Located on instrument cluster.



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.


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.


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 Bad wire 17P-A.


Open Circuit 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.


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

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.



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.



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




NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the parking brakeswitch (74) is OFF.

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

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

Terminal for wire 52C to ground 0 volt Bad instrument cluster (62). Also check circuit 52C.

Terminal for wire 52P-B to ground 24 volts Bad parking brake relay.

NOTE: Put the parking brake switch in the ON position.

Terminal for wire 52C to ground 24 volts Bad instrument cluster (62). Also check wire 52C.

4002-67


65 – Fuel Level Sender

Located on the fuel tank top right side.



Terminal for wire 0-BU to ground Continuity Bad ground circuit.


Terminal for wire 36F to groundApproximately

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 wiresfrom 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.



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

Terminal for wire 0-BY to ground Continuity Bad ground circuit.


Terminal for wire 31F to groundApproximately

11.5 volts Check the instrument cluster (62).

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

67 – Parking Brake Solenoid

Located on the foot brake valve.



Terminal for wire 0-AL to ground Continuity Bad ground circuit.

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

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.

4002-68


68 – Radiator Coolant Temperature Sender

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



Terminal for wire 0-BAE to ground Continuity Bad ground circuit.

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

Between terminals of radiator coolant temperature sender

3521 ohmsat 20° C (68° F) Replace radiator coolant temperature sender.


Terminal A for wire 36C to groundApproximately


69 – Brake Warning Pressure Switch




NOTE: Brake warning pressure switch opens at 110.3 bar (1600 psi).


Terminal 2 for wire 0-AL to ground Continuity Bad ground circuit.

Terminal 1 for wire 33P to groundApproximately

11.5 volts Check circuit 33P.

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

Between terminals 1 and 2 of the switch

Continuity Bad brake warning pressure switch.

NOTE: Start and run the engine at idle two minutes.

Between terminals 1 and 2 of the switch

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

4002-69


SWITCH PAD, INSTRUMENT CLUSTER 2, PARK BRAKE

BS06H241 / BS06H242


70. SWITCH PAD 74. PARK BRAKE SWITCH71. INSTRUMENT CLUSTER CONNECTOR 2 75. REDUNDANT BRAKE PRESSURE SWITCH 172. HYDRAULIC FILTER RESTRICTION SWITCH 76. REDUNDANT BRAKE PRESSURE SWITCH 273. HYDRAULIC OIL TEMPERATURE SENDER 77. COOLANT LEVEL SENDER

70 74

77

75

72

76

71

73

4002-70


70 – Switch Pad




NOTE: Disconnect switch pad connector, put master disconnect switch and ignition switch in ON position.

Terminal for wire 17P-A to ground. 24 volts Bad instrument cluster (62).

NOTE: Disconnect instrument cluster connector 1.

Between terminals for wire 17P-A Continuity Bad wire 17P-A.

4002-71


71 – Instrument Cluster Connector 2

Located on instrument cluster.



NOTE: Disconnect the connector AIC-2 from the instrument cluster and SW-PD from the switch pad.


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.

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


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


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.


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.


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.



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

4002-72


]

72 – Hydraulic Filter Restriction Switch

Located on hydraulic filter block.



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.


Terminal for wire 31H to ground.Approximately

11.5 volts Check the instrument cluster (62).

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

73 – Hydraulic Oil Temperature Sender

Located on hydraulic filter block.



Terminal for wire 0-HW to ground Continuity Bad ground circuit.

NOTE: Disconnect the connector from the hydraulic oil temperature sender.

Between terminals of hydraulic oil temperature sender

3521 ohmsat 20° C (68° F) Replace hydraulic oil temperature sender.


Terminal A for wire 36H to groundApproximately


4002-73


74 – Parking Brake Switch






Terminal for wire 19A-L to ground 24 volts Check fuse ECA-F1, also check circuit 19A.

NOTE: Apply parking brake switch.

Terminal for wire 33U to ground 24 volts Bad parking brake switch.

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

Terminal for wire 49-V to ground 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 brakeswitch.

75 – Redundant Brake Pressure Switch 1

Located on steel lines at accumulators.



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

Terminal for wireS 0-HM to ground Continuity Bad ground circuit.


Terminal A for wire 33R-C to groundApproximately

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

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

76 – Redundant Brake Pressure Switch 2

Located on steel lines at accumulators.



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

Terminal for wireS 0-HL to ground Continuity Bad ground circuit.


Terminal A for wireS 33R-B to ground

Approximately 11.5 volts Bad instrument cluster (62), also check circuit 33R.

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

4002-74


77 – Coolant Level Sender

Located on radiator top tank.



Terminal for wire 0-HV to ground Continuity Bad ground circuit.


Terminal A for wire 31D to groundApproximately 1.6 volts AC Check circuit 31D, also check the instrument cluster (62).

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

4002-75


BACK UP ALARM CONTROLS

BS06H241 / BS06H242


78. BACK UP ALARM RELAY 79. BACK UP ALARM DISABLE SWITCH

78

79

4002-76


78 – Back-up Alarm Relay




NOTE: Disconnect the transmission electronic control module (53) connector TECM.

Terminal for wire 35C to terminal 7 of connector TECM

Continuity Bad wire 35C.


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





NOTE: Put the master disconnect switch and the ignition switch in the ON position and the park brake to the OFFposition. 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 inNorth American models. The connectors are disconnected and the switch is installed in TUV road approved(Germany) models.

Terminal for wire 35R-C to ground 24 volts Bad back-up alarm disable switch.

4002-77


LIGHTS - 01

BS06H241 / BS06H242


80. WORK LIGHTS SWITCH 85. LEFT HAND FRONT WORK LAMP81. DOOR SWITCH 86. RIGHT HAND FRONT WORK LAMP82. ROTATING BEACON (OPTIONAL) 87. LEFT HAND REAR WORK LAMP83. DOME LIGHT 88. RIGHT HAND REAR WORK LAMP84. ROTATING BEACON SWITCH (OPTIONAL) 89. DIODES

86

80

81

85

83

84

82

88

87

89

4002-78


80 – Work Lamps Switch




Terminal for wire 0-B14 to ground Continuity 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.




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.



Bulb Continuity Bad bulb.

Terminal for wire 0-MC to ground Continuity Bad ground circuit.

NOTE: Put master disconnect switch and beacon switch (84) in ON position.

Terminal for wire 46-D to ground 24 volts Bad circuit between the beacon and the beacon switch (84). Also check the beacon switch (84).

NOTE: If readings are good replace the rotating beacon.

4002-79


83 – Dome Lamp

Located in top of cab.




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.

Terminal for wire 19U-C to ground 24 volts Check fuse ECC-F1, also check circuit 19U.

Terminal for wire 43-B to ground24 volts

3 to 5 secondsCheck 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)





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.



NOTE: Disconnect wiring harness connector LLFW from LH front work lamp connector.

Flood lamp connector pin A to pin B Continuity Bad lamp bulb.

NOTE: Connect wiring harness connector LLFW to LH front work lamp connector.

Terminal for wire 0-MU to ground Continuity Bad ground circuit.

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

Terminal for wire 42C-H to ground 24 voltsCheck fuse ECB-F1 and driving lamp switch (95). Also check circuit 42C from flood lamp to lamp switch (95) and wire 42-A to fuse ECC-F2.

4002-80


86 – Right Hand Front Work Lamp

Located on right front side of cab.



NOTE: Disconnect wiring harness connector LRFW from RH front work lamp connector.


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 voltsCheck 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.



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


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 voltsCheck 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.



NOTE: Disconnect wiring harness connector LRRW from RH rear work lamp connector.


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

4002-81


89 – Lights Diodes

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



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.

4002-82


LIGHTS - 02

BS06H241 / BS06H242


90. BRAKE LIGHTS SWITCH 93. HAZARD SWITCH91. BRAKE LIGHTS RELAY 94. TURN SIGNAL, HIGH-LOW BEAM, AND HORN SWITCH92. FLASHER MODULE 95. DRIVING LIGHTS SWITCH

91

95

94

90

93

92

4002-83


90 – Brake Lamp Pressure Switch




NOTE: Put master disconnect switch in ON position.

Terminal for wire 1-AA to ground 24 volts Check fuse ECC-F4, also check wires 1-AA and 1-DR.

Terminal for wire 44 to ground 0 volt 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




Terminal for wire 0-EF to ground Continuity Bad ground circuit.


Terminal for wire 1-DW to ground 24 volts Check fuse ECC-F4 and wires 1-DW and 1-DV.

Terminal for wire 44A to ground 0 volt Bad brake lamp pressure switch (90).

Terminal for wire 44A-A to ground 0 volt Bad brake lamps relay.

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

Terminal for wire 44A to ground 24 volts Bad brake lamp pressure switch (90).

Terminal for wire 44A-A to ground 24 volts Bad brake lamps relay.

4002-84


92 – Flasher Module




NOTE: Wiring harness connectors 64F and 64M must be connected for North American Machines for oppositeside 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.


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 groundIntermittent 24

volts Bad flasher module.

Terminal for wire 45R-E to groundIntermittent 24


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

Terminal for wire 45R-E to groundIntermittent 24


NOTE: Put turn signal switch (94) in LEFT turn position.

Terminal for wire 45A-A to ground 24 volts Bad turn signal switch (94) or fuse B. Also check wire 45A-A.

Terminal for wire 45L-D to groundIntermittent 24


4002-85


93 – Hazard Switch






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

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

Terminal for wire 49-D to ground 24 voltsCheck 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.

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




HORN SWITCH

Terminal for wire 0-EP to ground Continuity Bad ground circuit.


Terminal for wire 64C to ground 24 volts Check fuse ECC-F6 and horn relay (98). Also check wires 64C and circuit 19U.

NOTE: If readings are good, replace the switch.

TURN SIGNAL


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 Continuity Bad ground circuit.

4002-86


95 – Driving Lamp Switch





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.


Terminal for wire 41J to ground 24 volts Bad driving lamp switch.

4002-87


LIGHTS - 03 AND HORN

BS06H241 / BS06H242


96. LEFT HAND FRONT COMBINATION LAMPS 98. HORN RELAY97. RIGHT HAND FRONT COMBINATION LAMPS 99. HORN

97

9996

98

4002-88


96 – Left Hand Front Combination Lamp

Located on the left front of the machine.



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.


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.


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 voltsCheck 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 groundIntermittent 24

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

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

4002-89


97 – Right Hand Front Combination Lamp

Located on the right front of the machine.



NOTE: Disconnect wiring harness connector RF from RH front combination lamp connector.


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.


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 groundIntermittent 24

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

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

4002-90


98 – Horn Relay




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.

Terminal for wire 64C to ground 24 volts Bad horn relay.

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

Terminal for wire 64C to ground 0 volt Bad horn switch.

Terminal for wire 64-A to ground 24 volts Bad horn relay.

99 – Horn

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



Terminal for wire 0-AF to ground Continuity Bad ground circuit.

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

Terminal for wire 64 to ground. 24 volts Check the horn relay (98). Also check wires 64 and 64-A.

NOTE: If the readings are good replace the horn.

4002-91


LIGHTS - 04 AND BACK UP ALARM

BS06H241 / BS06H242


100.RIGHT HAND REAR COMBINATION LAMPS 102.LICENSE PLATE LAMP101.LEFT HAND REAR COMBINATION LAMPS 103.BACK UP ALARM

100

102

103

101

4002-92


100 – Right Hand Rear Combination Lamp (North America Only)

Located on the right rear of the machine.



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 holddown 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 groundIntermittent 24


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

Terminal for wire 18G-CN to ground 24 volts Check fuse ECB-F8 and lamp switch (95). Also check circuit 18G.

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

4002-93


100 – Right Hand Rear Combination Lamp (Europe Only)

Located on the right rear of the machine.



NOTE: Disconnect wiring harness connector LRR-E from RH rear combination lamp connector.








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.


Terminal for wire 44A-F to ground 24 volts Check brake lamps relay (91). Also check circuit 44 to brake lamps relay (91).

NOTE: Have assistant put transmission in reverse.

Terminal for wire 35A-K to ground 24 volts Check backup alarm relay (78). Also check circuit 35A to backup alarm relay (78).

NOTE: Have assistant put transmission in neutral. Put turn signal lever in RIGHT turn position.

Terminal for wire 45R-A to groundIntermittent 24



Terminal for wire 18G-A to ground 24 volts Check fuse ECB-F8 and lamp switch (95). Also check circuit 18G.

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

4002-94


101 – Left Hand Rear Combination Lamp (North America Only)

Located on the left rear of the machine.



NOTE: Disconnect wiring harness connector LLR-N from LH rear combination lamp connector.

Combination lamp connector pin A to pin D


Combination lamp connector pin C to pin D


Combination lamp connector pin B to pin D


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.


Terminal for wire 44A-FN to ground 24 volts Check brake lamps relay (91). Also check circuit 44 to brake lamps relay (91).

NOTE: Put turn signal lever in LEFT turn position.

Terminal for wire 45L-BN to groundIntermittent 24



Terminal for wire 18F-BN to ground 24 volts Check fuse ECB-F7 and lamp switch (95). Also check circuit 18F.

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

4002-95


101 – Left Hand Rear Combination Lamp (Europe Only)



NOTE: Disconnect wiring harness connector LLR-E from LH rear combination lamp connector.








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.


Terminal for wire 44A-E to ground 24 volts Check brake lamps relay (91). Also check circuit 44 to brake lamps relay (91).

NOTE: Have assistant put transmission in reverse.

Terminal for wire 35A-L to ground 24 volts Check backup alarm relay (78). Also check circuit 35A to backup alarm relay (78).

NOTE: Have assistant put transmission in neutral. Put turn signal lever in LEFT turn position.

Terminal for wire 45L-A to groundIntermittent 24


102 – License Plate Lamp (North America Only)

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




Terminal for wire 0-JC to ground Continuity Bad ground circuit.

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

Terminal for wire 18G-E to ground 24 volts Check fuse ECB-F8 and five driving lamp switch (95). Also check circuit 18G.

4002-96


102 – License Plate Lamp (Europe Only)

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




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.



Terminal for wire 0-JB to ground Continuity Bad ground circuit.

NOTE: Put the master disconnect switch and the ignition switch in the ON position and the park brake to the OFFposition. 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.



Terminal for wire 0-JB to ground Continuity Bad ground circuit.

NOTE: Put the master disconnect switch and the ignition switch in the ON position and the park brake to the OFFposition. 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.

4002-97


CAB WINDOW WASHER AND WIPER SYSTEM

BS06H241 / BS06H242


104.FRONT WIPER HIGH SPEED RELAY 109.FRONT WIPER MOTOR105.WIPER CUT OUT RELAY 110.REAR WIPER MOTOR106.FRONT WIPER LOW SPEED RELAY 111.REAR WASHER MOTOR107.REAR WIPER/WASHER SWITCH 112.FRONT WASHER MOTOR108.FRONT WIPER/WASHER SWITCH 113.DIODES

104

105

112

111

106113

108107

109110

4002-98


104 – Front Wiper High Speed Relay





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 Continuity Bad front wiper and washer switch (108).

Terminals for wire 63HC-B to ground 24 volts 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





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.


Terminals for wire 63HC-A to ground Continuity Bad front wiper and washer switch (108).

Terminals for wire 63L-B to ground 0 volts Bad wiper cut out relay.

4002-99


106 – Front Wiper Low Speed Relay





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.


Terminals for wire 63LC to ground Continuity Bad front wiper and washer switch (108).

Terminals for wire 63C3 to ground 24 volts Bad wiper low speed relay, also check high speed wiper relay (104).

107 – Rear Wiper and Washer Switch






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.


Terminal for wire 49-C to ground 24 voltsCheck rotary lamp switch (95) and circuit 49. If LEDs in rear wiper and washer switch are not ON with 24 volts at check point, replace rear wiper and washer switch.

4002-100


108 – Front Wiper and Washer Switch




Terminal for wire 0-DT to ground Continuity Bad ground circuit.

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the front wiper andwasher 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 24 volts Bad front wiper and washer switch.

4002-101


109 – Front Wiper Motor

Located in front of steering column.




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.


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

Terminal for wire 63C to ground 0 volt 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 24 volts Check fuse ECA-F12, also check circuit 19J. Bad front wiper and washer switch (108), high speed relay or cut out relay.

Terminal for wire 63C to ground 0 volt 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).

Terminal for wire 63C to ground 24 volts pulse Bad front wiper and washer switch (108).

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

4002-102


110 – Rear Wiper Motor

Located in top of rear cab head liner.



Terminal for wire 0-MA to ground Continuity Bad ground circuit.

NOTE: Make sure the rear wiper and washer switch (107) is in the OFF position.

Between terminals for wires 68C-A and 68L-A

Continuity Bad rear wiper and washer switch (107).


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 Bad rear wiper and washer switch (107).

Terminal for wire 68L-A to ground 0 volt Bad rear wiper and washer switch (107).

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

111 – Rear Washer Pump Motor

Located in left side engine compartment.



Terminal for wire 0-BL to ground Continuity Bad ground circuit.

NOTE: Put master disconnect switch and ignition switch in ON position. Depress and hold rear wiper and washerswitch (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.



Terminal for wire 0-B to ground Continuity Bad ground circuit.

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Connect volt meter to checkpoint then push down on front wiper and washer switch (108).

Terminal for wire 63W-A to ground 24 volts Bad front wiper and washer switch (108), also check circuit 63W.

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

4002-103


113 – Wiper Diodes




NOTE: Disconnect wiring harness connector 140M from diode connector.



Multimeter positive on pin D to pin C None Bad diode.

Multimeter positive on pin E to pin C None Bad diode.

Multimeter positive on pin F to pin C None Bad diode.



Multimeter positive on pin C to pin D Continuity Bad diode.

Multimeter positive on pin C to pin E Continuity Bad diode.

Multimeter positive on pin C to pin F Continuity Bad diode.

4002-104


SECONDARY STEERING

BS06H241 / BS06H242


114.SECONDARY STEERING DIODES 117.SECONDARY STEERING MOTOR115.SECONDARY STEERING SOLENOID 118.SECONDARY STEERING PRESSUR SWITCH116.SECONDARY STEERING MODULE

115 117

116114 118

4002-105


114 – Secondary Steering Diodes




NOTE: Disconnect wiring harness connector DM from diode connector.





115 – Secondary Steering Solenoid (Option)

Located in the rear frame of the machine.



NOTE: Disconnect connector YSS from secondary steering solenoid.

Between pins A and B of secondary steering solenoid

36 to 42 ohms Bad secondary steering solenoid.

Between pin 2 of connector YSS and ground


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

Between pin 1 of connector YSS and ground

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

4002-106


116 – Secondary Steering Module (Option)




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

Pin 2 of connector SSM to ground ContinuityBad relay on secondary steering motor (117) or bad secondary steering solenoid (115). Also Check wires 51-A, 51-B, and 51-C and ground circuit connections (wires 0-ND and 0-CF).

Pin 4 of connector SSM to ground Continuity Bad ground circuit.

Pin 8 of connector SSM to ground Continuity Bad secondary steering pressure switch (118). Also check wires 35X-D, 35X-C, and 35X-A.

Pin 9 of connector SSM to ground Open Circuit Bad secondary steering pressure switch (118). Also check wire 51P-A.



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

Pin 3 of connector SSM to ground 24 volts Bad wire 19S1-X to power relay module A fuse 2 (13).

Pin 7 of connector SSM to ground 24 volts Bad fuse ECA-F17 or ignition switch. Also check circuit 19M.

Pin 1 of connector SSM to ground 24 volts Check fuse ECA-F4, power relay module 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 Bad secondary steering pressure switch.

Pin 8 of connector SSM to ground 11 volts 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 secondarysteering module. Disconnect wire 51-B from secondary steering motor (117) relay terminal. Start and run engineat idle speed. Disconnect wiring harness connector PSS from secondary steering pressure switch (118). Apply aground to pin C of connector PSS.

Terminal for wire 51-B to ground 24 volts Bad secondary steering module.

4002-107


117 – Secondary Steering Motor (Option)




Motor ground stud to ground Continuity Bad ground circuit.

Secondary steering motor relay ground terminal to ground


Terminal for wire 51-B to ground. 10 to 45 ohmsBad secondary steering motor relay coil or secondary steering solenoid (115). Also check relay coil and solenoid ground circuit.

NOTE: Put the master disconnect switch in ON position.

Terminal for red wire to ground 24 volts Check circuit to batteries.

NOTE: Start and run engine for two or three minutes while turning steering wheel left and right several times. DONOT TURN STEERING WHEEL TO STEERING STOPS. Turn ignition switch to OFF position to stop engine, thenimmediately to ON position. Secondary steering motor should be heard operating. If motor is heard, problem isassociated pump; refer to Section 5002. If motor is not heard, leave ignition switch in ON position and disconnectwire 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)




NOTE: Disconnect wiring harness connector PSS from secondary steering pressure switch.

Pressure switch pin B to pin C Continuity Bad secondary steering pressure switch.

Pressure switch pin B to pin A Open Circuit Bad secondary steering pressure switch.

Pressure switch pin A to pin C Open Circuit Bad secondary steering pressure switch.

NOTE: Start and run engine at idle speed.

Pressure switch pin B to pin A Continuity Bad secondary steering pressure switch.

Pressure switch pin B to pin C Open Circuit Bad secondary steering pressure switch.

4002-108


CAN COMMUNICATION

BS06H241 / BS06H242


119.DIAGNOSTIC CONNECTOR

119

4002-109


119 – CAN Communication Diagnostics Connector




Terminal A for wire 0-DH to ground Continuity Bad ground circuit.

Terminal B for wire 18K-A to ground 24 volts Check fuse ECC-F9, check circuit 18K.

4002-110


RADIO AND POWER CONVERTER

BS06H241 / BS06H242


120.POWER RELAY MODULE E 123.RADIO121.POWER CONVERTER 24 TO 12 VOLT 124.RIGHT SPEAKER122.12 VOLT POWER OUTLETS (OPTION) 125.LEFT SPEAKER

120

121

124 123122

125

4002-111


120 – Power Relay Module E




Terminal for wire 0-DL to ground Continuity Bad ground circuit.

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

Terminal for wire PRM-E BUSS to ground


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)




Terminal for wire 0-EJ to ground Continuity Bad ground circuit.


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.



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


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

12 volts 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.

4002-112


123 – 12 Volt Radio Ready (Option)

Located in the cab.



Terminal in radio connector for wire 0-EN to ground



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.



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

Pin 1 in wiring harness connector RSPK to ground

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

Pin 2 in wiring harness connector RSPK to ground

Continuity 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.



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

Pin 1 in wiring harness connector LSPK to ground

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

Pin 2 in wiring harness connector LSPK to ground

Continuity Bad circuit between the left speaker and the radio (123).

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

4002-113


AIR SEAT - CIGAR LIGHTER - AIR CONDITIONING COMPRESSOR

BS06H241 / BS06H242


126.AIR SEAT 129.HIGH/LOW SWITCH127.CIGAR LIGHTER 130.AIR CONDITIONING COMPRESSOR CLUTCH128.AIR CONDITIONING CLUTCH REALY

126 130

129

128

127

4002-114


126 – Seat Compressor and Switch (Option)

Located in the cab.



Terminal for wire 0-DK to ground Continuity Bad ground circuit.


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.



Terminal for wire 19W to ground 24 volts Check fuse ECC-F8, also check circuit 19W.

Terminal for wire 0-DV to ground Continuity Bad ground circuit.

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

128 – Compressor Clutch Relay




Terminal for wire 0-DJ to ground Continuity Bad ground circuit.

NOTE: Put master disconnect switch and ignition switch in ON position. Put blower switch (149) to HIGH andthermostat switch to COLD.

Terminal for wire 61R-B to ground 24 volts Check thermostat switch, also check wire 61R-B.

Terminal for wire 61C to ground 24 volts Bad compressor clutch relay.

NOTE: Put ignition switch in OFF position. Disconnect wiring harness connector PR from A/C trinary pressureswitch. Connect a jumper wire between pins A and B of connector PR. Put ignition switch in ON position.

Terminal for wire 61R-C to ground 24 volts Check wires 61R-B and 61R.

4002-115


129 – A/C High/Low Pressure Switch

Located on the rear frame in front of the rear axle.



NOTE: Put master disconnect switch and ignition switch in ON position. Put the blower switch (149) to HIGH andthe 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.



NOTE: Put master disconnect switch and ignition switch in ON position. Put blower switch (149) to HIGH andthermostat switch to COLD.

Terminals for wire 61C-A to ground 24 volts Check the compressor clutch relay (128), also check circuit 61C.

4002-116


CLIMATE CONTROL - AUTOMATIC TEMPERATURE CONTROL

BS06H241 / BS06H242


131.ELECTRONIC PANEL 137.THERMOCOUPLE SENSOR132.EXTERNAL AIR TEMPERATURE SENSOR 138.MIXED AIR SENSOR133.INTERNAL AIR TEMPERATURE SENSOR 139.COMPRESSOR RELAY134.SUN SENSOR 140.RECYCLING MOTOR135.BLOWER FAN RESISTOR 141.ELETRONIC WATER VALVE136.BLOWER MOTORS 142.24 TO 12 VOLT CONVERTER

135 136 137

139

131

137140 141

132 133 134 138 142

4002-117


131 – Electronic Panel



NOTE: No information at time of print.

132 – External Air Temperature Sensor




133 – Internal Air Temperature Sensor




134 – Sun Sensor




135 – Blower Motor Resistor




136 – Blower Motors




137 – Thermocouple Sensor




138 – Mixed Air Sensor




4002-118


139 – Compressor Relay




140 – Recycling Motor




141 – Electronic Water Valve




142 – 24 to 12 Volt Converter




4002-119


STANDARD CLIMATE CONTROL

BS06H241 / BS06H242


143.AIR RECIRCULATION MOTOR 149.FAN SPEED SWITCH144.DRIVER 150.AIR CONDITIONING SWITCH145.ELETRONIC WATER VALVE 151.CONTROL PANEL LIGHTS146.BLOWER FAN RESISTOR 152.WATER VALVE POTENTIOMETER147.BLOWER MOTOR 153.AIR RECIRCULATING SWITCH148.THERMOSTAT

143 144 145

150149

137146 147 148

151

152 153

4002-120


143 – Air Recirculation Motor




144 – Driver




145 – Electronic Water Valve




146 – Blower Motor Speed Resistors with Thermal Fuse



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.





147 – Blower Motor



Terminals for wire DNS66 to ground Continuity Bad ground circuit.

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Turn the blower switch (149)to position 4.

Terminal for wire DNS65 to ground 24 volts Check the blower switch (149).

NOTE: If the readings are correct and the blower motor does not run, replace the blower motor. Turn the blowerswitch (149) to position 1. If the blower motor ran in position 4 but not in position 1, 2,or 3, check the blowermotor resistor (146).

4002-121


148 – Thermostat




149 – Blower Switch




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.







150 – Air Conditioning Switch




151 – Control Panel Lights




152 – Water Valve Potentiometer




4002-122


153 – Air Recirculating Switch




4002-123


HOOD RAISE AND LOWER SYSTEM

BS06H241 / BS06H242


154.HOOD UP RELAY 156.HOOD SWITCH155.HOOD DOWN RELAY 157.HOOD MOTOR

155

154156

157

4002-124


154 – Hood Up Relay





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





NOTE: Turn the master disconnect switch ON.

Terminal for wire 19Y-B 24 volts Check fuse ECC-F7, check circuit 19Y.

NOTE: Hold the hood switch (156) in the lower position.

Terminal for wire 59D 24 volts Bad hood switch (156), check wire 59D.

Terminal for wire 60D 24 volts Bad hood down relay.

156 – Hood Switch

Located in the right battery compartment with the master disconnect switch.



NOTE: Disconnect connector HD, turn the master disconnect ON.

Terminal for wire 19Y-D to ground 24 volts Check fuse ECC-F7, check circuit 19Y.

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

Continuity Bad hood switch.

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

Continuity Bad hood switch.

4002-125


157 – Hood Motor

Located in the left side of the engine compartment.



NOTE: Turn the master disconnect switch ON and disconnect connector HDM. Hold the hood switch (156) in theraise 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.

4002-126


CONNECTORSCONNECTOR 108F - DIAGNOSTIC CONNECTOR

291663A1

CONNECTOR 140M - DIODE MODULE

245488C1

CONNECTOR 197F - MAIN CAB FNR

225350C1

CONNECTOR 197M - FNR MAIN CAB

225351C1

CAV WIRE IDENT CIRCUIT

1 19A-W Diagnostic Conn. Fused Power

2 37D-A Diagnostic Signal

3 0-DAV Diagnostic TECM Ground

4 37E Diagnostic Signal Switched

5 Not Used

6 Not Used


A 63H-C Front Wiper High Speed

B 63L-C Front Wiper Low Speed

C 0-EE Diode Suppression Grounds

D 58-D Ride Control Solenoid Power

E 21D-B Starter Relay Signal

F 68L-C Rear Wiper Switch Power


1 19A-C FNR Switch Fused Power

2 26F-B FNR Forward Signal

3 26N-B FNR Neutral Signal

4 26R-B FNR Reverse Signal

5 32J-E Trans Enable Indication Lamp

6 25Y-B Trans Kick Down Signal


1 19A-B FNR Switched Fused Power

2 26F-A FNR Forward Signal

3 26N-A FNR Neutral Signal

4 26R-A FNR Reverse Signal

5 32J-A Trans Enable Indication Lamp

6 25Y-C Trans Kick Down Signal

4002-127


CONNECTOR 202M - ROLLBACK JUMPER

245482C1

CONNECTOR 209F - BACKUP ALARM DISABLE JUMPER

245481C1

CONNECTOR 209M - BACKUP ALARM DISABLE JUMPER

245480C1

CONNECTOR 20M - TRANSMISSION KICK-DOWN SWITCH

225316C1

CONNECTOR 215F - ALTERNATOR RESISTOR

199436A1

CONNECTOR 216F - ALTERNATOR RESISTOR

199436A1


A 58-A Ride Control Solenoid Power

B 58-A Ride Control Solenoid Power


A 35A-E Backup Alarm Relay Out


A 35A-D Backup Alarm Relay Out

B Not Used


1 19A-U Trans Kick Down Switched Pwr

2 25Y-C Trans Kick Down Signal


1 14-A Alternator D+


1 19R-D Alternator Resistor Fused Pwr

4002-128


CONNECTOR 64F - FLASHER CONNECTOR

245481C1

CONNECTOR 64M - FLASHER CONNECTOR

245480C1

CONNECTOR ACT - AIR CONDITIONING COMPRESSOR CLUTCH

8602417

CONNECTOR AIC1 - ADV INSTRUMENT CLUSTER 1

87419488


1 45N-A Flasher Optional Side Control


1 45N-B Flasher Optional Side Control


1 61C-A AC relay out


1 13V Voltmeter Input ANALOG

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 Dome Light Auto Mode

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 Brake Light Relay Out

16 51S Standard Steering Signal

17 51CS Comfort Steering Switch

18 Not Used

19 28J Ether AIC OK Signal

20 53C-A Pilot Control Solenoid LSD

21 51C Comfort Steering Control

22 Not Used

23 52 Fan Reverser LSD

24 Not Used

25 17P-A Switch Pad Pwr From AIC Pwr

26 56 Fan Control PWM

4002-129


CONNECTOR AIC2 - ADV INSTRUMENT CLUSTER 2

87410948

CONNECTOR BUZ - AIC BUZZER

222136A1


1 Not Used

2 43S-C Door Open Signal

3 Not Used

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

12 Not Used

13 Not Used

14 19S-D AIC Delay Fused Power

15 0-DB AIC Power Ground Red

16 57-C Pin Engage Solenoid Power

17 21K-A Ignition Switch Start Signal

18 31L Pilot Control Switch High

19 Not Used

20 19S-C AIC Delay Fused Power

21 19E-A AIC Wake Up Ignition

22 0-DA AIC Chassis Ground

23 Not Used

24 Not Used

25 Not Used

26 31D-A Coolant Level Signal


1 35B AIC Buzzer HSD

2 0-B27 Buzzer Ground

4002-130


CONNECTOR CAB-E - CAB TO ENGINE

225415C1


1 21C-C Starter Relay Signal

2 61C AC Relay Out

3 21G EDC7 Crank Control Relay

4 21H Crank Control Relay LSD

5 18F-A LH Position/Tail Fused Power

6 Not Used

7 35A-C Backup Alarm Relay Out

8 44A-C Brake Light Relay Out

9 18G-F RH Position/Tail Fused Power

10 45L-B Left Turn Signal

11 21F EDC7 Digital Ground

12 45R-B Right Turn Signal

13 18R-A Voltmeter Relay Fused Power

14 18J-G EDC7 Time Delay Fused Power

15 21D-C Starter Relay Signal

16 28H Ether Switch Signal

17 0-DX AIC Sensor Ground

18 18J EDC7 Time Delay Fused Power

19 0-DW AIC Power Ground

20 0-DB AIC Power Ground Red

21 13C-B Fuel Shutoff Fused Power

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 Rear Axle Temperature

33 36F-A Fuel Level ANALOG

34 36C-A Radiator Coolant Temp Signal

35 19Y-C Hood Switch Fused Power

36 60D Hood Down Relay Out

37 59D Hood Down Relay Control

38 60U Hood Up Relay Out

39 59U Hood Up Relay Control

40 35A-F Backup Alarm Relay Out


4002-131


CONNECTOR CAB-F - CAB FRONT CHASSIS

291661A1

CONNECTOR CAB-RF - CAB TO ROOF CONNECTION

388710A1


1 45L-C Left Turn Signal

2 51B-C Comfort Steering Solenoid Pwr

3 45R-D Right Turn Signal

4 Not Used

5 18G-G Position RH Fused Power

6 18F-E Position LH Fused Power

7 18B-A High Beam LH Fused Power

8 36B Front Axle Temperature

9 O-DY Front Axle Temperature Ground

10 Not Used

11 54B-A Height-RTT Signal

12 53B-B RTD Signal

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 Pilot Control Relay Out

20 57-A Pin Engage Sol Pwr

21 58-C Ride Control Sol Pwr

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


A 43-A Dome Light Auto Mode

B 42R-C Rear Work Light Fused Power

C 42C-A Front Work Lights Fused Power

D 19U-D Dome Light Fused Power

E 46-C Beacon Switch Power

F 0-DR Roof Splice Grounds

G 0-DS Roof Splice Grounds

J 19K-C Rear Wiper Motor Fused Power

K 68C Rear Wiper Park Control

L 68L-B Rear Wiper Switch Power

M 0-EM Radio Ground

N 12V-B 12V Fused Power to Radio

R 43S-A Door Open Signal

S 19U-G Door Switch Fused Power

4002-132


CONNECTOR CAB-T - CAB TO TRANMISSION

380839A1

CONNECTOR CAN - CAN BULK HEAD

87315266

CONNECTOR CAN2 - CAN BULK HEAD

87315267


1 33RFront Brake Accumulator Pressure Low

2 31D-A Coolant Level Signal

3 19MSecondary Steering Accessory Fused Power

4 19R-ESec. Steering Ignition Fused Power

5 36T-A Valve Body Temp Signal

6 35XSecondary 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

11 0-DM Speed Sensor Ground

12 36R-E Trans Temp/Filter Return

13 36G-A TCO Temp Signal

14 Not Used

15 Not Used

16 25K-A Trans Solenoid Valve Y1

17 25L-A Trans Solenoid Valve Y2

18 25M-A Trans Solenoid Valve Y3

19 25N-A Trans Solenoid Valve Y4

20 25P-A Trans Solenoid Valve Y5

21 25J-A Trans Solenoid Valve Y6

22 25S-A Output Sw Power VPS1

23 31H-A Hyd Filter Restriction Switch Sig

24 Not Used

25 Not Used

26 19S1 Sec. Steering Fused Power

27 Not Used

28 0-DN Output Speed Sensor Ground

29 19A-M Output Speed Sen. Fused Pwr

30 36H-A Hydraulic Oil Temp

31 32F-A Trans Filter Maint Switch


A CAN-HA CAN High

B CAN-LA CAN Low


A CAN-H CAN High

A CAN-HJ CAN High From Engine

B CAN-L CAN Low

B CAN-LM CAN Low From Engine

4002-133


CONNECTOR CL - CIGAR LIGHTER

3227856R1

CONNECTOR CLS - COOL JUMP - COOL SEND

194788A1

CONNECTOR CNV - 24V TO 12V POWER CONVERTER

225351C1

CONNECTOR D-OR - DIODE OR

245485C1

CONNECTOR DIA - DIAGNOSTIC

310057A1

CONNECTOR DISC - DISCONNECT ENGINE

245482C1


1 19W Cigar Lighter Fused Power

2 0-DV Cigar Lighter Ground


A 31D Coolant Level Signal

B 0-HV Coolant Level Sender Ground


1 19L-A Power Converter Fused Power

2 19L-B Power Converter Fused Power

3 0-EJ Power Converter Ground

4 Not Used

5 12V-C 12V Switched Power

6 0-ER Power Converter Ground


A 42C-D Front Work Lights Fused Power

B 41T-C Position Lights Switched Power

C 49 Back Light Power


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 EDC7 ISO-K Interface


A 13C Fuel Shutoff Fused Power

B 13M Fuel Shutoff Fused Power

4002-134


CONNECTOR DM - DIODE OR

245485C1

CONNECTOR DNS-AC-SWITCH

CONNECTOR DNS-ACTUATOR

CONNECTOR DNS-BLUE - ATC CONTROL PANEL

CONNECTOR DNS-COMPRESSOR-RELAY

CONNECTOR DNS-EXTERNAL-AIR-TEMP-SNS

CONNECTOR DNS-HVAC-CAN1

225294C1


A 19RR Sec. Steering Ignition Fused Pwr

B Not Used

C 19R Sec. Steering Ignition Fused Pwr


1 DNS72

2 DNS68

4 DNS71


5 DNS48

6 DNS49


1 DNS8

3 DNS10

5 DNS11

6 DNS2

7 DNS4

9 DNS3

10 DNS6

14 DNS9

15 DNS31

16 DBS13

17 DNS18

21 DNS7

23 DNS12

26 DNS19


85 DNS19

86 DNS20

30 DNS16

87 DNS14


1 DNS2

2 DNS1


A DNS9

B DNS8


4002-135


CONNECTOR DNS-HVAC1

225294C1

CONNECTOR DNS-HVAC2

225315C1

CONNECTOR DNS-INTERNAL-AIR-TEMP-SNS

CONNECTOR DNS-NOT-USED

225326C1

CONNECTOR DNS-YELLOW - ATC CONTROL PANEL


A DNS14

B DNS15

C DNS13


1 DNS36

2 DNS35


1 DNS4

2 DNS3

3 DNS17

4 DNS5


1 DNS12

2 DNS10

3 DNS11


1 DNS25

2 DNS24

5 DNS47

6 DNS43

8 DNS44

9 DNS21

10 DNS23

14 DNS28

15 DNS26

16 DNS22

17 DNS27

18 DNS29

21 DNS22

23 DNS45

24 DNS46

4002-136


CONNECTOR DNS-PWM-BLOWER-PIN4

HIRSCHMANN 772717-001

CONNECTOR DNS-PWM-BLOWER-PIN2

CONNECTOR DNS-PWM-BLOWER

CONNECTOR DNS-THERMOCOUPLE-SENSO

CONNECTOR DNS-MIXED-AIR-SENSOR

CONNECTOR DNS-VOLTAGE-CONVERTER

CONNECTOR DNS-ELECT-WATER-VALVE

CONNECTOR DNS-RECYCLING-MOTOR

CONNECTOR DNS-SPEED-SELECTOR


1 DNS38

2 DNS47

3 DNS37


1 DNS41

2 DNS42


1 DNS41

2 DNS42


1 DNS46

2 DNS40


1 DNS39

2 DNS45


1 DNS34

2 DNS33

3 DNS32

4 DNS31


1 DNS30

2 DNS29

3 DNS28

4 DNS27

6 DNS26


1 DNS21

2 DNS22

3 DNS23

5 DNS24

6 DNS25


1 DNS74

2 DNS61

3 DNS62

4 DNS63

5 DNS73

4002-137


CONNECTOR DNS-CTRL-PANEL-LIGHT

CONNECTOR DNS-WATER-VALVE-POT

CONNECTOR DNS-RECIRCULATING-SWITCH

CONNECTOR DNS-THERMOSTAT-1

CONNECTOR DNS-THERMOSTAT-2

CONNECTOR DNS-ELECTRIC-FAN

CONNECTOR DNS-RESISTOR

CONNECTOR DNS-ELECT-WATER-VALVE-S

CONNECTOR DNS-DRIVER

411311A1


1 DNS69

2 DNS70


1 DNS55

2 DNS54


1 DNS51

2 DNS53


1 DNS67


1 DNS68


1 DNS65

2 DNS66


1 DNS61

2 DNS62

3 DNS63

4 DNS64


1 DNS60

3 DNS56

4 DNS57

5 DNS58

6 DNS59


2 DNS50

3 DNS52

4 DNS49

5 DNS48

6 DNS55

7 DNS57

8 DNS58

9 DNS59

11 DNS51

12 DNS53

13 DNS54

14 DNS56

4002-138


CONNECTOR DNS-HVAC1-S

225294C1

CONNECTOR DNS-HVAC2-S

225315C1

CONNECTOR DS - DOOR SWITCH

245482C1

CONNECTOR E-HD - TRANSMISSION HOOD

245485C1


A DNS67

B DNS76

C DNS69


1 DNS74

2 DNS75


A 19U-F Door Switch Fused Power

B 43S-B Door Open Signal


A 18G-D Lic Plate Light Fused Power

B 35A-G Backup Alarm Relay Out

C 0-BAG Hood Ground (EURO)

4002-139


CONNECTOR ECA - ELECTRICAL CENTER A

87315248


A1 19A-N Transmission Fused Power

A2 18L-A Comfort Steering Fused Power

A3 19E-A AIC Wake Up Ignition

A4 19RRSec. Steering Ignition Fused Pwr

A5 19C-A Pilot Control Relay Fused Pwr

A6 19D-A Park Brake Relay Fused Power

A7 19P Pin Engage/Fan Fused Power

A8 19B Turn Signal Fused Power

A9 13C-B Fuel Shutoff Fused Power

C1 18N Blower Motor Fused Power

C2 19J Front Wiper Fused Power

C3 19K Rear Wiper Fused Power

C4 19H Backup Alarm Relay Fused Pwr

C5 18M AC Relay Fused Power

C6 19N Seat Compressor Fused Pwr

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

L1 J6 Pltem Dtnts Park Brake Sol

L1 J7 Park Brake Solenoid Horn

L1 J8 Fan Reverse/Turn Signal

L1 J9 Turn Signal Engine Shutdown

L2 J11 Blower Motor Power

L2 J12 Blower Mtr Front Wiper Washer

L2 J13 Front Wiper Rear Wiper Washer

L2 J14 Rear Wiper Washer Backup

L2 J15 Backup AC

L2 J16 AC Seat Compressor

L2 J18Seat Compressor Emergency Steering


4002-140


CONNECTOR ECB - ELECTRICAL CENTER B

87312843


A1 42FS Front Work Lights Power

A2 42RS Rear Work Lights Power

A3 41H-B High Beam LH Power

A4 41H-C High Beam RH Power

A5 41L-C Low Beam LH Power

A6 41L-B Low Beam RH Power

A7 41T-B Position Lights LH Sw Power

A8 41T-A Position Lights RH Sw Power

A9 21H Crank Control Relay LSD

A10 21C-B Neutral Start Relay Output

AA1 42C-C Front Work Lights Fused Power

AA2 42R-C Rear Work Lights Fused Power

AA3 18B-A High Beam LH Fused Power

AA4 18C-A High Beam RH Fused Power

AA5 18E-A Low Beam RH Fused Power

AA6 18D-A Low Beam LH Fused Power

AA7 18F-C Pos Tail Lights LH Fused Power

AA8 18G Pos Tail Lights RH Fused Power

AA9 21D-A Starter Relay Signal

AA10 21G EDC7 Crank Control Relay

B1 18R-A Voltmeter Relay Fused Power

B2 0-DD Voltmeter Relay control Ground

B3 21K-B Ignition Switch Start Signal

B4 0-DE Neutral Start Relay Control Gnd

B5 21F EDC7 Digital Ground

B6 0-DF Crank Request Relay Ctrl Gnd

B7 19P-E Fan Reverse Relay Fused Pwr

B8 52 Fan Reverser LSD

B9 19D-C Park Brake relay Fused Pwr

B10 52C Park Brake Solenoid LSD

D1 13K-C Ignition Switch Power

D2 13V Voltmeter Input ANALOG

D3 25T Neutral Signal

D4 21C Neutral Start Relay Output

D5 21C-A Neutral Start Relay Output

D6 21E Key Switch Crank

D7 19P-D Fan Reverse Relay Fused Pwr

D8 52A-A Fan Reverse Relay Out

D9 19D-B Park Brake Relay Fused Pwr

D10 52P-B Park Brake Relay Out


4002-141


CONNECTOR ECC - WORK LIGHTS

87315249


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 Horn Relay Fused Power

A7 19Y Hood Control Fused Power

A8 19W Cigar Lighter Fused Power

A9 18K-A Diagnostic Fused Power

B1 60U Hood Up Relay Out

B2 0-B25 Hood Up Control Ground

B3 60D Hood Down Relay Out

B4 0-B16 Hood Down Control Ground

B5 1-DW Brake Light Relay Bat Power

B6 0-EF Brake Light Relay Control Gnd

B7 19U-A Horn Relay Fused Power

B8 64C Horn Relay Control

B9 18L-C Comfort Steering Fused Pwr

B10 51C Comfort Steering Control

C2 0-B22 Hood Up Relay Ground

C4 0-B12 Hood Down Relay Ground

D1 59U Hood Up Relay Control

D2 19Y-A Hood Up Relay Fused Power

D3 59D Hood Down Relay Control

D4 19Y-B Hood Down Relay Fused Power

D5 44-A Brake Light Control Power

D6 44A-A Brake Light Relay Out

D7 19U-E Horn relay Fused Power

D8 64-A Horn Power

D9 18L-B Comfort Steering Fused Power

D10 51B-B Comfort Steering Solenoid Pwr

L1-1 ECC-L1 Beacon/Dome Lights LI ECC

L1-1 J2-ECC Beacon/Dome Lt Work Lights

L1-2 J2-ECC Beacon/Dome Lt Work Lights

L1-2 J3-ECC Work Lights Driving Lights

L1-3 J3-ECC Work Lights Driving Lights

L1-3 J4-ECC Driving Lights Brake Lights

L1-4 J4-ECC Driving Lights Brake Lights

L1-4 J5-ECC Brake Lights Delay Power

L1-5 J5-ECC Brake Lights Delay Power

L1-5 J6-ECC Delay Power Horn

L1-6 J6-ECC Delay Power horn

L1-6 J7-ECC Horn HOD Control

L1-7 J7-ECC Horn HOD Control

L1-7 J8-ECC HOD Control Cigar Lighter

L1-8 J8-ECC HOD Control Cigar Lighter

L1-8 J9-ECC Diagnostic Power

L1-9 J9-ECC Diagnostic Power


4002-142


CONNECTOR ECD - ELECTRICAL CENTER D

87312843


A1 13H-C Trans ECM Time Delay Pwr

A2 13H-D Engine ECM Time Delay Pwr

A3 13H-B AIC Time Delay Power

A4 12V-D Plug 1 12V Switched Power

A5 12V-E Plug 2 12V Switched Power

A6 12V-F Radio 12V Switched Power

A7 12V-G 2 Way Radio 12V Sw Power

A9 35C Backup Alarm Relay Control

A10 19H Backup Alarm Relay Fused Pwr

AA1 19T-A TECM Delay Fused Power

AA2 18J-K EDC7 Time Delay Fused Power

AA3 19S-B AIC Delay Fused Power

AA4 12V 12V Power to Outlet 1

AA5 12V-A 12V Power to Outlet 2

AA6 12V-B 12V Fused Power to Radio

AA9 35A-A Backup Alarm Relay Out

AA10 19A-PBackup Alarm Relay Ctrl Fused Pwr

B1 19J-E Front Wiper Relay Fused Power

B2 63HC-B Front Wiper HS Relay Control

B3 63C3 Front Wiper Park Control

B4 63LC Front Wiper LS Relay Control

B5 19C-B Pilot Control Relay Fused Pwr

B6 53C-A Pilot Control Solenoid LSD

B7 58T Ride Control Relay Switch Pwr

B8 58L Ride Control Relay LSD

B9 18M AC Relay Fused Power

B10 0-DJ AC Relay Control Ground

C2 63C2 Front Wiper Park Control

C4 63C Front Wiper Park Control

D1 19J-DFront Wiper Relay HS Ctrl Fused Pwr

D2 63H-B Front Wiper HS Relay Out

D3 19J-FFront Wiper Relay LS Ctrl Fused Pwr

D4 63C2 Front Wiper Park Control

D5 19C-C Pilot control Relay Fused Pwr

D6 53P-C Pilot Control Relay Out

D7 58H-A Ride Ctrl Switched Pwr VPS2

D8 58-E Ride Control Solenoid Power

D9 61R-B AC Relay Control

D10 61C AC Relay Out


4002-143


CONNECTOR EDC7 - ENGINE CONTROLLER

BOSCH-89-POLE

CONNECTOR EM - HEIGHT CONTROL RTD - RTT

225351C1


2 18J-C EDC7 Time Delay Fused Power

3 18J-B EDC7 Time Delay Fused Power

5 0-BE EDC7 Ground

6 0-BF EDC7 Ground

8 18J-D EDC7 Time Delay Fused Power

9 18J-E EDC7 Time Delay Fused Power

10 0-BD EDC7 Ground

11 0-BC EDC7 Ground

12 28G Grid Heater Source DR

13 0-BN Filter Heater Control

17 21H-A Crank Control Relay LSD

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 EDC7 Crank Control Relay

40 13M-A Fuel Shutoff Fused Power

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 EDC7 ISO-K Interface


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 RTT Float Switch Control


4002-144


CONNECTOR ENG - ENGINE TO CAB

225414C1

CONNECTOR ENG-D - DISCONECT HARNESS

245483C1


1 21C-D Starter Relay signal

2 61C-A AC Relay Out

2 61C-B AC Relay Out

3 21GA EDC7 Crank Control Relay

4 21H-A Crank Control Relay LSD

5 18F-AN LH Position/Tail Fuse Power

5 18F-B LH Position/Tail Fuse Power

6 Not Used

7 35A-R Backup Alarm Relay Out

7 35A-J Reverse Light

8 44A-D Brake Light Relay Out

8 44A-DN Brake Light Relay Out

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 Voltmeter Relay Fused Power

14 18J-F EDC7 Time Delay Fused Power

15 21D Starter Relay Signal

16 28E Ether Relay Signal

17 0-BJ AIC Sensor Ground

18 18J-A EDC7 Time Delay Fused Power

19 0-BG AIC Power Ground

20 0-BH AIC Power Ground Red

21 13C-A Fuel Shutoff Fused Power

22 52A-B Fan Reverse Relay Out

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

30 61A Trinary Pressure Switch Input

31 20G-A EDC7 ISO-K Interface

32 36A-A Rear Axle Temperature

33 36F Fuel Level ANALOG

34 36C Radiator Coolant Temp Signal

35 19Y-D Hood Switch Fused Power

36 60D-A Hood Down Relay Out

37 59D-A Hood Down Relay Control

38 60U-A Hood Up Relay Out

39 59U-A Hood Up Relay Control

40 35A-G Backup Alarm Relay Out

40 35A-GN Backup Alarm Relay Out


A 13C-A Fuel Shutoff Fused Power

B 13M-A Fuel Shutoff Fused Power

B 13M-B Key Switch Power Disc Switch


4002-145


CONNECTOR ENG-H - ENGINE TO HOOD

225320C1

CONNECTOR ENG-T - ENGINE TO TRANSMISSION

225326C1

CONNECTOR ESS - ENGINE SPEED SENSOR

291718A1

CONNECTOR FFH - FULE FILTER HEATER

182069A1


1 0-BAG-N Hood Ground (NA)

2 44A-DN Brake Light Relay Out

3 45L-AN Left Turn Signal

4 45R-AN Right Turn Signal

5 18G-HN RH Position/Tail Fused Pwr

6 18F-AN LH Position/Tail Fused Pwr

7 35A-GN Backup Alarm Relay Out

8 35A-R Backup Alarm Relay Out


1 0-BZ Sec. Steering Splice Ground

2 0-BK Transmission Splice Grounds

3 31D-CCoolant Level Sender Eng Transmission

4 Not Used


1 25A Engine Speed Signal

2 0-HF Engine Speed Sensor Ground


A 1-GB Fuel Filter Heater Power

B 0-BX Fuel Filter Heater Ground

4002-146


CONNECTOR FLSHR - FLASHER MODULE

225389C1

CONNECTOR FM - FILTER MAINTENANCE SWITCH

371614A1

CONNECTOR FRONT - CAB FRONT CHASSIS

373358A1CAV WIRE IDENT CIRCUIT

1 1-DU Flasher Module Power

2 45N-A Flasher Optional Side Control

3 0-EH Flasher Module Ground

4 0-EG Flasher Module Ground

5 Not Used

6 Not Used

7 45R-E Right Turn Signal

8 45L-D Left Turn Signal

9 45A-A Left Turn Switch Power

10 45B-A Right Turn Switch Power

11 45H Hazard Switch Power

12 45N-B Flasher Optional Side Control


1 32F Trans Filter Maint Sw

2 36R-B Trans FM Switch Return


1 45L Left Turn Signal

2 51B-D Comfort Steering Sol Power

3 45R Right Turn Signal

4 Not Used

5 18G-A RH Position/Tail Fused Power

6 18F LH Position/Tail Fused Power

7 18B LH High Beam Fused Power

8 36B-A Front Axle Temperature

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 Pilot Control Relay Out

20 57 Pin Engage Sol Pwr

21 58-B Ride Control Sol Pwr

21 58S-ERide Control Solenoid to Front Cab

22 1-AA Brake Lamp Switch Power

23 44 Brake Lamp Control Power

24 52P Park Brake Relay Out

25 Not Used

26 33P Low Brake Pressure Warning

27 19A-A Brake Declutch Sw Fused Pwr

28 25G Brake Declutch Switch Control

29 Not Used

30 Not Used

31 Not Used

4002-147


CONNECTOR FWM - FRONT WIPER MOTOR

245715C1

CONNECTOR FWMG - FRONT WIPER MOTOR GROUND

245480C1

CONNECTOR FWW - FRONT WASHER

3227856R1

CONNECTOR GHC - GRID HEATER RELAY

3227856R1


A 63H-A Front Wiper High Speed Rly Out

B 63L-A Front Wiper Low Speed Rly Out

C 19J-A Front Wiper Motor Fused Power

D 63C Front Wiper Park Control


1 0-B8 Front Wiper Ground


1 63W-A Front Washer Pump

2 0-B Front Washer Ground


1 28G Grid Heater Source DR

2 0-BV Grid Heater Control Ground

4002-148


CONNECTOR GND-CAB-SPL - CAB GROUND SPLICE

87324393

CONNECTOR GND-CAB-SPL2 - SPLICE BACK LIGHT GROUND

87324393

CONNECTOR HD - HOOD SWITCH

245485C1

CONNECTOR HD-E - HOOD HARNESS TO TRANSMISSION HARNESS

245484C1


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

I 0-DK Seat Compressor Motor Ground

K 0-DJ AC Relay Control Ground

L 0-DU Pilot Pressure Solenoid Gnd

M 0-DH Diagnostic Connector Ground


A 0-DC Time Delay Module Ground

B 0-EA Time Delay Relay Control Gnd

C 0-EB Ignition Relay Control Ground

D 0-EC ACC Relay Control Ground

E 0-DD Voltmeter Relay Control Gnd

F 0-DFCrank Request Relay Control Gnd

G 0-DE Neutral Start Relay Control Gnd

H 0-EQSplice Pack Gnd Cab SPL2 GND

J Not Used

K 0-EH Flasher Module Ground

L 0-EG Flasher Module Ground

M 0-EF Brake Lights Relay Control Gnd


A 59D-A Hood Relay Control Down

B 19Y-D Hood Switch Fused Power

C 59U-A Hood Relay Control Up


A 18G-E License Plate Light Fused Pwr

B 35A-H Backup Alarm Relay Out

C 0-JA Hood Ground (EURO)


4002-149


CONNECTOR HD-N - HOOD TO ENGINE

225319C1

CONNECTOR HDM - HOOD LIFT MOTOR

225316C1

CONNECTOR HOT - HYDRAULIC OIL TEMPERATURE SENDER

194788A1

CONNECTOR HVAC1 - HVAC1

225295C1

CONNECTOR HVAC2 - HVAC2

87552622


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 RH Position/Tail Fused Power

6 18F-BN LH Position/Tail Fused Power

7 35A-HN Backup Alarm Relay Out


1 60U-A Hood Up Relay Out

2 60D-A Hood Down Relay Out


A 36H Hydraulic Oil Temp Signal

B 0-HW Hydraulic Oil Temp Ground


1 61A-B Trinary Pressure Switch Input

2 18N-A Blower Motor Fused Power

3 49A Back Light Power


1 0-ED HVAC Grounds

2 18N-B Blower Motor Fused Power

4002-150


CONNECTOR HVAC-CAN1 - CAN-HVAC-ATC

87315267

CONNECTOR ISS - INT-SPEED-SENSOR

291718A1

CONNECTOR K-WCO - WIPER CUTOUT

245731C1

CONNECTOR LBEE - LIGHT BEACON EXTESION

291730A1


A CAN-HK CAN High

B CAN-LL CAN Low


1 25B INT Speed Signal

2 0-HG INT Speed Sensor Ground


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 Not Used

87A 63C3 Front Wiper Park Control


A 46-E Beacon Light Power

B 0-MD Beacon Light Ground

4002-151


CONNECTOR LLF - LH FRONT LIGHTS

225351C1

CONNECTOR LLFW - LH FRONT WORK LAMP

245483C1

CONNECTOR LLR-E - LH REAR COMBINATION LAMP

225351C1

CONNECTOR LLR-N - LH REAR COMBINATION LAMP

245715C1


1 0-AJ Lights Ground LH

2 18D Low Beam LH

3 18B High Beam LH

4 18F Position LH Fused Power

5 45L Left Turn Signal

6 Not Used


A 42C-H LH Front Work Lamp Power

B 0-MU LH Front Work Lamp Ground


1 44A-E Brake Light Relay Out

2 45L-A Left Turn Signal

3 18F-B Left Tail Fused Power

4 35A-L Reverse Lamp

5 0-BT LH Ground (EURO)

6 Not Used


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)

4002-152


CONNECTOR LLRW- LH REAR WORK LAMP

245483C1

CONNECTOR LPL - LICENSE PLATE LAMP

245482C1

CONNECTOR LRF - RH FRONT COMBINATION LAMP

225351C1

CONNECTOR LRFW - RH FRONT WORK LAMP

245483C1


A 42R-H LH Rear Work Lamp Fused Pwr

B 0-ME LH Rear Work Lamp Ground


A 18G-E License Plate Lamp Fused Pwr

A 18G-EN License Plate Lamp Fused Pwr

B 0-JC License Plate Lamp Ground


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


A 42C-G RH Front Work Lamp Fused Pwr

B 0-MJ RH Front Work Lamp Ground

4002-153


CONNECTOR LRR-E - RH REAR COMBINATION LAMP

225351C1

CONNECTOR LRR-N - RH REAR COMBINATION LAMP

245715C1

CONNECTOR LRRW - RH REAR WORK LAMP

245483C1

CONNECTOR LSPK - LEFT SPEAKER

195552A1

CONNECTOR OSS - OUTPUT SPEED SENSOR

291719A1


1 44A-F Brake Light Relay Out

2 45R-A Right Turn Signal

3 18G-J Right Position/Tail Fused Pwr

4 35A-K Reverse Lamp

5 0-BR Ground (EURO)

6 Not Used


A 44A-GN Brake Lamp Relay Out

B 18G-CNRH Position/Tail Lamp Fused Pwr

C 45R-BN Right Turn Signal

D 0-BT-N RH Rear Light Ground (NA)


A 42R-G RH Rear Work Lamp Fused Pwr

B 0-MF RH Rear Work Lamp Ground


A 65L Left Speaker Signal

B 0-PA Left Speaker Ground


1 0-HE Output Speed Ground

2 25D Output Speed Signal

3 19A Output Speed Fused Pwr

4002-154


CONNECTOR PAF - AIR FILTER RESTRICTION SWITCH

291718A1

CONNECTOR PBD - BRAKE DECLUTCH PRESSURE SWITCH

245482C1

CONNECTOR PBL - BRAKE LAMP PRESSURE SWITCH

222136A1

CONNECTOR PBW - BRAKE PRESSURE WARNING SWITCH

225316C1


1 31FAir Filter Restriction Switch Signal

2 0-BYAir Filter Restriction Switch Grnd


A 19A-A Brake Declutch Sw Fused Pwr

B 25G Brake Declutch Switch Control


1 1-AA Brake Lamp Switch Power

2 44 Brake Lamp Control Power


1 33P Low Brake Press Warning

2 0-AL Brake Press Warn Sw Ground

4002-155


CONNECTOR PO1 - POWER OUTLET

12176446

CONNECTOR PO2 - POWER OUTLET

12176446

CONNECTOR PR - TRINARY PRESSURE SWITCH

182068A1

CONNECTOR PRB1 - REDUNDANT BRAKE SWITCH

245483C1

CONNECTOR PRB2 - REDUNDANT BRAKE SWITCH

245483C1


A 12V 12V Pwr to Outlet 1

B Not Used

C 0-EK Aux Power Outlet 1 Gnd


A 12V 12V Pwr to Outlet 2

B Not Used

C 0-EK Aux Power Outlet 2 Gnd


A 61-A Trinary Pressure Switch Input

B 61R AC Relay Control


A 33R-CRDNT Brake Accumulator Press Low

B 0-HM Ground


A 33R-BRDNT Brake Accumulator Press Low

B 0-HL Ground

4002-156


CONNECTOR PRBF - ROLLBACK PRESSURE SWITCH

245483C1

CONNECTOR PRM-A1 - PRM SIGNAL

256340A1

CONNECTOR PRM-B1 - PRM SIGNAL

409084A1

CONNECTOR PRM-B2 - PRM SIGNAL

256340A1

CONNECTOR PRM-C1 - PRM OUTPUT

409084A1


A 58 Ride Control Solenoid Power

B 58-B Ride Control Solenoid Power


A 13K-B Ignition Switch Power

B 0-EB Ignition Relay Control Ground


A Not Used

C 13H Time Delay Power


A 13D Time Delay Relay Control Pwr

B 0-EA Time Delay Relay Control Gnd


A 18R Voltmeter Relay Fused Pwr

C 28P Ether Solenoid Power

C 1-GA Filter Heater Power

4002-157


CONNECTOR PRM-C2 - PRM SIGNAL

256340A1

CONNECTOR PRM-D1 - PRM SIGNAL

256340A1

ONNECTOR PRM-E1 - PRM SIGNAL

409084A1

CONNECTOR PRM-E2 - PRM SIGNAL

256340A1

CONNECTOR PSS - SECONDARY STEERING PRESSURE SWITCH

245485C1


A 28E Ether Relay Signal

A 28F Fuel Filter Heater Relay Control

B 0-BAM Ether Relay Signal Ground

B 0-BN Filter Heater Control


A 12ACC-B ACC PRM Control Power

B 0-EC ACC Relay Control Ground


A Not Used

C 19L Power Converter FSD Power


A 12ACC-C Pwr Converter PRM Control Pwr

B 0-DL Pwr Converter Relay Ctrl Gnd


A 51P-A Secondary Steer High Pressure

B 0-CC Sec. Steer Press Switch Ground

C 35X-A Secondary Steer Low Press Sig

4002-158


CONNECTOR PXF - RTD

245485C1

CONNECTOR PXH - HEIGHT CONTROL RTT

245485C1

CONNECTOR PXM - RTD

245485C1

CONNECTOR PXT - RTD

245485C1

CONNECTOR RAD - RADIO POWER

292495A1


A 53B RTD Signal

B 0-AC Proximity Switch Ground

C 53P-H Pilot Control Relay Out


A 54B RTT Signal

B 0-AA Proximity Switch Ground

C 53P-J Pilot Control Relay Out


A 53B-A RTD Control Signal

B 0-AM RTD Ground

C 53P-I Pilot Control Relay Out


A 53B-A RTD Control Signal

B 0-AM RTD Ground

C 53P-I Pilot Control Relay Out


1 Not Used

2 Not Used

3 Not Used

4 12V-HB 12V Fused Power to Radio

5 Not Used

6 Not Used

7 12V-HA 12V Fused Power to Radio

8 0-EN Radio Ground

4002-159


CONNECTOR RAD-J1 - RADIO POWER

292497A1

CONNECTOR RAD-J2 - SPEAKER

292501A1

CONNECTOR RAD-J3 - RADIO JUMPER

411311A1

CONNECTOR RECT - ENGINE COOLANT TEMPERATURE

194788A1


1 Not Used

2 Not Used

3 Not Used

4 RAD3 12V Fused Power to Radio

5 Not Used

6 Not Used


8 RAD1 Radio Ground


1 RAD11 Right Speaker

2 RAD10 Right Speaker Ground

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


1 RAD10 Right Speaker Ground

2 RAD8 Not Used

3 RAD4 Left Speaker Ground

4 RAD6 Not Used

5 RAD1 Radio Ground

6 Not Used


8 RAD11 Right Speaker

9 RAD9 Not Used

10 RAD5 Left Speaker

11 RAD7 Not Used


13 Not Used

14 Not Used


A 36C Radiator Coolant Temp Signal

B 0-BAE EDC7 Sender Ground

4002-160


CONNECTOR ROOF - ROOF TO CAB CONNECTION

388708A1

CONNECTOR RSPK - RIGHT SPEAKER

195552A1

CONNECTOR RTHP - THROTTLE PEDAL

225351C1

CONNECTOR RWM - REAR WIPER MOTOR

245715C1


A 43-B Dome Light Auto Mode

B 42R-F Rear Work Light Fused Power

C 42C-F Front Work Lights Fused Power

D 19U-C Done Light Fused Power

E 46-D Beacon Switch Power

F 0-MN Roof Grounds

G 0-MK Roof Grounds

J 19K-D Rear Wiper Motor Fused Power

K 68C-A Rear Wiper Park Control

L 68L-A Rear Wiper Switched Power

M 0-EN Radio Ground

N 12V-H 12V Fused Power to Radio

R 43S-B Door Open Signal

S 19U-F Door Switch Fused Power


A 65R Right Speaker Signal

B 0-PB Right Speaker Ground


1 21F-C EDC7 DIGITAL Ground

2 Not Used

3 24B Throttle Signal

3 24B-A Throttle Signal

4 24R Throttle Position Sensor Ground

4 24R-A Throttle Position Sensor Ground

5 24S Throttle Supply

5 24S-A Throttle Supply

6 24L Low Idle Switch


A Not Used

B 68L-A Rear Wiper Switch Power

C 19K-D Rear Wiper Motor Fused Power

D 68C-A Rear Wiper Park Control

4002-161


CONNECTOR RWMG - REAR WIPER MOTOR GROUND

245480C1

CONNECTOR RWW - REAR WASHER

3227856R1

CONNECTOR S-KEY - IGNITION SWITCH TO PEDESTAL HARNESS

225253C1

CONNECTOR SBE - BEACON SWITCH

382391A1


1 0-MA Rear Wiper Motor Ground


1 68W-A Rear Washer Pump

2 0-BL Rear Washer Ground


1 1A Ign Sw Fused Power

2 21K Ign Switch Start Signal

3 13K Ignition Switch Power

4 12ACC Ign Switch Accessory Power

5 Not Used

6 Not Used


1 Not Used

2 19U-H Beacon Switch Fused Power

3 46-C Beacon Switched Power

4 Not Used

5 Not Used

6 Not Used

7 0-B15 Back Light Ground

8 49-B Back Light Power

9 Not Used

10 Not Used

4002-162


CONNECTOR SBU - BACKUP ALARM DISABLE SWITCH

382391A1

CONNECTOR SC - SEAT COMPRESSOR MOTOR

245482C1

CONNECTOR SCS - COMFOR STEER SWITCH

382391A1

CONNECTOR SDC - DECLUTCH SWITCH

382391A1


1 35R-C Backup Alarm Switch

2 35A-B Backup Alarm Disable Switch

3 Not Used

4 Not Used

5 Not Used

6 Not Used


8 49-L Back Light Power

9 Not Used

10 Not Used


A 19N Seat Compressor Fused Pwr

B 0-DK Seat Compressor Motor Ground


1 51S Standard Steering Signal

2 18L-D Comfort Steering Fused Power

3 51CS Comfort Steering Switch

4 Not Used

5 Not Used

6 51B-A Comfort Steering Solenoid Pwr


8 49-U Back Light Power

9 Not Used

10 Not Used


1 25G-B Brake Declutch Switch Control

2 19A-R Declutch Switch Fused Power

3 Not Used

4 Not Used

5 Not Used

6 Not Used


8 49-R Back Light Power

9 Not Used

10 Not Used

4002-163


CONNECTOR SDR - DRIVING LIGHTS SWITCH

382391A1

CONNECTOR SETHR - ETHER SWITCH

382391A1

CONNECTOR SFC - FAN CONTROL SWITCH

382391A1

CONNECTOR SFL - RETURN-TO-TRAVEL SWITCH

382391A1


1 Not Used

2 19Z-A Driving lights Switch Fused Pwr

3 41T Position Lights Switch Power

4 Not Used

5 19Z-BDriving Lights Switch Fused Power

6 41J Driving Lights Power


8 49-P Back Light Power

9 Not Used

10 Not Used


1 Not Used

2 28J Ether AIC OK Signal

3 28H Ether Switch Signal

4 Not Used

5 Not Used

6 Not Used


8 49U Back Light Power

9 Not Used

10 Not Used


1 Not Used

2 52J Fan Control Switch Jumper

3 52-AU Fan Reverse Auto

4 52J Fan Control Switch Jumper

5 19P-C Fan Reverse Switch Fused Pwr

6 52M Fan Reverse Manual


8 49-Q Back Light Power

9 Not Used

10 Not Used


1 55A-B RTT/Float Switch Power

2 53P-B Pilot Control Relay Out

3 55A-C RTT/Float Switch Power

4 0-29 RTT/Float Ground

5 55B RTT Float Switch Control

6 54B-C HC-RTT Control Signal


8 49-K Back Light Power

9 Not Used

10 Not Used

4002-164


CONNECTOR SFNR - FNR SWITCH

382391A1

CONNECTOR SFWW - REAR WIPER AND WASHER SWITCH

87345132

CONNECTOR SHC - HEIGHT CONTROL SWITCH

382391A1

CONNECTOR SHZ - HAZARD SWITCH

382391A1


1 26R-A FNR Reverse Signal

2 26J FNR Switch Jumper

3 26N-A FNR Neutral Signal

4 26J FNR Switch Jumper

5 19A-V FNR Switch Fused Power

6 26F-A FNR Forward Signal

7 32J-A Trans Enable Indication

8 19A-G FNR Switch Fused Power

9 Not Used

10 Not Used


1 Not Used

2 0-DT Front Wiper/Washer Sw Gnd

3 63LC Front Wiper LS Relay Control

4 Not Used

5 19J-BINT Wiper/Washer Sw Fused Pwr

6 Not Used

7 63W Front Washer Pump

8 49-T Back Light Power

9 63HC Front Wiper HS Relay Control

10 Not Used


1 Not Used

2 53P-D Pilot Control Relay Out

3 Not Used

4 Not Used

5 Not Used

6 54A HC Control Switch Power


8 49-M Back Light Power

9 Not Used

10 Not Used


1 Not Used

2 1-KA Hazard Switch Power

3 45H Hazard Switch Power

4 Not Used

5 Not Used

6 Not Used

7 0-b24 Back Light Ground

8 49-D Back Light Power

9 Not Used

10 Not Used

4002-165


CONNECTOR SPB - PARKING BRAKE SWITCH

382391A1

CONNECTOR SPC - PILOT CONTROL SWITCH

382391A1

CONNECTOR SPE - PIN ENGAGE SWITCH

382391A1

CONNECTOR SPK - SPEAKER

292494A1


1 Not Used

2 19A-L Park Brk Switch Fused Power

3 33U Park Brake Switch

4 Not Used

5 Not Used

6 Not Used

7 0-B29 RTT/Float Ground

8 49-v Back Light Power

9 Not Used

10 Not Used


1 Not Used

2 19A-j Pilot Control Switch Fused Pwr

3 31L Pilot Control Switch High

4 Not Used

5 Not Used

6 Not Used


8 49-N Back Light Power

9 Not Used

10 Not Used


1 57-B Pin Engage Solenoid Power

2 19P-A Pin Engage Sw Fused Power

3 Not Used

4 Not Used

5 Not Used

6 Not Used

7 Not Used

8 Not Used


10 49-F Back Light Power


1 65R Right Speaker

2 0-PB Right Speaker Ground

3 Not Used

4 Not Used

5 Not Used

6 Not Used

7 65L Left Speaker

8 0-PA Left Speaker Ground

4002-166


CONNECTOR SPL-BCK-LGT - SPLICE BACK LIGHT POWER

87324393

CONNECTOR SPL-BCK-LGT2 - SPLICE BACK LIGHT POWER

87324393

CONNECTOR SPL-BCK-LT-GD - SPLICE BACK LIGHT GROUND

87324393


A 49 Back Light Power

B 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


A 49-E Back Light Power

B Not Used

C 49-J Back Light Power

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 Not Used

K 49-G Back Light Power

L Not Used

M 49-S Back Light Power


A 0-B13 Back Light Ground

B 0-B14 Back Light Ground

C 0-B15 Back Light Ground

D Not Used

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

M Not Used


4002-167


CONNECTOR SPL-BCK-LT-GD2 - SPLICE BACK LIGHT GROUND

87324393

CONNECTOR SPL-ENG-GND - GROUND SPLICE 6 PACK

87324391

CONNECTOR SPL-HOOD-GND - HOOD GROUND 6 PACK

87324391


A Not Used



D 0-B4 Back Light Ground

E 0-B5 Back Light Ground

F 0-B6 CAB2 Ground

G 0-B26 Buzzer Switch Pad Ground

H Not Used

J 0-B20 Back Light Ground

K 0-29 RTT/Float Ground

L 0-B11 Back Light Ground

M 0-B7 Back Light Ground


A 0-BM Engine Splice Grounds

B 0-BY Air Filter Restriction Switch Gnd

C Not Used

D 0-BS Fan Control Ground

E 0-B Front Washer Ground

F 0-BL Rear Washer Ground


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


4002-168


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

87324391

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

87324391

CONNECTOR SPL-PIN - SPL BACK LIGHT POWER 6 PACK

87324391


A 49-U Back Light Power

B 49-N Back Light Power

C 49-D Back Light Power

D 49U Back Light Power

E 49-V Back Light Power

F 49-S Back Light Power


A 0-B9 Back Light Ground



D 0-B30 Back Light Ground

E 0-B29 RTT/Float Ground

F 0-B11 Back Light Ground


A 19P-A Pin Engage Switch Fused Pwr

B 19P Pin Engage/Fan Fused Power

C 19P-C Ran Reverse Switch Fused Pwr

D Not Used

E 19P-D Fan Reverse Relay Fused Pwr

F 19P-E Fan Reverse Relay Fused Pwr

4002-169


CONNECTOR SPL-PK1 - SPLICE 3 - 4 WAY

87324462


87324462


A 42C-A Front Work Lights Fused Pwr

B 42C-E Front Work Lights Fused Pwr

C 42C-D Front Work Lights Fused Pwr

D 42C-C Front Work Lights Fused Pwr

E 13K Ignition Switch Power

F 13K-B Ignition Switch Power

G 13K-A Ignition Switch Power

H 13K-C Ignition Switch Power

J 35A-D Backup Alarm Relay Out

K 35A-B Backup Alarm Disable Switch

L 35A-A Backup Alarm Relay Out

M 35A-C Backup Alarm Relay Out


A 41T-B Position Lights LH Switch Pwr

B 41T-E Position Lights Switch Pwr

C 41T Position Lights Switch Pwr

D 41T-A Position Lights RH Switch Pwr

E 19Z-A Driving Light Switch Fused Pwr

F 19Z-B Driving Light Switch Fused Pwr

G 19Z Driving Light Switch Fused Pwr

H 19Z-C High Beam Flash Fused Pwr

J 41H-C High Beam RH Power

K 41H-B High Beam LH Power

L 41H-A High Beam Power

M 41H-D High Beam Power

4002-170



87324462

CONNECTOR SPL-ROOF - SPLICE ROOF GROUND

87324393

CONNECTOR SPL-SEC-STR - SEC STR 6PK

87324391


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-BFront Wiper/Washer Sw Fused Pwr

K 19J Front Wiper Fused Power

L 19J-C Front Wiper Relay Fused Power

M 19J-A Front Wiper Motor Fused Power


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

E 0-MF RH Rear Work Light Ground

F 0-MA Rear Wiper Motor Ground

G Not Used

H Not Used

J 0-MJ RH Front Work Light Ground

K Not Used

L 0-MN Roof Grounds

M 0-MK Roof Grounds


A 0-CB Sec. Steering Signal Ground

B 0-CA Sec. Steering Signal Ground

C 0-CC Sec. Steering Press Switch Gnd

D 0-CF Sec. Steering Solenoid Ground

E Not Used

F 0-CD Sec. Steering Splice Ground


4002-171


CONNECTOR SPL-TRN-GRD - SPLICE TRANSMISSION GROUND

87324391

CONNECTOR SPL-TRNS-PWR - TRANSMISSION POWER

87324393

CONNECTOR SRC - RIDE CONTROL SWITCH

382391A1

CONNECTOR SRC-1 - STARTER RELAY

225316C1


A 0-HC Transmission Splice Grounds

B Not Used

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


A 19A-N Trans Fused Power

B 19A-F Trans Enable Switch Fused Pwr

C 19A-Q Trans/Auto Switch Fused Pwr

D 19A-T Brake Declutch Sw Fused Pwr

E 19A-W Diagnostic Conn. Fused Pwr

F 19A-C FNR Switch Fused Pwr

G 19A-PBackup Alarm Rly Ctrl Fused Pwr

H 19A-R Declutch Switch Fused Pwr

J 19A-K TECM Fused Pwr

K 19A-MOutput Speed Sensor Fused Pwr

L 19A-S Trans Fused Pwr

M 19A-H Trans Shifter Fused Pwr


1 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


8 49-G Back Light Power

9 Not Used

10 Not Used


1 21D Starter Relay Signal

2 0-GB Starter Relay Control Ground


4002-172


CONNECTOR SRHSTLK - RH STALK SWITCH

87318288

CONNECTOR SRTD - DETENT SWITCH

382391A1

CONNECTOR SRWP - REAR WIPER SWITCH

382391A1

CONNECTOR SS-TR - SS-MOD-TRANS

245489C1


31b 64C Horn Relay Control

49a 19B Turn Signal Fused Power

56a 41H-A High Beam Power

56b 41L-A Low Beam Power

56d 19Z-C High Beam Flash 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


1 Not Used

2 53P-E Pilot Control Relay Out

3 53A RTD Switched Power

4 Not Used

5 Not Used

6 Not Used


8 49-J Back Light Power

9 Not Used

10 Not Used


1 68C Rear Wiper Park Control

2 68L Rear Wiper Switch Power

3 19K-A Rear Wiper Switch Fused Power

4 Not Used

5 19K-B Rear Wiper Switch Fused Power

6 68W Rear Washer Pump


8 49-C Back Light Power

9 Not Used

10 Not Used


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

4002-173


CONNECTOR SSM - SECONDARY STEERING MODULE

225389C1

CONNECTOR STA - TRANSMISSION AUTO SWITCH

382391A1

CONNECTOR STE - TRANSMISSION ENABLE SWITCH

382391A1


1 19R-C Sec. Steering Ignition Fused Pwr

2 51-A Secondary Steer Control

3 19S1-X Secondary Steer Fused Power

4 0-CE Secondary Steer Chassis Grnd

5 Not Used

6 Not Used

7 19M-C Secondary Steer ACC Fused Pwr

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


1 Not Used

2 19A-Q Trans Auto Sw Fused Power

3 25H Trans Auto Signal

4 Not Used

5 Not Used

6 Not Used


8 49S Back Light Power

9 Not Used

10 Not Used


1 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


4002-174


CONNECTOR SWL - WORK LIGHTS SWITCH

382391A1

CONNECTOR SW-PD - SWITCH PAD

87552623

CONNECTOR TCOT - TORQUE CONVERTER OUTPUT SENDER

291718A1

CONNECTOR TDM - TIME DELAY MODULE

225351C1


1 Not Used

2 42-A Work Lights Fused Power

3 42FS Front Work Lights Switch Power

4 Not Used

5 42-B Work Lights Fused Power

6 42RS Rear Work Lights Switch Power


8 49-A Back Light Power

9 Not Used

10 Not Used


1 41H-D High Beam Power

2 41T-D Position Lights Switch Pwr

3 42C-E Front Work Light Fused Pwr

4 31H-A Hydraulic Filter Rest Sw Signal

5 31F-A Air Filter Rest Switch Signal

6 Not Used

7 CAN-HF CAN High

8 CAN-LF CAN Low

9 17P-A Switch Pad Pwr From AIC Pwr

10 0-B28 Switch Pad Ground


A 36G TCO Temperature Signal

B 36R-D TCO Temperature Return


1 13D Time Delay Relay Ctrl Power

2 1DN Time Delay Fused Power

3 0-DC Time Delay Module Ground

4 43S-D Time Delay Mod Door Sw Reset

5 13K-A Ignition Switch Power

6 Not Used


4002-175


CONNECTOR TECM - TRANSMISSION ELECTRONIC CONTROL MODULE

411398A1


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 Backup Alarm Relay Control

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 Output Sw Power VPS1

13 25S-C Output Sw Power VPS1

15 37D-A Diagnostic Signal

17 32F-A Trans Filter Maint Switch

18 37E Diagnostic Signal Switched

19 25A-A Engine Speed Signal

20 26F-B FNR Forward Signal

21 52P-C Park Brake Relay Out

22 25Y-A Trans Kick Down Signal

23 19T-A Time Delay Fused Power

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 Valve Body Temp Signal

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 Trans Temp/Filter Return

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 Ride Control Relay LSD

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 Brake Declutch Switch Control

67 25T-C Neutral Signal


4002-176


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

245488C1

CONNECTOR TRAN-E - TRANS TO ENG

239451A1

CONNECTOR TRANS - CAB TO TRANSMISSION

380838A1


A 19M-A Sec. Steering ACC Fused Pwr

B 19R-ASec. Steering Ignition Fused Pwr

C 35X-B Sec. Steering Low Press Signal

D 0-HP Sec. Steering Splice Ground

E 19S1-E Sec. Steering Fused Power

F Not Used


1 0-HP Sec. Steering Splice Ground

2 0-HC Trans Splice Grounds

3 31D-BCoolant Level Sender Eng Trans

4 Not Used


1 33R-A Redundant Brake Switch Signal

2 31D-BCoolant Level Sender Eng Trans

2 31D Coolant Level Signal

3 19M-A Sec. Steering ACC Fused Pwr

4 19R-A Sec. Steering Ignition Fused Pwr

5 36T Valve Body Temp Signal

6 35X-B Sec. Steering Low Press Signal

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 Trans Temp/Filter Return

13 36G Torque Conv Output Temp Sig

14 Not Used

15 Not Used

16 25K Trans Solenoid Valve Y1

16 25K-9 Trans Solenoid Valve Y2

17 25L-9 Trans Solenoid Valve Y1

17 25L Trans Solenoid Valve Y2

18 25M Trans Solenoid Valve Y3

19 25N Trans Solenoid Valve Y4

20 25P Trans Solenoid Valve Y5

21 25J Trans Solenoid Valve Y6

22 25S Output Sw Power VPS1

23 31H Hyd Filter Restriction Sw Signal

24 Not Used

25 Not Used

26 19S1-E Sec. Steering Fused Power

27 Not Used

28 0-HE Output Speed Sensor Ground

29 19AOutput Speed Sensor Fused Pwr

30 36H Hydraulic Oil Temperature Sign

31 32F Trans Filter Maint Switch

4002-177


CONNECTOR TRC - TRANSMISSION CONTROL

371566A1

CONNECTOR TS1 - TRANSMISSION SHIFTER

245486C1

CONNECTOR TS2 - TRANSMISSION SHIFTER

245487C1


1 25K Trans Solenoid Valve Y1

1 25L-9 Trans Solenoid Valve Y1

2 25K-9 Trans Solenoid Valve Y2

2 25L Trans Solenoid Valve Y2

3 25M Trans Solenoid Valve Y3

4 25N Trans Solenoid Valve Y4

5 25P Trans Solenoid Valve Y5

6 25J Trans Solenoid Valve Y6

7 25S Output Sw Power VPS1

8 36T Valve Body Temp Signal

9 36R-C Valve Body Temp Return

10 Not Used

11 Not Used

12 Not Used

13 Not Used

14 Not Used

15 Not Used

16 Not Used


A 19A-H Trans Shifter Fused Power

B 25F Forward Signal

C 25R Reverse Signal

D 25T-B Neutral Signal


A Not Used

B 25W 3rd and 4th Gear Signal

C 25Z 1st and 4th Gear Signal

D 25Y Transmission Kick Down Signal

4002-178


CONNECTOR TSS - TURBINE SPEED SENSOR

291718A1

CONNECTOR WF - WATER IN FUEL SENSOR

8602416

CONNECTOR WSH - WATER SEPARATOR HEATER

182069A1

CONNECTOR YCS - COMFOR STEERING SOLENOID

245482C1

CONNECTOR YFN - FNA PWM SOLENOID

256340A1

CONNECTOR YFR - FAN REVERSING SOLENOID

225316C1


1 25C Turbine Speed Signal

2 0-HH Turbine Speed Ground


1 35W Water Indicator

2 0-BP Sensor Ground

3 18J-H Sensor Fused Power


A 0-BW Water Separator Heater Ground

B 1-GC Water Separator Heater Power


A 51B-D Comfort Steering Solenoid Pwr

B 0-AQ Comfort Steering Solenoid Gnd


A 56-A Fan Control PWM

B 0-BQ Fan Speed PWM Solenoid Gnd


1 52A-B Fan Reversing Relay Out

2 0-BB Fan Reversing Solenoid Ground

4002-179


CONNECTOR YPB - PARKING BRAKE SOLENOID

291718A1

CONNECTOR YPE - PIN ENGAGE OPT

245482C1

CONNECTOR YPP - PILOT PRESSURE SOLENOID

245482C1

CONNECTOR YRC - RIDE CONTROL OPT

291718A1

CONNECTOR YSS - SECONDARY STEERING SOLENOID

225316C1


1 52P Parking Brake Relay Out

2 0-AN Park Brake Solenoid Ground


A 57 Pin Engage Solenoid Power

B 0-AE Pin Engage Ground


A 5P-A Pilot Control Relay Out

B 0-DU Pilot Pressure Solenoid Gnd


1 58 Ride Control Solenoid Power

1 58S-E Ride Control Sol To Front Cab

2 0-AD Ride Control Ground


1 51-C Sec. Steering Solenoid Control

2 0-CF Sec. Steering Solenoid Ground

4002-180


NOTES

4002-181


Symbols12 Volt Radio .......................................................112

AA/C High/Low Pressure Switch ............................115Air Filter Restriction Switch ....................................67Air Seat Compressor and Switch .........................114Alarm

Back-up (Europe Only) ......................................96Back-up (North America Only) ..........................96Back-up, Disable Switch ...................................76Back-up, Relay ..................................................76

Alternator ...............................................................40

BBack-up Alarm (Europe Only) ................................96Back-up Alarm (North America Only) ....................96Back-up Alarm Disable Switch ..............................76Back-up Alarm Relay .............................................76Batteries ................................................................41Beacon Switch .......................................................79Beacon, Rotating (Option) .....................................78Brake Lamp Pressure Switch ................................83Brake Lamps Relay ...............................................83Brake Warning Pressure Switch ............................68Buzzer ...................................................................66

CCAN Communication Diagnostics Connector ......109Cigar Lighter ........................................................114Circuit Breaker Cab B+ ..........................................47Climate Control, Automatic

24 to 12 Volt Converter ...................................118Blower Motor Resistor .....................................117Blower Motors .................................................117Compressor Relay ..........................................118Electronic Panel ..............................................117Electronic Water Valve ....................................118External Air Temperature Sensor ....................117Internal Air Temperature Sensor .....................117Mixed Air Sensor .............................................117Recycling Motor ..............................................118Sun Sensor .....................................................117Thermocouple Sensor .....................................117

Climate Control, StandardAir Conditioning Switch ...................................121Air Recirculation Motor ....................................120Air Recirculation Switch ..................................122Blower Motor ...................................................120Blower Motor Speed Resistors with Thermal Fuse

120Blower Switch ..................................................121Control Panel Lights ........................................121Driver ...............................................................120Electronic Water Valve ....................................120Thermostat ......................................................121Water Valve Potentiometer .............................121

Cluster, Instrument Connector 1 ...........................65Cluster, Instrument Connector 2 ...........................71Compressor Clutch ..............................................115Compressor Clutch Relay ...................................114Compressor, Seat ...............................................114Connector 108F ...................................................126Connector 140M ..................................................126Connector 197F ...................................................126Connector 197M ..................................................126Connector 202M ..................................................127Connector 209F ...................................................127Connector 209M ..................................................127Connector 20M ....................................................127Connector 215F ...................................................127Connector 216F ...................................................127Connector 64F .....................................................128Connector 64M ....................................................128Connector 69 .......................................................161Connector ACT ....................................................128Connector AIC1 ...................................................128Connector AIC2 ...................................................129Connector CAB_E ...............................................130Connector CAB_F ...............................................131Connector CAB_RF .............................................131Connector CAB_T ...............................................132Connector CAN ...................................................132Connector CAN2 .................................................132Connector CL ......................................................133Connector CLS ....................................................133Connector CNV ...................................................133Connector D_OR .................................................133Connector DIA .....................................................133Connector DISC ..................................................133Connector DM .....................................................134Connector DNS-AC-SWITCH ..............................134Connector DNS-ACTUATOR ..............................134Connector DNS-BLUE .........................................134Connector DNS-COMPRESSOR-RELAY ...........134Connector DNS-CTRL-PANEL-LIGHT ................137Connector DNS-DRIVER ....................................137Connector DNS-ELECTRIC-FAN ........................137Connector DNS-ELECT-WATER-VALVE ...........136Connector DNS-ELECT-WATER-VALVE-S ........137Connector DNS-EXTERNAL-AIR-TEMP-SNS ....134Connector DNS-HVAC1 ......................................135Connector DNS-HVAC1-S ..................................138Connector DNS-HVAC2 ......................................135Connector DNS-HVAC2-S ..................................138Connector DNS-HVAC-CAN1 .............................134Connector DNS-INTERNAL-AIR-TEMP-SNS .....135Connector DNS-MISED-SIR-SENSOR ...............136Connector DNS-NOT-USED ...............................135Connector DNS-PWM-BLOWER ........................136Connector DNS-PWM-BLOWER-PIN2 ...............136Connector DNS-PWM-BLOWER-PIN4 ...............136Connector DNS-RECIRCULATING-SWITCH .....137Connector DNS-RECYCLING-MOTOR ..............136

4002-182


Connector DNS-RESISTOR ................................137Connector DNS-SPEED-SELECTOR .................136Connector DNS-THERMOCOUPLE-SENSO ......136Connector DNS-THERMOSTAT-1 ......................137Connector DNS-THERMOSTAT-2 ......................137Connector DNS-VOLTAGE-CONVERTER .........136Connector DNS-WATER-VALVE-POT ................137Connector DNS-YELLOW ...................................135Connector DS ......................................................138Connector E_HD .................................................138Connector ECA ....................................................139Connector ECB ....................................................140Connector ECC ...................................................141Connector ECD ...................................................142Connector EDC7 .................................................143Connector EM ......................................................143Connector ENG ...................................................144Connector ENG_D ...............................................144Connector ENG_H ...............................................145Connector ENG_T ...............................................145Connector ESS ....................................................145Connector FFH ....................................................145Connector FLSHR ...............................................146Connector FM ......................................................146Connector FRONT ...............................................146Connector FWM ..................................................147Connector FWMG ................................................147Connector FWW ..................................................147Connector GHC ...................................................147Connector GND_CAB_SPL .................................148Connector GND_CAB_SPL2 ...............................148Connector HD ......................................................148Connector HD_E .................................................148Connector HD_N .................................................149Connector HDM ...................................................149Connector HOT ...................................................149Connector HVAC_CAN1 .....................................150Connector HVAC1 ...............................................149Connector HVAC2 ...............................................149Connector ISS .....................................................150Connector K_WCO ..............................................150Connector LBEE ..................................................150Connector LLF .....................................................151Connector LLFW .................................................151Connector LLR_E ................................................151Connector LLR_N ................................................151Connector LLRW .................................................152Connector LPL .....................................................152Connector LRF ....................................................152Connector LRFW .................................................152Connector LRR_E ...............................................153Connector LRR_N ...............................................153Connector LRRW ................................................153Connector LSPK ..................................................153Connector OSS ...................................................153Connector PAF ....................................................154Connector PBD ....................................................154

Connector PBL ....................................................154Connector PBW ...................................................154Connector PO1 ....................................................155Connector PO2 ....................................................155Connector PR ......................................................155Connector PRB1 .................................................155Connector PRB2 .................................................155Connector PRBF .................................................156Connector PRM_A1 ............................................156Connector PRM_B1 ............................................156Connector PRM_B2 ............................................156Connector PRM_C1 ............................................156Connector PRM_C2 ............................................157Connector PRM_D1 ............................................157Connector PRM_E1 ............................................157Connector PRM_E2 ............................................157Connector PSS ....................................................157Connector PXF ....................................................158Connector PXH ...................................................158Connector PXM ...................................................158Connector PXT ....................................................158Connector RAD ...................................................158Connector RAD_J1 .............................................159Connector RAD_J2 .............................................159Connector RAD_J3 .............................................159Connector RECT .................................................159Connector ROOF ................................................160Connector RSPK .................................................160Connector RTHP .................................................160Connector RWM ..................................................160Connector RWMG ...............................................161Connector RWW .................................................161Connector S_KEY ...............................................161Connector SBE ....................................................161Connector SBU ...................................................162Connector SC ......................................................162Connector SCS ...................................................162Connector SDC ...................................................162Connector SDR ...................................................163Connector SETHR ...............................................163Connector SFC ....................................................163Connector SFL ....................................................163Connector SFNR .................................................164Connector SFWW ...............................................164Connector SHC ...................................................164Connector SHZ ....................................................164Connector SPB ....................................................165Connector SPC ...................................................165Connector SPE ....................................................165Connector SPK ....................................................165Connector SPL_BCK_LGT ..................................166Connector SPL_BCK_LGT2 ................................166Connector SPL_BCK_LT_GD .............................166Connector SPL_BCK_LT_GD2 ...........................167Connector SPL_ENG_GND ................................167Connector SPL_HOOD_GND .............................167Connector SPL_PED_BL ....................................168

4002-183


Connector SPL_PED_BL_GD .............................168Connector SPL_PIN ............................................168Connector SPL_PK1 ...........................................169Connector SPL_PK2 ...........................................169Connector SPL_PK3 ...........................................170Connector SPL_ROOF ........................................170Connector SPL_SEC_STR ..................................170Connector SPL_TRN_GRD .................................171Connector SPL_TRNS_PWR ..............................171Connector SRC ...................................................171Connector SRC_1 ...............................................171Connector SRHSTLK ..........................................172Connector SRTD .................................................172Connector SRWP ................................................172Connector SS_TR ...............................................172Connector SSM ...................................................173Connector STA ....................................................173Connector STE ....................................................173Connector SW_PD ..............................................174Connector SWL ...................................................174Connector TCOT .................................................174Connector TDM ...................................................174Connector TECM .................................................175Connector TR_SS ...............................................176Connector TRAN_E .............................................176Connector TRANS ...............................................176Connector TRC ....................................................177Connector TS1 ....................................................177Connector TS2 ....................................................177Connector TSS ....................................................178Connector WF .....................................................178Connector WSH ...................................................178Connector YCS ....................................................178Connector YFN ....................................................178Connector YFR ....................................................178Connector YPB ....................................................179Connector YPE ....................................................179Connector YPP ....................................................179Connector YRC ...................................................179Connector YSS ....................................................179Connector, Diagnostic ...........................................63Coolant Level Sender ............................................74Crank Control Relay ..............................................41Crank Request Relay ............................................41

DDeclutch Brake Switch ...........................................63Declutch Switch .....................................................63Diagnostic Connector ............................................63Diodes

Lights .................................................................81Secondary Steering .........................................105Wipers .............................................................103

Dome Lamp ...........................................................79Door Switch ...........................................................78Driving Lamp Switch ..............................................86

EElectrical Wire Identification ....................................8Electromagnetic Detents .......................................54Electronic Diesel Control .......................................51Engine Speed Sensor ...........................................63

FFan PWM Solenoid ...............................................61Fan Reverse Relay ................................................59Fan Reversing Solenoid ........................................61Fan Reversing Switch ...........................................59Filter Maintenance Switch .....................................63Flasher Module ......................................................84FNR Switch for Joystick Controls ..........................63FNR Switch for Single Axis Controls .....................63Front

Left Hand Work Lamp .......................................79Right Hand Work Lamp .....................................80

Front Left Hand Combination Lamp ......................88Front Right Hand Combination Lamp ....................89Front Washer Pump Motor ..................................102Front Wiper and Washer Switch ..........................100Front Wiper Cut Out Relay ....................................98Front Wiper High Speed Relay ..............................98Front Wiper Low Speed Relay ..............................99Front Wiper Motor ...............................................101Fuel Filter Heater ...................................................48Fuel Filter Heater Relay ........................................46Fuel Level Sender .................................................67

GGrid Heater ............................................................47Grid Heater Relay ..................................................47

HHazard Switch .......................................................85Heater

Fuel Filter ..........................................................48Grid ...................................................................47Water Separator ................................................47

Height Control Switch ............................................53Height Control/Return-To-Travel Proximity Switch 55High-Low Beam Switch .........................................85Hood

Down Relay .....................................................124Motor ...............................................................125Switch .............................................................124Up Relay .........................................................124

Horn .......................................................................90Horn Relay ............................................................90Horn Switch ...........................................................85Hydraulic Filter Restriction Switch .........................72Hydraulic Oil Temperature Sender ........................72

IIgnition Switch .......................................................43Instrument Cluster Connector 1 ............................65

4002-184


Instrument Cluster Connector 2 .............................71Intermediate Speed Sensor ...................................63

LLamp

Dome .................................................................79High Beam ..................................................88, 89Left Hand Front Combination ............................88Left Hand Front Work ........................................79Left Hand Rear Combination (Europe Only) .....95Left Hand Rear Combination (North America Only)

............................................................94Left Hand Rear Work ........................................80License Plate (Europe Only) .............................96License Plate (North America Only) ..................95Low Beam ...................................................88, 89Position .......................................................88, 89Right Hand Front Combination ..........................89Right Hand Front Work .....................................80Right Hand Rear Combination (Europe Only) ...93Right Hand Rear Combination (North America

Only) ...................................................92Right Hand Rear Work ......................................80Switch, Driving ..................................................86Turn .............................................................88, 89

Left Hand Front Combination Lamp ......................88Left Hand Front Work Lamp ..................................79Left Hand Rear Combination Lamp (Europe Only) 95Left Hand Rear Combination Lamp (North America

Only) .........................................................94Left Hand Rear Work Lamp ...................................80Left Speaker ........................................................112License Plate Lamp .........................................95, 96License Plate Lamp (Europe Only) ........................96License Plate Lamp (North America Only) ............95Lights Diodes .........................................................81Locating Components on the Schematic Posters ..38

MMagnetic Detents ...................................................54Master Disconnect Switch .....................................42Module

Flasher ..............................................................84Secondary Steering .........................................106Time Delay ........................................................42Transmission Electronic Control .......................63

MotorHood ................................................................125Starter ...............................................................43

NNeutral Start Relay ................................................44

OOutlet, Power .......................................................111Output Speed Sensor ............................................63

PParking Brake Relay ..............................................66Parking Brake Solenoid .........................................67Parking Brake Switch ............................................73Pilot Control Relay .................................................55Pilot Control Switch ...............................................60Pilot Pressure Solenoid .........................................56Pin Engage Solenoid .............................................56Pin Engage Switch ................................................56Potentiometer

Throttle ..............................................................50Power Converter (24 volts to 12 volts) ................111Power Outlet ........................................................111Power Relay Module

A Ignition Power ................................................46B Ignition Power ................................................46C Fuel Filter Heater ...........................................46D Accessory Power ...........................................48E Power Converter 24V to 12V .......................111

Proximity SwitchHeight Control/Return-To-Travel .......................55Return-To-Dig ...................................................54

RRadiator Coolant Temperature Sender .................68Radio

12 Volt .............................................................112Rear

Left Hand Combination Lamp (Europe Only) ....95Left Hand Combination Lamp (North America

Only) ..................................................94Left Hand Work Lamp .......................................80Right Hand Combination Lamp (Europe Only) .93Right Hand Combination Lamp (North America

Only) ..................................................92Right Hand Work Lamp .....................................80

Rear Washer Pump Motor ...................................102Rear Wiper and Washer Switch ............................99Rear Wiper Motor ................................................102Redundant Brake Pressure Switch 1 ....................73Redundant Brake Pressure Switch 2 ....................73Relay

Backup Alarm ....................................................76Brake Lamps .....................................................83Compressor Clutch .........................................114Crank Control ....................................................41Crank Request ..................................................41Fan Reverse .....................................................59Front Wiper Cut Out ..........................................98Front Wiper High Speed ...................................98Front Wiper Low Speed ....................................99Fuel Filter Heater ..............................................46Grid Heater .......................................................47Hood Down .....................................................124Hood Up ..........................................................124Horn ..................................................................90Neutral Start ......................................................44

4002-185


Parking Brake ....................................................66Pilot Control .......................................................55Power Relay Module A Ignition Power ..............46Power Relay Module B Ignition Power ..............46Power Relay Module C Water Separator Htr ....46Power Relay Module D Accessory Power .........48Power Relay Module E Power Converter ........111Ride Control ......................................................58Starting ..............................................................40Voltmeter ...........................................................44

ResistorAlternator ...........................................................40

Return to Dig Switch Switch ..................................55Return-To-Dig Proximity Switch ............................54Return-To-Travel/Float Switch ...............................53Ride Control Relay ................................................58Ride Control Solenoid ............................................60Ride Control Switch ...............................................58Right Hand Front Combination Lamp ....................89Right Hand Front Work Lamp ................................80Right Hand Rear Combination Lamp (Europe Only) .

93Right Hand Rear Combination Lamp (North America

Only) .........................................................92Right Hand Rear Work Lamp ................................80Right Speaker ......................................................112Rollback Jumper ....................................................61Rollback Pressure Switch ......................................60Rotating Beacon (Option) ......................................78

SSeat Compressor and Switch ..............................114Secondary Steering

Module ............................................................106Motor ...............................................................107Pressure Switch ..............................................107Solenoid ..........................................................105

Secondary Steering Diodes .................................105Sender

Coolant Level ....................................................74Fuel Level ..........................................................67Hydraulic Oil Temperature ................................72Radiator Coolant Temperature ..........................68Torque Converter Output Temperature .............63

SensorEngine Speed ....................................................63Intermediate Speed ...........................................63Output Speed ....................................................63Transmission Solenoid Valve and Temperature ...

63Turbine Speed ...................................................63Water In Fuel .....................................................50

Shifter, Transmission .............................................63Solenoid

Fan PWM ..........................................................61Fan Reversing ...................................................61Parking Brake ....................................................67

Pilot Pressure ....................................................56Pin Engage .......................................................56Ride Control ......................................................60Secondary Steering .........................................105

SpeakerLeft ..................................................................112Right ................................................................112

Specifications ..........................................................7Speed Resistors

Blower Motor ...................................................120Starter Motor .........................................................43Starting Relay ........................................................40Steering

Secondary, Module .........................................106Secondary, Motor ............................................107Secondary, Pressure Switch ...........................107Secondary, Solenoid .......................................105

SwitchA/C High/Low Pressure ...................................115Air Filter Restriction ...........................................67Back-up Alarm Disable ......................................76Beacon ..............................................................79Blower .............................................................121Brake Lamp Pressure .......................................83Brake Warning Pressure ...................................68Declutch ............................................................63Declutch Brake ..................................................63Door ..................................................................78Driving Lamp .....................................................86Fan Reversing ...................................................59Filter Maintenance .............................................63FNR for Joystick Controls .................................63FNR for Single Axis Controls ............................63Front Wiper and Washer .................................100Hazard ..............................................................85Height Control ...................................................53High-Low Beam .................................................85Hood ...............................................................124Horn ..................................................................85Hydraulic Filter Restriction ................................72Ignition ..............................................................43Master Disconnect ............................................42Pad ....................................................................70Parking Brake ....................................................73Pilot Control Switch ...........................................60Pin Engage .......................................................56Proximity, Height Control/Return-To-Travel ......55Proximity, Return-To-Dig ...................................54Rear Wiper and Washer ....................................99Redundant Brake Pressure 1 ............................73Redundant Brake Pressure 2 ............................73Return to Dig .....................................................55Return-To-Travel/Float ......................................53Ride Control ......................................................58Rollback Pressure .............................................60Seat Compressor ............................................114Secondary Steering Pressure .........................107

4002-186


Transmission Auto ............................................63Transmission Enable .........................................63Transmission Kick-down ...................................63Turn Signal ........................................................85Work Lamps ......................................................78

Switch Pad .............................................................70

TThermal Fuse

Blower Motor ...................................................120Throttle Potentiometer ...........................................50Time Delay Module ................................................42Torque Converter Output Temperature Sender ....63Transmission Auto Switch .....................................63Transmission Electronic Control Module ...............63Transmission Enable Switch .................................63Transmission Kick-down Switch ............................63Transmission Shifter ..............................................63Transmission Solenoid Valve and Temperature Sen-

sors ...........................................................63Turbine Speed Sensor ...........................................63Turn Signal Switch .................................................85

UUnderstanding the Troubleshooting Tables ...........38

VVoltmeter Relay .....................................................44

WWarning Buzzer .....................................................66Water In Fuel Sensor .............................................50Water Separator

Heater ...............................................................47Heater Relay .....................................................46

WiperFront Cut Out Relay ..........................................98Front Motor ......................................................101Front Switch ....................................................100Front Washer Pump Motor ..............................102Front Washer Switch .......................................100Front Wiper High Speed Relay .........................98Front Wiper Low Speed Relay ..........................99Rear Motor ......................................................102Rear Switch .......................................................99Rear Washer Pump Motor ..............................102Rear Washer Switch .........................................99

Wiper Diodes .......................................................103Wire Identification ....................................................8Work Lamp Switch .................................................78

Section4003

4003




BATTERIES

4003-2


TABLE OF CONTENTS

SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Electrolyte Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Inspecting and Cleaning a Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

BATTERY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Visual Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Specific Gravity Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Capacity (Load) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

CHARGING A BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Charging Guide For Maintenance Free Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Charging Guide For Batteries Other Than Maintenance Free Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

PREPARING A DRY CHARGED BATTERY FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4003-3


SAFETY RULES

47-83A

13-8A

47-55A

48-57B

D-47-53A

SPECIAL TOOLS

B795328

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

WARNING: Never try to charge the battery ifthe electrolyte in the battery is frozen.

WARNING: Never cause sparks to occur orsmoke near batteries that are charging orhave been recently charged.

WARNING: Disconnect the ground cablefirst when the battery cables aredisconnected from the battery.

Connect the ground cable last when thebattery cables are connected to the battery.

WARNING: Some batteries have aventilation tube. If there is battery acid in theventilation tube, this battery acid can bereleased when the battery is turned upsidedown. If you turn the battery upside down,make sure that the end of the ventilation tubeis away from you and away from any otherpeople in the area. Battery acid can causesevere burns.

WARNING: Battery acid causes severeburns. Batteries contain sulfuric acid. Avoidcontact with skin, eyes, or clothing. Antidote:EXTERNAL-Flush with water.INTERNAL-Drink large quantities of water ormilk. Follow with milk of magnesia, beatenegg, or vegetable oil. Call physicianimmediately. Eyes: Flush with water for 15minutes and get prompt medical attention.

Batteries produce explosive gases. Keepsparks, flame, and cigarettes away. Ventilatewhen charging or using in enclosed area.Always shield eyes when working nearbatteries.

Keep out of reach of children.

4003-4


MAINTENANCE

Electrolyte LevelIf the battery is a maintenance free battery, check thelevel of the electrolyte every 1000 hours of operationor six months, whichever occurs first. For all otherbatteries, check the level of the electrolyte every 250hours of operation.

NOTE: A maintenance free battery will have thewords Maintenance Free on the decal on the top ofthe battery. If the center part of the decal has beenremoved for access to the battery caps, it is possiblethat the words Maintenance Free have been removedfrom the decal.

Check the level of the electrolyte more often duringhot weather. The use of a large amount of water bythe ba t te r y can be caused by h igh ba t te r ytemperature or a voltage regulator setting that is toohigh. Keep the electrolyte level above the top of theplates in the battery at all times to prevent damage tothe battery.

NOTE: On maintenance free batteries it isnecessary to remove the center part of the decal foraccess to the battery caps. Do not discard the centerpart of the decal. Install the center part of the decalafter the battery caps have been installed.

If the level of the electrolyte is low, add distilled wateror other clean water until the electrolyte is just belowthe cell opening. Do not add more water than isneeded . Too much wate r can cause badperformance, a short service life, and corrosionaround the battery.

NOTE: Add water only. DO NOT add electrolyte.

Inspecting and Cleaning a BatteryIf damage causes an electrolyte leak, replace thebattery.

Inspect the battery at regular intervals for dir t,corrosion, and damage. Electrolyte and dirt on thetop of the battery can cause the battery to dischargeby making a passage for the current to flow.

If the battery must be cleaned, remove the batteryfrom the battery carrier and clean the battery, cableterminals, and the battery carrier. When available,use Case Battery Saver and Cleaner according tothe instructions on the container. Case Battery Saverand Cleaner also helps prevent corrosion. If CaseBattery Saver and Cleaner is not available, usebaking soda and water as a cleaner. DO NOT permitany type of cleaner to enter the cells of the battery.

Install the battery in the machine and make sure thefasteners are tight. Apply Case Battery Saver andCleaner or Urethane Seal Coat to the cable terminalsto prevent corrosion. See the Parts Counter Catalog.DO NOT apply grease.

4003-5


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

Visual Checks1. Make sure the cable connections are clean and

tight. Clean foreign material from the top of thebattery.

2. Inspect the battery case, battery posts, andcables for damage.

3. Check the electrolyte level. See Page 4.

4. If you added water to the battery, the batterymust be charged for 15 minutes at 15 to 25amperes to mix the water with the electrolyte.

Specific Gravity CheckA hydrometer is used to check the specific gravity(weight) of the electrolyte. The specific gravity is anindication of the level of charge for each cell.

Hydrometers are made to show the correct specificgravity when the temperature of the electrolyte is26.7°C (80°F).

When you check the specific gravity, you must knowthe temperature of the electrolyte. If your hydrometerdoes not have a thermometer, get a thermometer tocheck the temperature of the electrolyte. Thethermometer must indicate a high temperature of atleast 52°C (120°F).

1. Remove enough electrolyte from a cell so thatthe float is free in the tube.

NOTE: If the specific gravity cannot be checkedwithout first adding water to the cell, the battery mustbe charged for 15 minutes at 15 to 25 amperes to mixthe water with the electrolyte. Then check the specificgravity.

2. Read the float.

3. Read the thermometer. If the reading is above26.7°C (80°F) add specific gravity points to thereading for specific gravity. If the reading is below26.5°C (80°F) subtract specific gravity pointsfrom the reading for specific gravity. See thefollowing illustration and add or subtract specificgravity points as needed.

B790863

SPECIFIC GRAVITY CHART

4. Make a record of the corrected specific gravityreading for each cell.

5. If the difference between the high reading andthe low reading is 0.050 or more, charge thebattery and check the specific gravity again. Ifafter charging, the difference is still 0.050 ormore, install a new battery.

6. The corrected specific gravity reading shows thelevel of charge for the cell. The level of chargemust be at least 75% in each of the cells. lnmaintenance free batteries the level of charge isat least 75% if the corrected specific gravityreading is 1.240 or higher. In all other batteriesthe level of charge is at least 75% if the correctedspecific gravity reading is 1.230 or higher.

7. If the difference between the high reading andthe low reading is less than 0.050, and the levelof charge is at least 75% in all of the cells, do theCapacity (Load) Test.

8. If the difference between the high reading andthe low reading is less than 0.050, but the level ofcharge is less than 75% in any of the cells,charge the battery and check the specific gravityagain. If after charging:

A. The level of charge is less than 75% in any ofthe cells, discard the battery.

B. The level of charge is at least 75% in all of thecells, do the Capacity (Load) Test.

1. TEMPERATURE IN F 2. TEMPERATURE IN C

1 2

4003-6


Capacity (Load) TestThis test can be done using a variable load testersuch as the Sun Electr ic VAT-33. Other testequipment can be used. Connect the test equipmentaccording to the instructions of the manufacturer ofthe equipment.

1. The level of charge of the battery must be atleast 75%. Do the Specific Gravity Check in thissection.

2. Prepare the tester (Sun Electric VAT-33 shown)for the test.

A. Select the voltmeter range that will measure 1to 18 volts.

B. Make sure the load control knob is in the OFFposition.

C. Select the ammeter range that will measure 0to 1000 amperes.

D. Move the volt lead switch to the NT. position.

3. Connect the tester to the battery as shown.

B790499

NOTE: Never apply a load for longer than 15seconds. After each 15 seconds, turn the load controlknob to OFF for at least one minute.

4. Apply a 15 ampere load to the battery for 15seconds. Wait at least three minutes beforeapplying the load again.

5. Check and make a record of the temperature ofthe electrolyte.

6. Find the correct load for this test in Specificationsin Section 4001.

NOTE: The correct load is half of the cold crankingamperes at -17°C (0°F).

7. Turn the load control knob until the ammeterindicates the specified load. Keep the load for 15seconds and read the voltmeter. Turn the loadcontrol knob to OFF.

8. Compare the test reading and the temperature ofthe electrolyte to the chart below.

Temperature of . . . . . . . . . . . . . . . Minimum Voltageelectrolyte21°C (70°F) and above . . . . . . . . . . . . . . . . . . . . 9.616°C (60°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.510°C (50°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.44°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 thevol tage shown, the bat ter y is in goodcondition.

B. If the test result is less than the voltageshown, discard the battery.

1. LOAD CONTROL KNOB 2. AMMETER CLAMP (TIP OF ARROW AWAY FROM BATTERY)

2

1

4003-7


CHARGING A BATTERY

47-83

Before you charge the battery, check the level of theelectrolyte.

It is difficult to give an exact charging rate because ofthe following variable conditions: (1) temperature ofthe electrolyte, (2) level of charge, and (3) conditionof the battery. Use the charging guide for the correctcharging rate and time.

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

The charging rate must be decreased if:

1. Too much gas causes the electrolyte to flow fromthe cells.

2. The temperature of the electrolyte rises above52°C (125°F).

NOTE: For the best charge, use the slow chargingrates.

The battery is fully charged when, over a three hourperiod at a low charging rate, no cell is giving toomuch gas, and the specific gravity does not change.

NOTE: A maintenance free battery will have the words Maintenance Free on the decal on the top of the battery. Ifthe center part of the decal has been removed to get access to the battery caps, it is possible the wordsMaintenance Free will have been removed from the decal.

Continued on next page

WARNING: Never try to charge the battery ifthe electrolyte in the battery is frozen.

Charging Guide For Maintenance Free BatteriesRecommended Rate* and Time for Fully Discharged Battery

Battery Capacity - SeeReserve Capacity underSpecifications

Slow Charge Fast Charge

80 Minutes or Less10 Hours at 5 Amperes5 Hours at 10 Amperes

2.5 Hours at 20 Amperes1.5 Hours at 30 Amperes

Above 80 to 125 Minutes15 Hours at 5 Amperes

7.5 Hours at 10 Amperes3.75 Hours at 20 Amperes1 .5 Hours at 50 Amperes


10 Hours at 10 Amperes5 Hours at 20 Amperes2 Hours at 50 Amperes


15 Hours at 10 Amperes7.5 Hours at 20 Amperes

3 Hours at 50 Amperes

*lnitial rate for standard taper charger.

4003-8


PREPARING A DRY CHARGED BATTERY FOR USE1. Remove the caps from the battery.

2. Fill each cell to the top of the separators withelectrolyte. This wil l permit the volume ofelectrolyte to increase when heated by chargingthe battery.

3. Install the caps on the battery.

4. Connect a battery charger to the battery.

5. Charge the battery at 30 amperes until thespecif ic gravi ty is 1.250 or more and thetemperature of the electrolyte is at least 15.5°C(60°F).

6. If necessary, fill each cell with electrolyte until theelectrolyte is just below split ring at the bottom ofthe cell opening.

Charging Guide For Batteries Other Than Maintenance Free Batteries

Recommended Rate* and Time for Fully Discharged Battery

Battery Capacity - SeeReserve Capacity underSpecifications

Slow Charge Fast Charge

80 Minutes or Less10 Hours at 5 Amperes5 Hours at 10 Amperes

2.5 Hours at 20 Amperes1.5 Hours at 30 Amperes


7.5 Hours at 10 Amperes3.75 Hours at 20 Amperes1 .5 Hours at 50 Amperes


10 Hours at 10 Amperes5 Hours at 20 Amperes2 Hours at 50 Amperes


15 Hours at 10 Amperes7.5 Hours at 20 Amperes

3 Hours at 50 Amperes

Above 250 Minutes 24 Hours at 10 Amperes6 Hours at 40 Amperes4 Hours at 60 Amperes

*lnitial rate for standard taper charger.

Section4005

4005




INSTRUMENT CLUSTER

4005-2


TABLE OF CONTENTS

INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Self-Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Power Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4LCD Multi-function Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Navigating Through The LCD Multi-function Display Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Entering The Service Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Select Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Hardware Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Software Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Selecting Power Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Language Screen, Measurement Units, and Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Options Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Fan Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Display Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13MPH/KPH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

RETRIEVING FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14General Fault Code Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Fault Code Grouping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

VEHICLE FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15ENGINE FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17TRANSMISSION FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27INSTRUMENT CLUSTER FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

4005-3


INSTRUMENT CLUSTER

BD06H039

The instrument cluster monitors a number of functions and can be tailored to fit the operator’s preferences Theinstrument cluster not only monitors machine functions, it warns the operator when caution is needed due to apossible malfunction and when immediate action is needed due to a possible critical malfunction. When themachine is started, the instrument cluster will perform the following self-test:

1. LOW BRAKE PRESSURE INDICATOR 9. LACK OF AUX STEER PRESSURE (OPTIONAL)2. HIGH BEAM INDICATOR 10. PARKING BRAKE INDICATOR3. TRANSMISSION OIL TEMPERATURE GAUGE 11. RIGHT TURN INDICATOR4. CAUTION MASTER INDICATOR 12. FUEL LEVEL GAUGE5. MULTI FUNCTION LCD DISPLAY 13. FUEL LEVEL AT MINIMUM6. STOP MASTER INDICATOR 14. ENGINE COOLANT TEMPERATURE GAUGE7. HYDRAULIC OIL TEMPERATURE GAUGE 15. LEFT TURN INDICATOR8. WAIT TO START ENGINE PREHEAT

1415

1 2 34

56 7 8 9 10

11

1312

4005-4


Self-Test1. Turn the ignition (key) switch to the ON position.

2. The instrument cluster will automatically checkeach monitored system.

3. All LED’s (Light Emitting Diodes) will illuminatefor 2 - 3 seconds.

4. Four gauges will energize for 2 - 3 seconds.

5. The warning alarm will sound for 2 - 3 seconds.

6. If there is an open circuit between a sensor andthe instrument cluster, the LED will flash and thewarning alarm will sound for 5 seconds.

7. If there were no faults detected during the check,all monitored systems will return to normaloperation.

8. If only some of the LEDs illuminate, replace theinstrument cluster.

9. If the LEDs illuminate, but the warning alarmdoes not sound, see section 4002 and test thealarm circuit.

10. If the warning alarm sounds but the LEDs do notilluminate, if no power is present at buzzer,replace the instrument cluster, if power is presentat the buzzer, replace the buzzer.

11. If the warning alarm does not sound and theLEDs do not illuminate on the instrument cluster,do the following steps to test the power circuit:

Power Circuit Test A. Check fuse ECA-F3. If the fuse is bad, replace

the fuse and repeat Self-Test. If the fuse isgood, go to next step.

B. Check wire 19EA for continuity.Repair/replace the wire as required. I fcontinuity is found go to next step.

C. Check power relay module A for properoperation, see Section 4002. If the powerrelay module checks good, go to next step.

D. Check the ignition switch for proper operation,see Section 4002. If the ignition switch checksgood, go to next step.

E. Check fuse ECC-F5. If the fuse is bad, replacethe fuse.

4005-5


LCD Multi-function Display

BD06J132

The LCD Multi-Function Display is located at thecenter of the modular dashboard. On start up thecluster will flash the instructional lamps and the LCDMulti-Display will display, CASE, with the machinemodel and current hour reading.

BD06F185

LCD MULTI-FUNCTION DISPLAY

Information will be displayed in different zones on theLCD, as directed by the operator or machine. Inmost situations the operator or technician will begiven specific information to follow if conditions arenot correct.

1. In the example, above, the machine hours aredisplayed. Machine hours wi l l a lways bedisplayed briefly, on start up. After, the machineis started, the display will show engine rpm’s.After, beginning travel, the machine will displaytravel speed, if default settings were not changedby the operator.

2. This example, shows that the TransmissionControl Lever is in Neutral. The display will showForward, Neutral, or Reverse, depending onwhere the D i rec t iona l Con t ro l Lever i spositioned.

NOTE: Forward and Reverse will blink if thetransmission clutches are disconnected.

3. This example shows the maximum gear allowedwhen in Automatic mode. If display is blank theManual mode has been selected.

4. This example shows the current transmissionmode that has been selected.

A. If the Transmission is operating normally it willdisplay either

● A - Automatic

● M - Manual operation.

B. If the Transmission is not operating normallythe display will show

● C - Substitute Clutch.

● L - Limp Home.

● S - Transmission Shutdown.

● U - TCU Shutdown.

5. This example (not displayed) will show thetransmission clutches disengaged, if the ParkBrake is OFF.

6. This example shows the Power Boost Status.

● MAX - Maximum Power.

● STD - Normal/Standard mode of Operation.

● AUTO - Switches automatically betweenMaximum and Standard Power.

● ECO - Limited Power for fuel efficiency.

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

12

3

76

5 4

4005-6


Navigating Through The LCD Multi-function Display Screens

BD06F186

Located on the steering column, just to the left of thePark Switch, is the key pad. Use this key pad tomove from one screen to another, choose variousselections, monitor the machine functions, andretrieve information. All functions can be accessed inthe same basic manner.

A. Escape key: Use this key to exit and return tothe driving screen. Use this key anytime youwould like to start over and begin again, plususe to check active, acknowledge errors.

B. Enter key: Use this key to confirm, yes, this isthe desired function.

C. Up arrow key: Use this key to scroll up toselections.

D. Down arrow key: Use this key to scroll downto selections.

NOTE: Arrows on the screen will indicate ifselections are up or down from the current selection.

NOTE: Display units can be changed by theoperator.

Using The Arrow Keys

At any time, during operation or with the key switchon, the operator may scroll through three informationscreens and two trip screens by using the arrowkeys. These five screens are in a circular loop andmay be reached by pressing the up or down key. Thefollowing sequence is using the down key only.

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

BD06F188

From the driving screen push the down arrow, asshown.

BD06F183

Info 1 is the first information screen using the downarrow from the driving screen. It displays engineRPM’s, speed, fuel level, and the voltage level.

A

B

C

D

4005-7


BD06F027

Info 2 will be displayed next. The Info 2 screen willdisplay coolant temperature, turbocharger airtemperature, engine oil temperature in eitherFahrenheit or Celsius, as well as oil pressure PSI.

BD06F184

Push the down button again and the Info 3 screen.This screen displays the temperature in Fahrenheitor Celsius of the transmission oil, hydraulic oil, sumpoil, and radiator coolant temperature.

BD06F169

Press the down button again and the Trip 1 screenwill display. The LCD provides two trip computers.These will display since last reset the total time inhours, the to ta l fue l , and the average fue lconsumption per hour.

BD06F170

By continuing to scroll down, the fifth screen willdisplay the Trip 2 screen. Trip 1 and Trip 2 screenscan be reset independently. The previous screen canbe accessed by using the up arrow key.

4005-8


Reset The Trip Information

BD06F170

Highlight the trip screen you wish to set.

BD06F187

Press the confirm button to reset the trip selection tozero.

BD06F172

The trip screen will indicate a reset message. At thisscreen, press confirm to clear the numbers and resetthe trip information. The current date and time willdisplay automatically. The hours, fuel consumption,and fuel used per hour will reset and revert to zero.

4005-9


Entering The Service Screens After the machine has been started or the key switch has been turned to on the operator or service technican mayuse this service menu to adjust machine configurations to working conditions, test components, view faults thatmay have occurred, or select preferences.

NOTE: When all the selections have been made they will be stored in memory. If there is an abrupt batterydisconnect 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 toscroll through the menu’s.

Items and selections in this menu are:

1. Power Mode Menu

● Max - Maximum power possible

● Standard - Standard operation

● Auto - Will cycle between Max and Standard

● Eco - Limited power for economy

2. Preferences Menu

● Language - English, Italian, French, Spanish,Portuguese, German

● Units - Metric, English or Imperial

● Clock - 24 or 12 hour

3. Options Menu

● Fan Auto - manual or automatic

● Idle Auto - manual or automatic

● Show RPM

● Show MPH/KPH

4. Display Menu

● Day Display

● Day LED

● Night Display

● Night LED

5. Clock Menu

● Hour

● Minute

● Day

● Month

● Year

6. Cluster H/W

● Part Number

● Serial Number

● ID

● Version

7. Cluster S/W

● Part Number

● Loader Version

● ID

● Version

8. Config Menu

● Change Model *

● Select Tires (Select tire sizes)

● Clutch Calibration (calibrate gear box)*

● Gear Limits (choose maximum gear)

● Park Brake (Park brake test)

● Cold Start (choose cold start system)

● FAN Test (sound level)

● Special

- Reset Error

- Factory Set

4005-10


* The tests in the configuration menu should beperformed only by a qualified operator or technician,as some tests require the engine to be running athigh RPM’s.

Select Screen

The select screen will allow you to make timeset t ings as wel l as g ive access to machineinformation. Navigate this screen also by highlightingyour selection and pressing confirm. This will allowyou to change clock settings or view the hardwareand software screens. No operator changes can bemade to the hardware or software screens.

BS06F177

Hardware ScreenScroll to the hardware selection and press confirm todisplay machine information.

BD106F193

The cluster hardware selection will display the CNHpart number, serial number, ID number and versionof the Instrument cluster. This display is a convenientsource of information when ordering par ts oraccessories. Press escape to exit from this field andreturn to the selection menu or use the up or downarrow key to toggle to the software informationscreen.

Software Screen

BD06H028

The cluster software selection will display the CNHpart number, serial number, ID number and softwareversion of the Instrument cluster. This display is aconvenient source of information when ordering partsor accessories. Press escape to exit from this fieldand return to the selection menu or use the up ordown arrow key to toggle to the software informationscreen.

Selecting Power Modes

The power mode allows the operator to choose themost effective machine power for the current jobconditions. Most commonly auto is chosen, as thepower will automatically increase or decreasebetween maximum power and standard power whilethe machine is working. This allows for maximumpower if necessary, but will switch to standard modefor economy. Maximum power can be chosen formore severe work conditions. Economy can bechosen for limited power and fuel efficiency.

Press and hold the confirmation button for twoseconds to arrive at the service screen.

BD06H038

At the screen shown above, highlight the powermode and press the confirmation button to move tothe Power Mode Selection Menu.

4005-11


BD06F178

At the Power Mode Menu press the confirmationbutton again to act ivate the select ions. Thehighlighted section will flash to indicate a newselection can be made.

Press the up or down button to select the PowerMode, 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) ofthe Multi-Function Display when power mode iscorrectly selected.

NOTE: Selecting options and navigating through thescreen menus are the same for all functions. Thedisplay will tell the operator if errors have occurred.

BD06F176

Should an error message display, press theconfirmation button to acknowledge and begin again.

Preferences

BD06F179

Language Screen, Measurement Units, and ClockThe LCD screen can be set with language, units, andclock preferences. Use the arrow keys to scroll to thepreferences menu. Press confirm.

Choose the preferences desired, language in(English, Italian, Spanish, Portuguese, German,French, measurement units in English, Metric, orImperial and clock units in either 12 or 24 hour).Highlight the preference you wish to change andpress the confirm key. The preference will flash andallow you to scroll through the choices. When thecorrect preference is chosen, use the confirm key tolock in the preference for the display. The escapekey will allow you to leave this application.

4005-12


Clutch Calibration

After warming the oil temperature:

1. Park the machine on a firm level surface.

2. Place the Transmission Control Lever inNEUTRAL.

3. Set the Park Brake.

4. With the engine running, at idle, enter theService Screen Menu and scroll to Config.

BD06F202

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

BD06F195

This screen will prompt the operator or technican toconfirm or escape.

BD06F196

If, conditions are not correct, an error message willappear and guide the operator or technican.

There are six, if conditions not met, screens:

● 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 willsee six calibration screens pass. They will display inthis order:

● Adjust K1

● Adjust K2

● Adjust K3

● Adjust K4

● Adjust KV

● Adjust KR

Once the process is completed this screen will directthe operator or technican to shut the engine OFF andthen re-start.

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

4005-13


BD06F174

Options Menu

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

Fan AutoThe fan can be set to run at automatic or the fan willrun at maximum speed. Automatic is the morecommon or preferred setting. It will switch betweenhigh speed, low speed, or reverse as conditionsrequire depending on actual temperature of thecoolant, turbocharger air, transmission oil, andhydraulic oil.

The operator can choose fan speed or reversingcapabilities. Highlight the fan auto selection by usingthe arrow keys, then press confirm. When you havechosen the selection, lock the selection into memoryby pressing the confirm key.

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

Display MenuThe display menu can be used to change thebackground and brightness of the screen. Use thearrow keys to make your selection from the displaymenu and press the confirm key to lock the selectioninto memory. The screen display can be changed tosuit working conditions for day and night separately.

RPMEngine speed in RPM will show on the display if theengine speed is running up to 550 RPM’s, and willdisappear if the engine speed is lower than 300RPM.

MPH/KPH

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

4005-14


RETRIEVING FAULT CODES

General Fault Code Identification1. Press and hold the escape key and up arrow key

for more than 2 seconds to access the faultcodes.

BD06F186

A. Escape key

B. enter key

C. up key

D. down key

2. Yellow Faults, buzzer will beep once every 2seconds:

A. Operator can acknowledge it by pressing theenter key.

B. The message will disappear.

C. Buzzer will not beep anymore.

D. Yellow lamp will stay ON.

E. Fault will remain in Yellow list until it is closed.

3. Red Faults, buzzer will be continuous,alternating sounds:

A. Operator can acknowledge it by pressing theenter key.

B. Buzzer will change to a less stressing sound,but will remain.

C. Message will remain on display with indicationof URGENT STOP.

Fault Code Grouping1. 1000 to 1999 vehicle errors.

2. 2000 to 2999 not used.

3. 3000 to 3999 engine errors.

4. 4000 to 4999 transmission errors.

5. 5000 to 5999 eltro-hydraulic system errors.

6. 6000 to 6999 reserved.

7. 7000 to 7999 reserved.

8. 8000 to 8999 optional equipment IE: GPS.

9. 9000 to 9999 internal AIC errors.

A

B

C

D

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 1. Stop machine operations2. Run engine at 1500 rpm3. Check fan operation4. Check cooling core for clogs

1313 Hydraulic oil temperature to high

1314 Transmission oil temperature above normal

1315 Transmission oil temperature to high

1316 Brake pressure too low

1. Stop machine operations2. Run engine at 1500 rpm3. Check brake system pressure4. Check brake system for leaks

1317 Steering pressure too low

1. Stop machine operations2. Run engine at 1500 rpm3. Check steering system for operation4. Check steering system for leaks

1318 Engine coolant temperature above normal 1. Stop machine operations2. Run engine at 1500 rpm3. Check fan operation4. Check radiator core for clogs

1319 Engine coolant temperature high - critical

1320 Engine oil pressure too low 1. Stop machine operations2. Check engine oil level3. Check pressure sender unit1321 Engine oil pressure below normal

1322 Engine oil pressure above normal1. Check engine oil for proper type2. Check pressure sender unit

1323 Battery voltage lowCheck charging system

1324 Battery voltage high

1325 Oil temperature too high1. Stop machine operations2. Run engine at 1500 rpm3. Check sending unit

1326 Coolant level low Fill radiator level

1327 Moved during accelerated idle No information available at time of print.

1328 Moving when shifting to low idle No information available at time of print.

1331 Electrical charging system voltage low - critical level

1. Stop machine operations2. Check charging system

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

1335 Brake pressure too low

1. Stop machine operations2. Run engine at 1500 rpm3. Check brake system pressure4. Check brake system for leaks

4005-16


NOTE: The following fault codes are for optional climate controlled heating and air conditioning system.

1336 Transmission oil filter blocked Replace filter

CODE DEFINITIONDESCRIPTION AND POSSIBLE

STEPS FOR REPAIR

1909 Open circuit evaporator temperature sensor AC relay compressor is disabled.

1. Check sensor for short circuit to ground oropen circuit.

2. Check harness between control module andrelay.

1910 Short circuit evaporator temperature sensor

1919 Water valve motor output failure, does not work correctly

1. Verify if the system controls are functioningproperly when requesting heat or AC.

2. The motor is working in a degraded mode,replace valve.

1920 Recirculation actuator DC motor output failure, does not work correctly

1. Turn system on with fan speed on low, verifyposition of flap.

2. Place the fan speed on high, check position offlap.

3. Check harness between controller and flapmotor.

1921 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.


4005-17


ENGINE FAULT CODES


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.Sensor defective or short circuit to external source. Check wiring or replace sensor.

3016 Fuel temperature signal below range min.Sensor defective or short circuit to ground.Check wiring or replace sensor.

3019 Boost pressure sensor signal above range max.


3021 Boost pressure sensor null (via CAN)No CAN plausibility check performed, restart system, if problem reoccurs. Check wiring or replace sensor.

3022 Boost pressure sensor signal not plausibleDifference of ambient and boost pressure is out of range.Check wiring or replace sensor.

3023 Atmospheric pressure sensor signal not plausible

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

3024 Atmospheric pressure sensor signal above range max.

3025 Atmospheric pressure sensor signal below range min.

4005-18


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 batterySensor defective or short circuit to external source. Check wiring or replace sensor.

3030 Oil pressure sensor short-circuit to groundSensor defective or short circuit to ground. Check wiring or replace sensor.

3031 Oil pressure sensor ADC conversion error No information available at time of print.

3032 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.

Sensor defective or short circuit to ground. Check wiring or replace sensor.

3036 Oil temperature sensor signal CAN transmission disturbed

No CAN plausibility check performed, restart system, if problem reoccurs. Check wiring or replace sensor.

3037 Boost pressure sensor signal lowSensor defective or short circuit to ground. Check wiring or replace sensor.

3043 Vehicle speed sensing hardware conversion error

No information available at time of print.

3046 Vehicle speed sensing signal not plausible No information available at time of print.

3051 Battery voltage to ECM too highAlternator voltage governor defect. Replace alternator governor device or alternator.

3052 Battery voltage to ECM too low

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

3060 Cylinder 1 unclassified error in injector

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


STEPS FOR REPAIR

4005-19


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 lowCheck the wiring and the injection signals, replace ECU

3063 Cylinder 1 short-circuit high side to groundDefective coil of injector.Check the wiring and replace injector





3066 Cylinder 5 signal lowCheck the wiring and the injection signals, replace ECU.















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


STEPS FOR REPAIR

4005-20












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 defectiveCheck 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 onlyCheck 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


STEPS FOR REPAIR

4005-21


3104 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. Rail pressure sensor inaccurate.

Ensure correct wiring and proper functioning of rail pressure sensor, replace sensor3111 Rail pressure sensor offset monitoring signal

below range min.

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 Ambient pressure sensor inside ECU is defective.Replace ECU (not necessary if never running in high altitude and if turbocharger without VGT)3119 ECM 12V sensor supply voltage low

3131 Grid heater always switched onShort circuit to ground of grid heater.Check grid heater switch and replace it

3137 Metering unit open loadBroken or disconnected wiring or defective relay.Check of wiring or replace relay

3138 Metering unit signal not plausible

Defective wiring, ECU, power stage or metering unit.Check wiring, ECU, power stage and metering unit


STEPS FOR REPAIR

4005-22


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 batteryShort circuit of wiring to external source or inside relay.Check wiring or replace relay

3155 Grid heater relay short-circuit to groundShort circuit of wiring to ground or inside relay.Check wiring or replace relay

3156 Grid heater relay no loadBroken or disconnected wiring or defective relay.Check wiring or replace relay

3161 Fan actuator signal low No information available at time of print.

3171 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 valveLow 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

3175 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.

3176 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.


STEPS FOR REPAIR

4005-23


3178 Time-out of CAN message BC2EDC1Defective 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.

3179 Time-out of CAN message BC2EDC2

3180 Time-out of CAN message VCM2EDC

Defective CAN controller of Vehicle Control Module, undervoltage of VCM, missing VCM, CAN cable connecting the VCM is disconnected or broken. Short circuit in wiring. Check presence and correct connection of the VCM to the network, Check correct functioning of the VCM CAN controller and its voltage supply. Check wiring.

3188 Cylinder 1 open load

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






3210 Bank 1 general short-circuit on injection cableShort 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 No information available at time of print.

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 cableShort 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 No information available at time of print.

3221 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


STEPS FOR REPAIR

4005-24


3227 Injection processor error - stop engine

Clock error or interruption of the power supply voltage.Check the power supply or replace ECU if problem reoccurs.

3228 Injection processor error - stop engineDefective 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


Defective SPI-bus participant, timing problem due to software bug.Replace ECU if problem reoccurs (Send in ECU for investigation)


Defective ECU.Replace ECU if problem reoccurs




3238 Communication error of CJ940 processorElectric disturbances, internal defect of the ECU leading to a SPI bus communication error.Replace ECU if failure remains present

3242 Recovery which is locked 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.

3243 Recovery which is suppressed

3244 Recovery which is visible

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 initialWatch dog switch off path defect. If failure remains after ECU initialization: replace ECU

3247 Redundant shutoff paths during initial Electronic disturbances, internal ECU problem. If failure remains after ECU initialization: replace ECU3248 Redundant shutoff paths during initial


STEPS FOR REPAIR

4005-25


3253 Error status ADC monitoring

Buffer overrunNo additional information available at time of print




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 stageBroken 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 stageShort 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 checkElectronic disturbances, internal ECU problem. If failure persists after reinstallation replace ECU

3278 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)

3279 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)

3280 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


STEPS FOR REPAIR

4005-26


3281 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


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


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


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


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

3290 Turbo compound monitoring signal not plausible

No information available at time of print.


STEPS FOR REPAIR

4005-27


TRANSMISSION FAULT CODES


4113 Logical error at FNR switch

1. Check the cables from the TCU to the FNRswitch.

2. Check the connectors from the TCU to the FNRswitch.

3. Check the FNR switch.

4114 Logical error at direction select signal



3. Check the FNR switch signal combinations.

4116 Logic error at park brake status1. 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



3. Check the FNR switch signal combinations.

4119 Short circuit to ground at ride control 1. Check the cables from the TCU to the ridecontrol relay.

2. Check the connectors from the TCU to the ridecontrol relay.

3. Check the ride control relay.

4120 Short circuit to battery voltage at ride control

4121 Open circuit at ride control

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

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

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

4145 Short circuit to battery voltage or open circuit at engine speed sensor

1. Check the parking brake fuse.2. Check the parking brake relay.3. Check the parking brake solenoid.4146 Short circuit to ground at engine speed sensor

4147 Logical error at engine speed sensor input

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 theTCU. It is also reset if the signal is above zerospeed threshold.

4005-28


4148 Short circuit to battery voltage or open circuit at turbine speed sensor input 1. Check the cables from TCU to the sensor.

2. Check the connectors.3. Check the speed sensor.4149 Short circuit to ground at turbine speed sensor

input

4150 Logical error at turbine speed sensor input


NOTE: This fault code is reset after power up of theTCU.

4151 Short circuit to battery voltage or open circuit at intermediate speed sensor input 1. Check the cables from TCU to the sensor.

2. Check the connectors.3. Check the speed sensor.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

1. Check the cables from TCU to the sensor.2. Check the connectors.3. Check the speed sensor.4155 Short circuit to ground at output speed sensor

4156 Logical error at output speed sensor



4158 Output speed zero, does not match other speeds.

1. Check the sensor signal of the output speedsensor.

2. Check the connector connected to the outputspeed.

3. Check the cable from the TCU to the sensor.


4160 Invalid gear range restriction (CAN)1. Check the cluster controller.2. Check wire of CAN-Bus.3. Check the cable to the cluster controller.

4180 Vehicle controller time-out (CAN) 1. Check the cluster controller.2. Check wire of CAN-Bus.3. Check the cable to the cluster controller.

4185 Invalid test mode signal (CAN)

4186 Invalid park brake status (CAN)


4005-29


4209 Short circuit to battery voltage at clutch K1

1. Check the cable from the TCU to thetransmission control valve.

2. Check the connectors from the TCU to thetransmission control valve.

3. Check the regulator resistance.4. Check internal wire harness of the transmission

control valve.

4210 Short circuit to ground at clutch K1

4211 Open circuit at clutch K1










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 1. Check the cable from the TCU to the backup.alarm relay.

2. Check the connectors from the backup alarmrelay to TCU.

3. Check the resistance of backup alarm relaycircuit.

4242 Short circuit to battery voltage at backup alarm relay

4243 Open circuit at backup alarm relay

4273 Slippage at clutch K1

1. Check pressure at clutch K1.2. Check main pressure in the system.3. Check signal at internal speed sensor.4. Check signal at output speed sensor.5. Replace clutch.






4005-30




4277 Slippage at clutch KV

1. Check pressure at clutch KV.2. Check main pressure in the system.3. Check signal at internal speed sensor.4. Check signal at output speed sensor.5. Replace clutch.

4278 Slippage at clutch KR

1. Check pressure at clutch KR.2. Check main pressure in the system.3. Check signal at internal speed sensor.4. Check signal at output speed sensor.5. 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

Check engine speed sensor

4282 TCU sensed a voltage at oil filter maintenance switch out of the allowed range (dirty filter)

1. Check oil filter.2. Check wiring from TCU to filter maintenance

switch.3. Check filter maintenance switch (measure

resistance).

4284 Overspeed output No information available at time of print.

4288 Engine torque or engine power overload No information available at time of print.

4289 Transmission output torque overload No information available at time of print.

4290 Transmission input torque overload No information available at time of print.

4291 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.

4292 Joystick status indicator short-circuit to ground

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

joystick.3. Check the resistance of the joystick.


4005-31


4293 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 1. Check batteries.2. Check B+ wires from batteries to TCU.3. Check voltage at TCU connector pin 45.4308 High voltage at battery

4309 Error at VPS 1 for solenoid power supply 1. Check fuse A2.2. Check cable from control valve to TCU.3. Check connectors from control valve to TCU.4. Replace TCU.

4310 Error at VPS 2 for solenoid power supply

4325 Vehicle ID #1 time out No information available at time of print.

4326 Undefined VIN request via CAN. No information available at time of print.

4337 General EEPROM fault Replace the TCU.

4338 Configuration errorReprogram the correct configuration for the vehicle.

4339 Application error (ZF internal) Replace the TCU.

4341 Clutch calibration faultDo the transmission clutch calibration procedure.

4342 Clutch adjustment data lost


4005-32


INSTRUMENT CLUSTER FAULT CODES


STEPS FOR REPAIR

9128 CAN timed out during operationIf error is permanent or repeats often, check CAN wiring harness and connections on the CAN bus circuits.

9129 CAN timed out during operation

9130 CAN timed out during operation

Section5001

5001




REMOVAL AND INSTALLATION OF STEERING COMPONENTS

5001-2


TABLE OF CONTENTS

STEERING CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

AUXILIARY STEERING PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

STEERING PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

AUXILIARY STEERING PUMP AND MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

STEERING BACK PRESSURE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

5001-3


STEERING CONTROL VALVE

Removal

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

STEP 2Remove all dirt and grease from steering controlvalve.

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

STEP 4Tag hoses connected to steering control valve.

STEP 5

BD06G262

Disconnect hoses from steering control valve, cap orplug the fittings and hoses, turn off the vacuumpump.

STEP 6

BD06G244

Remove the center cap from the steering wheel.

STEP 7

BD06G245

Remove the mounting nut and washers from thesteering shaft.

STEP 8

BD06G246

Remove the steering wheel from the shaft.

STEP 9

BD06G247

Remove the six mounting screws from the instrumentcover.

5001-4


STEP 10

BD06G248

Remove the five mounting screws for the left andright hand trim.

STEP 11

BD06G249

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

STEP 12

BD06G257

Remove the screw from the brace.

STEP 13

BD06G258

Remove the two mounting screws from the lowertrim.

STEP 14

BD06G259

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

STEP 15

BD06G260

Remove the two lower mounting screws from thefront vent.

5001-5


STEP 16

BD06G261

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

STEP 17

BD06G263

Remove the four mounting bolts for the steeringcontrol valve.

IMPORTANT: Have an assistant support andremove the valve while removing the mounting bolts.

Installation

STEP 18

BD06G264

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

STEP 19Have an assistant push the valve into place whileturning the steering shaft, this will engage thesplines.

STEP 20

BD06G263

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

5001-6


STEP 21

BD06G261

Install the front trim, install and tighten the threemounting bolts inside of the vent holes, install threevents into the front trim.

STEP 22

BD06G260

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

STEP 23

BD06G258

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

STEP 24

BD06G257

Install the screw into the brace.

STEP 25

BD06G249

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

STEP 26

BD06G248

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

5001-7


STEP 27

BD06G247

Install and tighten the six mounting screws for theinstrument cover.

STEP 28

BD06G245

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

STEP 29

BD06G244

Install the center cap on the steering wheel.

STEP 30

BD06G262

Start the vacuum pump, remove the caps and plugsthe fittings and hoses. Connect hoses to steeringcontrol valve according to the tags installed duringremoval, remove and discard the tags.

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

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

STEP 33Install the skirts onto the cab or canopy.

STEP 34Check fluid level in hydraulic reservoir. Add oil asrequired. See Section 1002 for specifications.

5001-8


AUXILIARY STEERING PRIORITY VALVE

Removal1. Park loader on level ground and lower bucket to

ground. Put transmission in NEUTRAL, applyparking brake, and shut down engine,

2. Put master disconnect switch in OFF position.

3. Remove all dirt and grease from auxiliarysteering priority valve and adjacent area. Seeillustration on page 9.

4. Remove hydraulic reservoir fill cap.

5. Connect a vacuum pump to hydraulic reservoir.

6. Start vacuum pump.

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

8. Tag and disconnect tank return tube (10) fromthe priority valve. Install a cap on the elbow anda plug in the tube.

9. Stop the vacuum pump.

10. Tag and disconnect the wiring from the steeringsolenoid (8).

11. Tag and disconnect the wiring from the pressureswitch (3).

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

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

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

15. Tag and disconnect pressure hose (7) frompriority valve. Install a cap on the fitting and aplug in the hose.

16. Loosen fitting (5) connected to elbow installed insteering priority valve.

17. Support auxiliary steering priority valve. Removefour nuts (6), cap screws, and washers.

18. Remove auxiliary steering priority valve.

Installation1. Connect and hand tighten fitting (5) to the elbow

in the steering priority valve.

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

3. Tighten pressure tube fitting (5).

4. Tighten the nuts (6).

5. Connect and tighten pressure hose (7).

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

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

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

9. Connect electrical connector to the pressureswitch (3).

10. Connect electrical connector to the steeringsolenoid (8).


12. Connect and tighten tank return tube (10).

13. Connect and tighten hose to auxiliary steeringpump port (4).

14. Stop vacuum pump. Disconnect vacuum pumpfrom hydraulic reservoir.

15. Install fill cap on hydraulic reservoir.

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

17. Check to make sure priority valve operatescorrectly. See Section 5002.

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

5001-9


BC05M084

AUXILIARY STEERING PRIORITY VALVE ILLUSTRATION

1. STEERING LOAD SENSING HOSE TO PRIORITY VALVE 6. CAP SCREWS AND NUTS 2. STEERING LOAD SENSING HOSE TO STEERING VALVE 7. PRESSURE HOSE3. PRESSURE SWITCH 8. STEERING SOLENOID4. SUCTION PORT 9. STEERING PRESSURE HOSE5. PUMP OUT PRESSURE TUBE FITTING 10. TANK RETURN TUBE

4

2

9

3

6

57

1

10

86

5001-10


STEERING PRIORITY VALVE




3. Remove all dirt and grease from steering priorityvalve (7) and adjacent area. See illustration onpage 11.




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

8. Loosen and remove eight bolts (4) and four spitflanges (3).

9. Remove the high pressure pump discharge tube(5), discard O-rings (6).

10. Support the steering priority valve (7), removemounting bolts (8).

11. Remove steering priority valve (7).

Installation1. Install bolts with washers (8) through priority

valve. Install new O-ring on top of priority valve(not shown). Install priority valve (7) onto lowpressure pump, tighten bolts to37 to 48 Nm(27 to 35.5 pound feet).

2. Install new O-rings (6) onto high pressure pumpdischarge tube (5).

3. Place tube into position and intsall four splitflanges (3) and eight bolts (4) with washers,tighten bolts.

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

5. Stop vacuum pump.

6. Disconnect vacuum pump from hydraulicreservoir.

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 valveoperates correctly. See Section 5002.


5001-11


BC05M087

STEERING PRIORITY VALVE ILLUSTRATION

1. LOW PRESSURE PUMP (LOADER PUMP) 5. STEERING PUMP OUTPUT LINE2. HIGH PRESSURE PUMP (STEERING PUMP) 6. O-RINGS 3. SPLIT FLANGE 7. STEERING PRIORITY VALVE 4. BOLT 8. BOLT

3 8

7

5

3

4

4

2

1

6

5001-12


AUXILIARY STEERING PUMP AND MOTOR




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

4. Tag and disconnect positive cable (2) from B+stud of auxiliary steering pump and motor (7).

5. Tag and disconnect ground cable (1) fromground stud of auxiliary steering pump and motor(7).




9. Disconnect suction hose (4) from auxiliarysteering pump and motor (7). Install a plug insuction 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 washerssecuring auxiliary steering pump and motor (7).

13. Remove pressure tube (5) and auxiliary steeringpump and motor (7).

Installation1. Position auxiliary steering pump and motor (7) on

its mounting plate while connecting and handtightening pressure tube (5) to auxiliary steeringpriority valve (6). See illustration on page 13.

2. While supporting auxiliary steering pump andmotor (7) have an assistant install cap screws,washers, and nuts (3) to secure auxiliary steeringpump and motor (7), tighten the nuts.

3. Tighten pressure tube (5) fittings securely.


5. Remove plug from suction hose (4) and cap fromelbow. Connect suction hose to elbow installed inauxiliary steering pump and motor (7).

6. Stop and disconnect vacuum pump. Install fillcap in hydraulic reservoir.

7. Connect ground cable (1) to ground stud ofauxiliary steering pump and motor (7) followingtag installed during removal.

8. Connect positive cable (2) to B+ stud of auxiliarysteering pump and motor (7) following taginstalled during removal.

9. Connect wiring harness wires (8) to auxiliarysteering pump and motor (7) following tagsinstalled during removal.

10. Put master disconnect switch in ON position.

11. Start and run engine at low idle and raise bucket500 mm (20 inches) above ground. Check thatauxiliary steering light on information center isOFF.

IMPORTANT: In following Step, do not run auxiliarysteering pump and motor continuously for more than20 seconds at a time without a two minute cool down.

12. With engine at low idle and machine steeringstraight ahead, turn key switch to OFF position tostop engine and then immediately back to ONposition (not START position). Auxiliary steeringpump and motor shou ld s ta r t opera t ingimmediately. Check that auxiliary steering lighton information center is ON and auxil iarysteering pump and motor is operating.

13. Turn steering wheel all the way to left and right tomake sure that auxiliary steering pump andmotor operates correctly.

14. Restart engine. Check that auxiliary steering lighton information center stays ON and auxiliarysteering pump and motor is operating. Afterabout three seconds motor should stop operatingand auxiliary steering light should go out.

15. Let engine run and allow batteries to recharge fora minimum of 10 minutes.

5001-13


BC05M085

AUXILIARY STEERING PUMP AND MOTOR ILLUSTRATION

1. GROUND CABLE 4. SUCTION HOSE 7. AUXILIARY STEERING PUMP AND MOTOR2. POSITIVE CABLE 5. PRESSURE TUBE 8. WIRING HARNESS 3. NUT (4) 6. AUXILIARY STEERING PRIORITY VALVE

1

2

8

45

7

6

3

5001-14


STEERING CYLINDER

Removal1. Loosen the fill cap for the hydraulic reservoir to

release pressure in the reservoir, then tighten thefill cap.

2. Disconnect grease hoses (1 and 16) fromsteering cylinders (11). See illustration on page15.

3. Disconnect hydraulic hoses (2, 3, 9, and 10) fromsteering cylinders (11).

4. Install a plug in each hose (2, 3, 9, and 10) toprevent 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 steeringcylinders (11).

10. Use a suitable driver and drive pivot pin (5) out ofsteering cylinder (11).

11. Remove washer(s) (4) from between steeringcylinders (11) and rear frame of machine.

12. Remove steering cylinders (11).

Installation1. Put steering cylinders (11) in position in machine.

Make sure that washers (4) are instal ledbetween steering cylinder (11) and rear frame.See illustration on page 15.

NOTE: Install a washer (4) on top and bottom ofsteering cylinders (11) if possible. If only one washer(4) can be installed, place washer (4) at bottom ofsteering cylinders (11).

2. Make sure washers (14) are installed betweensteer ing cyl inders (11) and front frame ofmachine.

3. Install the pivot pin (5) to secure rear of steeringcylinders (11) to machine frame. Install spacer(6), washer (7), and cap screw (8) to secure pivotpin (5).

4. Tighten cap screw (8).

5. Install pin (12) in front of steering cylinders (11).Make sure that washers (14) are installed incorrect position.

6. Install cap screw (13) and new locknut (15) insteering cylinders (11) rod end and pin (12).Tighten locknut (15).

NOTE: Cap screw (13) should turn freely in holeafter tightening.

7. Connect hose assemblies (2, 3, 9, and 10) tosteering cylinders (11).

8. Connect grease hoses (1 and 16) to steeringcylinders (11).

9. Tighten hydraulic reservoir fill cap.

10. Start engine.

11. Turn steering wheel all the way to right and thento the left several times.

12. Stop the engine. Check fluid level in hydraulicreservoir. Add oil as required. See Section 1002for specifications.

5001-15


BS03B141

STEERING CYLINDER ILLUSTRATION

1. GREASE HOSE 5. PIVOT PIN 9. HOSE ASSEMBLY 13. CAP SCREW2. HOSE ASSEMBLY 6. SPACER 10. HOSE ASSEMBLY 14. WASHER3. HOSE ASSEMBLY 7. WASHER 11. STEERING CYLINDER 15. LOCKNUT4. WASHER 8. CAP SCREW 12. PIN 16. GREASE HOSE

1 1

109

32

15

13

12

8

7

6

5

11

11

14

4

16

5001-16


STEERING BACK PRESSURE VALVE

Removal1. Remove the fill cap for the hydraulic reservoir to

release pressure in the reservoir, attach avacuum pump to the reservoir, start the pump.

2. Disconnect hoses 2 and 6 from the pressurevalve.

3. Remove the nuts, bolts and spacers from thepressure vale, remove the valve from themachine.

Installation1. 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 thereservoir filler cap.

4. Start and run the machine at low idle, turn thesteering wheel from full left lock to full right lockholding the steering over relief.

5. Stop the machine and check for leaks.


5001-17


BS06G529

STEERING BACK PRESSURE VALVE ILLUSTRATION

1. STEERING CONTROL VALVE 5. RELIEF VALVE2. RETURN HOSE 6. RETURN HOSE TO FILTERS3. PRESSURE HOSE 7. RETURN MANIFOLD4. CONNECTOR M27 ORB

1

2

3

4

5

7

6

5001-18


NOTES

Section5002 50

02




STEERING SPECIFICATIONS, PRESSURE CHECKS, AND TROUBLESHOOTING

5002-2


TABLE OF CONTENTS

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TROUBLESHOOTING THE STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3AUXILIARY STEERING SYSTEM PUMP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

AUXILIARY STEERING SYSTEM MOTOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Understanding The Results Of The Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

STEERING PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Pressure Setting Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Pressure Setting Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

STEERING CYLINDER LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8STEERING BACK PRESSURE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

5002-3


SPECIAL TOOLS

B785789

B797157

B009638

TROUBLESHOOTING THE STEERING SYSTEMNOTE: The steering hydraulic schematic is includedin the hydraulic schematic. Refer to the rear pocket ofthis manual.

1. Make sure the oil level in the hydraulic reservoiris correct. Visually inspect the steering systemfor leakage and damage.

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

3. Do the steering limit valve pressure test. Refer topage 6. If the pressure is above or belowspecifications, adjust the steering limit valve.

4. Do the main hydraulic pump test. See Section8002. If the main pump is bad, repair or replacethe main hydraulic pump.

5. Test the steering cylinders for leakage, refer toinstructions on page 8. If a steering cylinder isleaking, repair or replace the steering cylinder.

6. If the steering system is noisy test the backpressure relief valve, refer to instructions onpage 9.

OEM-1239 (CAS-10280) FLOWMETER

CAS-1808 FLOWMETER FITTING KIT

CAS-1804 PRESSURE TEST FITTING KIT

5002-4


AUXILIARY STEERING SYSTEM PUMP TEST

Equipment Required1. CAS- 10280 Flowmeter

2. CAS-1808 Flowmeter fitting kit

Test Procedure1. Install articulation lock.

BD03A040

NOTE: When performing this pressure check,always be sure the articulation lock is in place,especially when working in the articulation jointareas.

2. Loosen and remove the outlet hose to theAuxiliary Steering Pump from the AuxiliarySteering Priority Valve.

3. Install a plug into the Auxiliary Steering PriorityValve.

4. Connect the inlet of the flowmeter to the outletline of the Auxiliary Steering Pump.

5. Install the outlet hose of the flowmeter in thehydraulic reservoir and hold in place with wire.

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

BB830300

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

8. Make sure that the oil is at operatingtemperature.

9. Make sure that the load valve for the flowmeter isopen (zero pressure).

10. Start and run the engine.

11. Stop the engine and turn the key back to the Onposition.

12. Turn the steering wheel, this will activate theauxiliary steering pump.

13. Turn the load valve on the flowmeter towardsCLOSED until the pressure is 104 bar (1500 psi).

14. Read the flowmeter and ammeter gauges andrecord the readings.

15. The flowmeter reading must not be less than24.6 L/min, (6.5 U.S. gpm). The ammeter readingmust be 315 amps.

16. Turn the key switch to the OFF position. If theflow was less than the specification, or if theamperage was more than 315 amperes, removethe auxiliary steering motor and pump. Test theauxiliary steering motor. If the motor is good,make repairs to the pump.

1. ARTICULATION LOCK

1

1. AMMETER CLAMP

1

5002-5


AUXILIARY STEERING SYSTEM MOTOR TEST

Test Equipment1. A 24 volt battery that is fully charged.

NOTE: A 24 volt battery system (two 12 voltbatteries in a series) is used for this test. A 12 voltbattery system will cause damage to the auxiliarysteering motor.

2. A remote starter switch.

3. A tachometer to check the armature speed.

4. A Sun Electric VAT-33 Starting and ChargingSystem Tester.

Test Procedure1. Remove the connector that is between the

terminals on the magnetic switch and theauxiliary steering motor.

2. Remove the auxiliary steering motor from theauxiliary steering pump.

3. Remove the drive coupling from the auxiliarysteering motor (3).

4. Connect the auxiliary steering motor (3), remotestarter switch (1) and tester (2) to the 24 voltbattery system (5) as illustrated.

B790852

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

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

B795328

7. Hold the tachometer against the armature shaft.Look at the tachometer. Make a record of theindication.

8. Release the button on the remote starterswitch (1).

Understanding The Results Of The Test

1. If the ammeter indication in step 6 was 30amperes or less and the tachometer indication instep 7 was 6950 r/min (rpm) or more, theauxiliary steering motor is good.

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

1. REMOTE STARTER SWITCH2. TESTER3. AUXILIARY STEERING MOTOR4. AMMETER CLAMP5. 24 VOLT BATTERY SYSTEM

1 2

43

5

6. AMMETER7. VOLTMETER8. LOAD CONTROL

6

8

7

5002-6


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

Pressure Setting Test

1. Install articulation lock (1).

BD03A040

IMPORTANT: When performing the followingpressure check and adjustment, the articulation lockmust be installed. Use caution when working in ornear the articulation area.

2. Remove the dust cap from the test port (1).

BD06F148

3. Connect a 345 bar (5000 psi) pressure gauge tothe test port (2).

NOTE: Make sure when you connect the pressuregauge that you do so in a manner that you can readthe pressure gauge while sitting in the operatorsseat.

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

5. To measure the temperature of the oil using theinstrument panel:


B. Stop at the info screen with the temperaturesthat 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 inthe FLOAT position.

9. Hold the bucket control lever in the rollbackposition.

10. Continue holding until the specified temperatureof the oil is reached.


12. Start the engine and operate the machine at fullthrottle.

13. With the articulation lock still in place, turn andhold the steering wheel for a hard right turn.

14. Continue holding the steering wheel, and readthe pressure gauge.

15. The pressure gauge must indicate 239 to 243bar (3465 to 3525 psi). If the pressure is notcorrect, adjust the steering relief valve.


1. G1 TEST PORT2. G2 TEST PORT

1

1

2

5002-7


Pressure Setting Adjustment1. Turn the adjusting screw clockwise to increase

the pressure setting. Turn the adjusting screwcounterclockwise to decrease the pressuresetting.

2. Repeat pressure test procedure.

3. If necessary, adjust the limit valve again untilwithin the specified range.

4. Stop the engine before removing the pressuregauge.

BD06F147

1. STEERING PRIORITY VALVE2. LIMIT VALVE

1

2

5002-8


STEERING CYLINDER LEAK TESTNOTE: Make sure all persons are clear of the areaof the center pivot. Make sure the center pivot is freeof 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 ofthe left-hand steering cylinder. Disconnect thetube from the left-hand cylinder.

5. Install a plug in the tube.


7. Turn the steering wheel to the right. Hold thesteering wheel for a full right turn. Have anotherperson check for leakage from the opening of therod end of the left-hand steering cylinder.

8. If there is constant leakage from the rod end, thepiston packing in the left-hand steering cylinderis damaged. Repairs must be made. See Section5005.

9. Connect the tube to the rod end of the left-handsteering cylinder.

10. Turn the machine all the way to the left.


12. Find the tube that is connected to the rod end ofthe right-hand steering cylinder. Disconnect thetube from the right-hand steering cylinder.

13. Install a plug in the tube.


15. Turn the steering wheel to the left. Hold thesteering wheel for a full left turn. Have anotherperson check for leakage at the opening of therod end of the right-hand steering cylinder.

16. If there is constant leakage from the rod end, thepiston packing in the right-hand steering cylinderis damaged. Repairs must be made. See Section5005.

17. Connect the tube to the rod end of the right-handsteering cylinder.

5002-9


STEERING BACK PRESSURE VALVE

BS06G529

1. STEERING CONTROL VALVE 5. RELIEF VALVE2. RETURN HOSE 6. RETURN HOSE TO FILTERS3. PRESSURE HOSE 7. RETURN MANIFOLD4. CONNECTOR M27 ORB

1

2

3

4

5

7

6

5002-10


Pressure Test1. Disconnect the return hose (2) from the

connector (4).

2. Install a “T” fitting and connect a pressure gaugecapable of reading 35 bar (500 psi).

3. Start and run the machine at high idle.

4. Turn the steering wheel and observe thepressure.

5. The pressure should be 8 to 10 bar (115 to 145psi).

6. If pressure is not as specified, replace the reliefvalve.

NOTE: The relief valve is not adjustable.

Section5005

5005




STEERING CYLINDERS

5005-2


TABLE OF CONTENTS

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

5005-3


SPECIFICATIONSTorque 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

Disassembly1. 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 oftube (18).

4. Fasten piston rod (14) yoke in vise and put asupport below piston rod near piston (9). Put ashop cloth between support and piston rod toprevent damage to piston rod.

5. Loosen and remove bolt and washer (8) that holdpiston (9).

6. Remove piston (9) from piston rod (14).

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), andbearing (5) from gland (1).

Inspection1. Clean all parts in cleaning solvent.

2. Check to be sure that piston rod (14) is straight. Ifpiston rod is bent, install a new piston rod.

3. Inspect inside of tube (18) for deep grooves andother damage. If there is any damage to tube, anew tube must be used.

4. Remove small scratches on piston rod (14) orinside tube (18) with emery cloth of medium grit.Use emery cloth with a rotary motion.

5. Inspect bushing (17). If bushing requiresreplacement, remove grease fitting (15) andretaining rings (16) then press bushing from tubeend.

5005-4


BC05M089

STEERING CYLINDER ILLUSTRATION

1. GLAND 6. BACKUP RING 11. WEAR RING 15. GREASE FITTING2. ROD WIPER 7. O-RING 12. RING LOADER 16. RETAINING RING3. ROD SEAL 8. BOLT AND WASHER 13. SEAL 17. BUSHING4. BUFFER SEAL 9. PISTON 14. PISTON ROD 18. TUBE5. BEARING 10. RING CAST IRON

9

8

45

37

6

13

10

1211

15

14

1

16

2

1617

18

19

5005-5


Assembly1. Install bearing (5) in gland (1).

2. Install buffer seal (4) in gland (1) so that lips ofseal are toward small end of gland.

3. Install rod seal (3) in gland (1). Rod seal must beinstalled so that lips of seal are toward small endof gland. Seal can be difficult to install. Use toolsthat will not damage seal. See illustration onpage 4.

4. Install rod wiper (2) in gland (1) with wiper lipstoward large end of gland.

5.

6. Install O-ring (7) on gland (1).

7. Install backup ring (6) on gland (1). The backupring must be toward large end of gland. If backupring is not flat on both sides, the side that is notflat must be toward O-ring (7).

8. Fasten piston rod (14) yoke in vise.

9. Lubricate piston rod (15) and bore in gland (1)with clean hydraulic oil.

NOTE: If a new gland (1) is being installed, writepart number of cylinder on gland.

10. Push gland (1) onto piston rod (14) large endfirst. If necessary, use a soft hammer to drive thegland onto piston rod.

11. Put a support below and near the end of pistonrod (14). Put a cloth between support and pistonrod to prevent damaging piston rod.

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 cleaningsolvent. Allow to dry. Apply Loctite 243 to pistonrod threads 6.4 mm (1/4 inch) from open end ofpiston rod so that there is 12.7 mm (1/2 inch) ofLoctite 243 on piston rod threads. DO NOT applyLoctite to first 6.4 mm (1/4/inch) of piston rodthreads.

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 todamage tube.

21. Apply petroleum jelly to O-rings (7) and backupring (6) on gland (1) and to sealing surface intube (18).

22. Lubricate piston (9) and inside of tube (18) withclean hydraulic oil.

23. Push the piston (9) straight into tube (18). Becareful not to damage cast iron ring (10), wearring (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:

A. Tighten gland to a torque of 339 to 475 Nm(250 to 350 pound-feet).

B. Install and tighten self-tapping screw (19) to atorque of 2.3 Nm (20 inch-pounds).

C. If, after tightening gland, the self-tappingscrew (19) holes are not aligned, a new holefor self-tapping screw must be drilled. SeeStep 26.

26. If a new gland (1) or a new tube (18) are beingassembled:

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 ingland (1) and half in tube (18). Drill to a depthof 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 atorque of 2.3 Nm (20 inch-pounds).

27. If hoses were removed with cylinder, install newO-rings, if equipped, on hose fittings. LubricateO-rings with clean oil. Install hoses.

5005-6


NOTES

Section5006

5006




CENTER PIVOT

5006-2


TABLE OF CONTENTS

SPECIFICATIONs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3CENTER PIVOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

CONNECTING THE FRONT FRAME TO THE REAR FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

5006-3


SPECIFICATIONS

SPECIAL TORQUESM16 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)

LUBRICANTPivot bearings and seals ............................................................................... Case AKCELA molydisulfide greaseSteering cylinder rod eyes............................................................................. Case AKCELA molydisulfide grease

SPECIAL TOOLSCAS10219 ....................................................................................................................... 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

5006-4


CENTER PIVOT

Disassembly1. Remove all dirt and grease from the area of the

center pivot. Park the machine on a level surface.

2. Lower the bucket until the bucket is flat on thefloor.

3. Stop the engine and apply the parking brake.

4. Remove the covers from both sides of themachine.

5. Disconnect the front wiring harness from the cabfloor.

6. Remove any tie straps that fasten the front wiringharness to the chassis near the center pivot.

7. Loosen and remove the nut and washer thatfasten the chassis ground wire and cab groundwire to the studs.

8. Loosen and remove the bolt, lock washer, andnut that fasten the clamp on the front wiringharness to the bracket on the rear frame. Movethe front wiring harness out of the way.

9. Loosen and remove the fill cap for the hydraulicreservoir.

10. Connect a vacuum pump to the hydraulicreservoir. Start the vacuum pump.

11. Disconnect the brake hose from the backside offront brake line bracket.

12. Install a plug in the tube and a cap on the fitting.

13. Disconnect the hoses for the steering cylinder.

14. Install caps on the fittings and plugs in the hoses.

15. Loosen and remove the bolts, lock washers, andself-locking nuts that fasten the mounting bracketfor the hoses to the bracket on the front frame.

16. Loosen and remove the bolts, flat washers, andself-locking nuts that fasten the bracket for thehoses to the rear frame.

17. Disconnect the return hose.

18. Install the cap on the hose and a plug in thefitting.

19. Disconnect the supply hose.

20. Install a cap on the hose and a plug in the fitting.


22. Loosen and remove the self-locking nut and boltthat hold the pivot pin for the steering cylinder rodeye.

23. Remove the pivot pin from the rear frame and thesteering cylinder rod eye.

24. Remove the washer from the rear frame. Movethe steering cylinder out of the way.

25. Repeat steps 22, 23 and 24 for the other steeringcylinder.

26. Loosen and remove the Ferry head screws andretainers that fasten the drive shaft to the frontyoke. Move the drive shaft out of the way.

27. Place two stands below and in contact with thefront frame.

28. Install blocks between the rear axle and the rearframe on both sides of the machine to preventthe rear frame from tipping.

29. Put a jack in contact with both sides of the rearframe near the center pivot area. Use anotherjack at the rear of the machine to prevent the rearframe from tipping.

30. Loosen and remove the bolt (1), washer (2), andspacer (3) that fasten the upper pivot pin (4) tothe rear chassis (5).

31. Use a prybar to remove the upper pivot pin (4).

32. Loosen and remove the bolts (1) and washers (2)that fasten the lower pin plate (15) to the lowerpivot pin (10).

33. Loosen and remove the bolts (1) and washers (2)that fasten the lower pin plate (15) to the bottomof the rear chassis (5).

34. Use the ram and hand pump to remove the lowerpivot pin (10).

35. Install the puller on the bottom spacer (14), seeSpecial Tools in this section.

5006-5


BS03B152

CENTER PIVOT ASSEMBLY

1. BOLT 5. REAR CHASSIS 9. UPPER PIVOT BEARING 13. BEARING RETAINER2. WASHER 6. SEAL 10. LOWER PIVOT PIN 14. BOTTOM SPACER3. SPACER 7. BEARING RETAINER 11. LOWER BEARING SPACER 15. LOWER PIN PLATE4. UPPER PIVOT PIN 8. SHIM 12. LOWER PIVOT BEARING 16. FRONT CHASSIS

1 2

34

51

26

7

8

96

5

5

5

10

11

6

12

8

13

6

142

1

8

15 2

12

1

16

5006-6


36. Remove the bottom spacer (14).

37. Release the parking brake.

38. Use prybars to turn the left rear wheel backwardsand the right rear wheel forward to move the frontof the rear frame to the left for access to thebearings. Install blocks under the wheels toprevent the rear frame from moving.


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

41. Remove the bearing retainer (13) and shims (8).

42. Remove the lower bearing spacer (11) from thetop of the lower pivot.

43. Loosen and remove the bolts (1) and washers (2)that fasten the bearing retainer (7) and shims (8)to the top of the top pivot.

44. Remove the bearing retainer (7) and shims (8).

45. Use the puller to remove the seal (6) from the topof the bottom pivot.

46. Use the puller to remove the seal (6) from thebottom of the top pivot.

47. Use an acceptable driver, the hydraulic ram, andthe hand pump to remove the upper pivotbearing (9) from the top pivot. See Special Toolsin this section.

NOTE: The spacers are matched to the bearingsets. Do not mix the spacers. Do not use the oldspacers if new bearing sets are being installed.

48. Use an acceptable driver, the hydraulic ram, andthe hand pump to remove the lower pivot bearing(12) from the bottom pivot. See Special Tools inthis section.

NOTE: The spacers are matched to the bearingsets. Do not mix the spacers. Do not use the oldspacers if new bearing sets are being installed.

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

Assembly1. 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).

BC06A118

5. Tighten a nut (18) on the screw (19) until thebearing cup (20) is seated in the bore of the toppivot (22). Remove the bearing driver (17) andplate (21) from the top pivot (22).

6. Install a bearing cone (25), spacer (24), the otherbearing cone (23), and the remaining bearingcup (26) in the top pivot (22).


8. Tighten a nut (18) on the screw (19) until thebearing cup (26) is seated against the spacer(24). Remove the bearing driver (17) and plate(21) from the top pivot (22).

BC06A119

17. BEARING DRIVER 20. BEARING CUP18. NUT 21. PLATE19. SREW 22. TOP PIVOT

23. BEARING CONE 25. BEARING CONE24. SPCAER 26. BEARING CUP

17 18 19

2021 22

25

24

23 26

17 18 19

21 22

5006-7


9. Put the bearing retainer (7) in place on the upperpivot bearing assembly (9).


11. Tighten a nut (18) on the screw (19) until thebearing retainer (7) is tight against the upperpivot bearing assembly (9).

BC06A120

12. Measure the gap (27) between the bearingretainer (7) and the top pivot (22). Make a recordof the measurement. Subtract 0.0762 to 0.1016mm (0.003 to 0.004 inch) from the measurement.Select shims (8) equal to that value.

13. Remove the bearing driver (17), plate (21), andbearing 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 thebolts (1) to 124 Nm (91 pound-feet).

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

BC06A121

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

18. Use an acceptable driver to install the seal (6) inthe bottom of the top pivot.

19. The bottom of the seal (6) must be even with thebottom of the top pivot.

BC06A125.

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

21. Install the upper pivot pin (4) in the top pivot.

22. Lubricate the top pivot until grease is forced outof the seal (6).

23. Rotate the upper pivot pin (4) to check thebearing assembly. The upper pivot pin (4) mustrotate smoothly, but not easily. Leave the upperpivot pin (4) in place to keep dirt out of the upperpivot bearing (9).

24. Lubricate the bore for the bottom pivot withgrease. Install a bearing cup in the bottom pivot.


BC06A123

26. Tighten a nut (18) on the screw (19) until thebearing cup (28) is seated in the bore in thebottom 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 otherbearing cone (23), and the remaining bearingcup (26) in the bottom pivot (29).


17

21

18 197

9

22

27

17

2118

19

28

29

5006-8


BC06A124

30. Tighten a nut (18) on the screw (19) until thebottom bearing cup (26) is seated against thespacer (24).

31. Remove the bearing driver (17) and plate (21)from the bottom pivot (29).

32. Put the bearing retainer (13) in place on thelower pivot bearing (12).

33. Install the bearing driver and plate.

BC06A125

34. Tighten a nut (18) on the screw (19) until thebearing retainer (13) is tight against the lowerpivot bearing assembly (12).

35. Measure the gap (30) between the bearingretainer (13) and the bottom pivot (29). Make arecord of the measurement. Subtract 0.0762 to0.1016 mm (0.003 to 0.004 inch) from themeasurement. Select shims (8) equal to thatvalue.

36. Remove the bearing driver (17), plate (21) andbearing retainer (13) from the bottom pivot.

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) withgrease.

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

BC06A126

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

BC06A121

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

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

44. Install the lower pivot pin (10) in the bottom pivot.

45. Hold the bottom spacer (14) in place andlubricate the bottom pivot until grease is forcedout of the seal (6).

46. Rotate the lower pivot pin (10) to check thebearing assembly. The lower pivot pin (10) mustrotate smoothly, but not easily.

47. Remove the lower pivot pin (10) and the upperpivot pin (4).

48. Remove the bottom spacer (14).

23

24

25

26

21 18 19

17

29

12

21 18 19

17

30

13

29

5006-9


CONNECTING THE FRONT FRAME TO THE REAR FRAME1. Release the parking brake.

2. Move the rear frame into alignment with the frontframe.

3. Move the steering cylinders as required to movethe rear frame into alignment with the frontframe.


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

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

7. Tighten the bolt (1) to 220 to 250 Nm (162 to 184pound-feet).

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

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

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

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

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

13. Measure the gap between the lower pin plate(15) and the bottom pivot. Make a record of themeasurement. 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 pinplate (15) to the lower pivot pin (10).

15. Start the six outer bolts (1) into the lower pinplate (15) and the bottom pivot.

16. Install the shims (8).

17. Tighten the six outer bolts (1) to 128 to 136 Nm(94 to 100 pound-feet).

18. Tighten the three inner bolts (1) to 124 Nm (91pound-feet).

19. Remove the jacks from the rear frame.

20. Remove the blocks from the rear axle.

21. Remove the stands from the front frame.

22. Put the drive shaft in position on the front yoke.

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

24. Tighten the Ferry head screws to 61 to 81 Nm(45 to 60 pound-feet).

25. Put the steering cylinder rod eye in position in theframe. Install the washer between the steeringcylinder rod eye and the rear frame.

26. Align the hole in the pivot pin with the holes in thesteering cylinder rod eye, and install the pivot pin.

27. Install the bolt and self-locking nut that hold thepivot pin.

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

29. Start the vacuum pump.

30. Connect the return hose.

31. Connect the supply hose.

32. Put the bracket for the hoses in position on therear frame. Install the bolts, flat washers, andself-locking nuts that fasten the bracket to therear frame.

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

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

35. Connect the hoses for the steering cylinders.

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


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

39. Put the clamp on the wiring harness in positionon the bracket. Install the bolt, lock washer, andnut that fasten the clamp on the wiring harness tothe bracket.

40. Put the ground wire in position on the stud. Installthe washer and nut that fasten the ground wire tothe stud.

41. Install a tie strap to fasten the wiring harness tothe tube.

42. Disconnect the vacuum pump from the hydraulicreservoir.

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

44. Install the fill cap in the hydraulic reservoir.

45. Bleed air from the front axle bleed screws. Referto Section 7002 for complete brake bleedinginstructions.

46. Lubricate the pivot pins for the steering cylinderrod eyes.

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

5006-10


NOTES

Section5008

5008




AUXILIARY STEERING MOTOR AND PUMP

5008-2


TABLE OF CONTENTS

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3AUXILIARY STEERING MOTOR AND PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4


5008-3


SPECIFICATIONSAuxiliary steering motor

Maximum amperes...............................................................................................................................30 amperes

Minimum armature speed ............................................................................................................ 6950 r/min (rpm)

Motor ...........................................................................................................................................................24 volts

Auxiliary steering pump

Minimum flow ..............................................................................................24.6 L/min at 104 bar at 315 amperes(6.5 U.S. gpm at 1500 psi at 315 amperes)

5008-4


AUXILIARY STEERING MOTOR AND PUMP

DisassemblyNOTE: Refer to Section 5001 for removal andinstallation of the auxiliary steering motor and pump.

NOTE: The pump is the only component that isdisassembled. The switch (8) and motor (1) arereplaced as units and are not serviced. Refer to theillustration on page 5.

1. Make an alignment mark on the pump assemblyand motor (1).

2. Loosen and remove the two screws (15) and lockwashers (14) that hold the pump assembly to themotor (1).

3. Remove and discard the mounting gasket (13),retaining ring (3) and seal (4) from the pumpassembly.

4. Loosen and remove the four bolts (2) that holdthe 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) anddriven gear (19) from the body (18).

8. Remove the body (18) from the plate (17).

9. Remove and discard the O-rings (7) from thebody (18).

10. Remove the pins (22) and wear plate (23) fromthe body (18).

11. Remove and discard the seal (6) and backup ring(5) from the plate (17).

NOTE: The only serviceable items on the pumpassembly are the seals (6), backup rings (5), O-rings(7), seal (4), retaining ring (3) and gasket (13). If anyof the other items are damaged, replace the pumpassembly.

Inspection1. Inspect the wear plates (23) for grooves, scoring

and pitting. If damage is found replace the pumpassembly. 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 thepump 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.

Assembly1. Lubricate all parts with clean hydraulic oil before

assembly.

2. Lubricate and install a new seal (4) and retainingring (3) on the plate (17). Refer to the illustrationon page 5.

3. Lubricate and install a new backup ring (5) and anew 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 thebody (18).

6. Lubricate and install a new backup ring (5) and anew seal (6) on the end plate (21).

7. Align the marks, made during disassembly, onthe end plate (21), body (18) and plate (17) andinstall 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, onthe 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 348pound-inches).

5008-5


BS01C121

AUXILIARY STEERING PUMP AND MOTOR ILLUSTRATION

1. MOTOR 7. O-RING 13. GASKET 19. DRIVEN GEAR2. BOLT 8. SWITCH 14. LOCK WASHER 20. DRIVE GEAR3. RETAINING RING 9. CABLE 15. SCREW 21. END PLATE4. SEAL 10. SCREW 16. WIRE 22. PINS5. BACKUP RING 11. LOCK WASHER 17. PLATE 23. WEAR PLATE6. SEAL 12. WASHER 18. BODY

1

16

9810

11

12

13

34

1714

15

5

6

23

722

18

22

720

19

236

5

21

2

5008-6


NOTES




SECTION INDEX

POWER TRAIN

Removal and Installation of Power Train Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6001

Transmission Specifications, Pressure Checks, and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6002

Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6003

Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6004

Rear Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6004

Drive Shafts, Center Bearing, and Universal Joints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6005

Wheels and Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6006

Transmission Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6007


Section6001

6001




REMOVAL AND INSTALLATION OF POWER TRAIN COMPONENTS

6001-2


TABLE OF CONTENTS

TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Transmission Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Front Axle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Rear Axle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

6001-3


TRANSMISSION

Removal

STEP 1Park the machine on a level surface and lower thebucket to the floor. Stop the engine and apply theparking brake.

STEP 2Place the master disconnect switch in the OFFposition.

STEP 3Refer to Section 9007 and remove ROPS cab orROPS canopy.

STEP 4Refer to Section 8001 and remove the hydraulicpump.

STEP 5Put a 25.5 l i ter (27 quar ts) container undertransmission drain plug. Remove drain plug and draintransmission oil. Install drain plug after oil hasdrained.

STEP 6

BD01D306

Identify, tag, and disconnect brake pump pressurehose and brake to hydraulic reservoir hose. Positionhoses away from transmission. Remove and discardO-ring face seals from fittings. Plug hoses and capfitt ings to prevent entry of foreign matter intohydraulic system.

STEP 7

BD01D315

Disconnect transmission wiring harness connectorfrom control valve connector. Remove socket headbolt securing wiring harness clamp. Move wiringharness away from transmission.

STEP 8

BD01D317

Just above where clamp was installed, tag anddisconnect transmission wiring harness connectorfrom temperature sensor. Move wiring harness awayfrom transmission.

STEP 9

BD01D310

Remove two socket head bolts securing transmissionwiring harness clamps.

6001-4


STEP 10

BD01D312

Identify, tag, and disconnect transmission wiringharness connectors from engine speed sensor,intermediate speed sensor, and turbine speedsensor. Move transmission wiring harness away fromtransmission.

STEP 11

BD01D316

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

STEP 12

BD01D314

Identify, tag, and disconnect transmission wiringharness connectors from filter maintenance switchand output speed sensor. Move transmission wiringharness away from transmission.

STEP 13

BD01F281

Remove two bolts and washers securing hoseretainer to front of rear chassis. Move hose retainertowards front of machine.

STEP 14

BD03A165

Identify, tag, and disconnect parking brake hose fromparking brake. Plug hose and cap fitting to prevententry of foreign matter into hydraulic system. Movehose away from transmission. Remove four bolts andtwo straps securing center drive shaft to transmissionoutput flange. Disconnect center drive shaft fromtransmission.

6001-5


STEP 15

BD03A161

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

STEP 16

BD03A160

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

STEP 17

BD01D318

Identify, tag, and disconnect cooler hose from fittinginstalled in LH side of transmission. Install a plug inhose. Remove and discard O-ring face seal fromfitting.

STEP 18

BD01D339

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

STEP 19

BD01D340

Repeat Steps 17 and 18 and disconnect the othercooler hose and remove fitting.

STEP 20

BD01D343

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

6001-6


STEP 21

BD01D342

In area between the transmission and the engine,remove four bolts and two straps. Use pry bar todisconnect engine drive shaft from transmission.Using 3/4 inch drive socket, extensions, and impactwrench, remove four bolts and washers securingtransmission to top mounting bracket.

STEP 22

BD03A163

Remove bolts and washers securing RH and LHmounting brackets to rear chassis.

STEP 23

BD03A164

Raise transmission just enough to enable removal ofRH and LH mounting brackets. Remove two boltsand washers securing RH and LH mounting bracketsto transmission. Remove RH and LH mountingbrackets.

STEP 24

BD01D345

Slowly and carefully raise transmission from loaderwhile checking that all hoses, electrical connectors,and wires have been disconnected and nothinginterferes with transmission removal. Removetransmission from loader.

STEP 25

BD01D361

If top mounting bracket requires removal, remove boltand washer then remove bracket.

6001-7


Transmission Mounting

BS03B153

1. ISOLATOR BOLT 6. MOUNTING BRACKET2. WASHER 7. TOP MOUNTING BRACKET3. BOLT A. REAR CHASSIS TRUNNION4. BOLT B. BRACKET (6 OR 7)5. BOLT C. SMALLER PIECE ON TOP

2

14

1

5

5

6

A

7

5

1

3

C

3

1

B

5

4

2

1

2

1

2

22

6001-8


Installation

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

STEP 27

BD01D361

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

STEP 28

BD01D345

Move transmission into position above loader. Slowlylower transmission into loader.

STEP 29

BD03A164

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

STEP 30

BD03A163

Loosely install washers and bolts to secure RH andLH mounting brackets to rear chassis. Tighten boltssecu r ing RH and LH mount ing b racke ts totransmission to a torque of 481 to 590 Nm (355 to435 pound feet).

6001-9


STEP 31NOTE: In this step, new straps and bolts securingthe drive shaft must be installed whenever theseparts are removed. Bolts have a nylon patch tomaintain torque which requires new bolts.

BD01D342

Using 3/4 inch drive socket, extensions, and impactwrench, install four washers and bolts to secure topmounting bracket to transmission. Then tighten boltsto a torque of 251 to 319 Nm (185 to 235 pound feet).If bracket had been removed, tighten bolt to a torqueof 890 to 1000 Nm (655 to 735 pound feet). Connectengine drive shaft to transmission. Install two newstraps and four new bolts. Tighten bolts to a torque of61 to 81 Nm (45 to 60 pound feet).

STEP 32

BD03A163

Tighten bolts securing RH and LH mounting bracketsto a torque of 890 to 1000 Nm (655 to 735 poundfeet).

STEP 33

BD01D343

Disconnect lifting equipment from transmission liftingeyes.

STEP 34

BD01D340

Install new O-ring on fitting and install fitting intransmission. Install new O-ring face seal in fittingthen connect cooler hose to fitting following taginstalled during removal. Remove and discard tag.

STEP 35

BD01D318

Install new O-ring on fitting and install fitting intransmission. Install new O-ring face seal in fittingthen connect cooler hose to fitting following taginstalled during removal. Remove and discard tag.

6001-10


STEP 36

BD03A160

Position fill tube, two new seals, and metal straineron transmission; metal strainer is installed betweenseals. Secure using two bolts. Tighten bolts to atorque of 17 to 33 Nm (12 to 24 pound feet).

STEP 37

BD03A161

Connect rear drive shaft to transmission then installtwo straps and four bolts. Tighten bolts to a torque of61 to 81 Nm (45 to 60 pound feet).

STEP 38

BD03A165

Connect center drive shaft to transmission and installtwo straps and four bolts. Tighten bolts to a torque of61 to 81 Nm (45 to 60 pound feet). Connect parkingbrake hose to parking brake following tag installedduring removal. Remove and discard tag.

STEP 39

BD01F281

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

STEP 40

BD01D314

Connect transmission wiring harness connectors tooutput speed sensor and filter maintenance switchfollowing tags installed during removal. Remove anddiscard tags.

STEP 41

BD01D316

Install socket head bolt to secure wiring harnessclamp.

6001-11


STEP 42

BD01D312

Connect transmission wiring harness connectors toturbine speed sensor, intermediate speed sensor,and engine speed sensor following tags installedduring removal. Remove and discard tags.

STEP 43

BD01D310

Install two socket head bolts to secure transmissionwiring harness clamps.

STEP 44

BD01D317

Connect transmission wiring harness connector totemperature sensor following tag installed duringremoval. Remove and discard tag.

STEP 45

BD01D315

Install socket head bolt to secure wiring harnessclamp. Connect transmission wir ing harnessconnector to control valve connector.

STEP 46

BD01D306

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

STEP 47

BD03A177

Check that transmission drain plug is tight.

6001-12


STEP 48Fill transmission with 15-40W engine oil until oil levelis up to the arrow in sight glass.

STEP 49Refer to Section 8001 and install the hydraulic pump.

STEP 50Refer to Section 9007 and install ROPS cab or ROPScanopy.

STEP 51Start and run engine at idle speed with transmissionin neutral. If transmission oil level is at or belowbottom of crosshatch region, put articulation lock inLOCKED position and add engine oil, 15-40W, untiloil level is up to crosshatch region. Shut down engineand put articulation lock in OPERATING position.

6001-13


FRONT AXLE

Removal

STEP 1

BD03A040

Park machine on level surface. Have assistant putarticulation lock in LOCKED position.

IMPORTANT: If machine is equipped withquick-attached components, disconnect them frommachine prior to proceeding.

STEP 2

BD03A092

Raise bucket and have assistant install safety link.Lower loader arms slowly unt i l safety l ink issupporting loader arms.

STEP 3Stop engine. Actuate brake pedal several times todischarge brake accumulators. Put key switch in ONposition and move loader control lever back and forthat least 30 times to release any pressure fromhydraulic circuit. Put key switch in OFF position.

STEP 4

BD03A167

Remove four bolts and two straps securing front driveshaft to front axle.

STEP 5

BD03A166

Remove clamp securing lubrication hose to machineand nut securing opposite end of hose. Remove fourbolts and two straps securing center drive shaft tofront drive shaft. Use a pry bar to separate driveshafts. While supporting center bearing and frontdrive shaft, remove four nuts and bolts and eightwashers. Lower center bearing and front drive shaftfrom mounting plate and remove from machine.

6001-14


STEP 6

BD03A168

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

STEP 7

BD01F298

BD01D392

Using an acceptable hydraulic jack, raise one tirefrom ground and install an acceptable jack standunder machine.

STEP 8Repeat Step 68 to raise other front axle tire fromground.

STEP 9

BD01F297

Use an acceptable jack to hold front axle.

STEP 10

BD01F295

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

STEP 11

BD01F296

Remove eight nuts bolts, and washers securing frontaxle to machine.

STEP 12Carefully lower front axle and remove from undermachine.

6001-15


Front Axle Mounting

BS03B151

1. BOLT 4. NUT2. WASHER 5. FRONT AXLE3. WASHER

1

2

3

4

5

6001-16


Installation

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

STEP 14

BD01F296

Apply one drop of engine oil to threads prior toassembly. Install eight washers, bolts, washers, andnuts to secure front axle to machine. Tighten bolts toa torque of 765 to 865 Nm (565 to 630 pound feet).

STEP 15

BD01F295

BS06G052

Install both wheels on front axle and secure. Tightenbolts to a preliminary torque of 298 Nm (230 poundfeet) in sequence indicated; then tighten to a torqueof 640 to 720 Nm (475 to 530 pound feet) in samesequence.

STEP 16

BD01F297

Remove jack from front axle.

6001-17


STEP 17

BD01F298

BD01D392

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

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

STEP 19

BD03A168

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

STEP 20

BD03A166

Position and support center bearing and front driveshaft and install eight washers and four bolts andnuts. Tighten bolts to a torque of 99 to 128 Nm (73 to94 pound feet). Install two straps and four bolts.Tighten bolts to a torque of 61 to 81 Nm (45 to 60pound feet). Secure lubrication hose to machineusing clamp; secure opposite end of hose using nut.

STEP 21

BD03A167

Secure drive shaft to front axle using two straps andfour bolts. Tighten bolts to a torque of 61 to 81 Nm(45 to 60 pound feet).

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

STEP 23Refer to Section 7002 and bleed brakes.

STEP 24Star t engine and raise bucket. Have assistantremove safety link. Lower bucket to ground and stopengine.


6001-18


REAR AXLE

Removal

STEP 1Park machine on a level surface; be sure to allowadequate space at side of machine for removal ofrear axle. Stop engine. Actuate brake pedal severaltimes to discharge brake accumulators. Put keyswitch in ON position and move loader control leverback and for th at least 30 times to release anypressure from hydraulic circuit.

STEP 2

BD03A040


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

STEP 4

BD03A162

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

STEP 5

BD03A169

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

STEP 6

BD01F299

Using an acceptable hydraulic jack, raise one tirefrom ground and install an acceptable jack standunder machine. Repeat this step for other tire.

STEP 7

BD01F302

Use an acceptable jack to hold rear axle.

6001-19


STEP 8

BD01F295

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

STEP 9

BD03A170

At front of trunnion, remove two Allen head bolts andwashers. Remove front cap: if necessary use twoM12 by 32 mm (1.25 inches) bolts in puller holes (A);tighten bolts evenly to pull cap from axle andtrunnion. Remove and discard O-ring from cap.Repeat this step at rear of trunnion except removeand retain shim(s) after removal of rear cap. Removepivot shaft using acceptable sleeve or rod i fnecessary.

STEP 10Carefully lower rear axle and remove through side ofmachine.

STEP 11Remove and discard two seals from rear axle pivotpoint.

A

A

6001-20


Rear Axle Mounting

BS01D132

1. TRUNNION 5. WASHER 9. REAR AXLE2. O-RING 6. BOLT 10. PIVOT PIN3. SEAL 7. WASHER 11. SHIM(S)4. FRONT CAP 8. BOLT 12. REAR CAP

65

43

2 65

7

8

10

2

3

125

6

56 9

1

11

6001-21


InstallationNOTE: If shim(s) (11) have been lost or pivot pin(10) has been replaced, do Step 12 to determinerequired shim(s) otherwise go to Step 13.

STEP 12

BS01E091A

Install pivot pin (10) and caps (4 and 12) in trunnion(1) without rear axle or shim(s). Install washers (5)and bo l ts (6) . T ighten bo l ts secure ly. Pushassembled pivot pin and caps to rear of machine asfar as possible. Measure and record gap (A) betweenrear cap (12) and trunnion. Select shims from thefollowing:

NOTE: Shims are available in following sizes: 0.50mm (0.020 inch), 1.0 mm (0.039 inch), and 1.50 mm(0.059 inch).

STEP 13

BD01D482A

BD01D499

Clean front (A) and rear (B) pivot area of rear axlewhere seals (3) will be installed.

STEP 14

BS01E092

Lubricate two new seals (3) and new O-rings (2)using Molydisulfide Grease. Install seals, smoothside out, into front and rear of axle housing (A) untilflush with housing or recessed 2.0 mm (0.079 inch).Install an O-ring in each cap (4 and 12).

STEP 15Carefully move rear axle under machine. Raise axleinto position in trunnion and align pivot holes intrunnion with pivot holes in axle.

MEASUREDGAP (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

1012

16

4

1 6

A

A

B

2

3

A

4

12

6001-22


STEP 16

BS01E091

Lubricate pivot pin (10) using Molydisulfide Grease.At rear of trunnion (1), install pivot pin into trunnionand 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-ringinstalled, and two washers and bolts (6). Tightenbolts (6) to a torque of 651 to 678 Nm (480 to 500pound feet).

STEP 17

BD01F295

BS06G052

Install both wheels on front axle and secure. Tightenbolts to a preliminary torque of 298 Nm (220 poundfeet) in sequence indicated; then tighten to a torqueof 640 to 720 Nm (475 to 530 pound feet) in samesequence.

STEP 18Remove hydraulic jack supporting rear axle and jackstands supporting loader.

4 6

10

1211

6

1 1

A

6001-23


STEP 19

BD03A169

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

STEP 20

BD03A162

Connect rear drive shaft to rear axle. Install twostraps and four bolts. Tighten bolts to a torque of 61to 81 Nm (45 to 60 pound feet).

STEP 21If necessary, fill axle with gear lubricant specified inSection 1002.

STEP 22Refer to Section 7002 and bleed brakes.


6001-24


NOTES

Section6002 60

02




TRANSMISSION SPECIFICATIONS, PRESSURE CHECKS, AND TROUBLESHOOTING

6002-2


TABLE OF CONTENTS

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TRANSMISSION OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Transmission ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Electrical Shift Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Transmission ECM Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Transmission Sensor Data Collection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Automatic Problem Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Clutch Modulation Substitute Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Limp-Home Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Transmission/Transmission ECM Shutdown Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Transmission Clutch Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Gear Selections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Automatic/Manual Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Upshifting in Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Downshifting in Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Upshifting in Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Downshifting in Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Downshift Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Cold Start Protection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Brake Pedal Transmission Declutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

TRANSMISSION PRESSURE TEST POINTS DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13CHART FOR RECORDING PRESSURE READINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15PRESSURE TEST RESULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

All or Most Pressures Low and/or Flow Test Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Some Pressures Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Not Enough Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Machine Stops or Hesitates While Shifting - Intermittent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

CONVERTER OUT PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Test Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

LUBRICATION PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Test Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

FLOWMETER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Test Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Flowmeter Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

CONSUMPTION TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17TRANSMISSION OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19TRANSMISSION SHIFTER LOGIC INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19RELATIONSHIP BETWEEN TRANSMISSION ECM, VALVES, AND CLUTCHES . . . . . . . . . . . . . . . . . . . . . . 19

6002-3


SPECIAL TOOLSCAS-1953A Transmission supplemental fitting kit.Includes: CAS-2324 special 90 degree adapter andCAS-2325 plug and cap set.

CAS-1804 Master pressure test kit

CAS-1808 Flowmeter kit

CAS-2702 Flowmeter adapter

CAS-2278 Flow test kit

SPECIFICATIONSMain 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)

6002-4


BS01A190

COMPONENT LOCATIONS SYSTEMS

1. TRANSMISSION ELECTRONIC CONTROL MODULE 8. INDUCTIVE TRANSMITTER - INTERMEDIATE SPEED SENSOR2. DOWNSHIFT BUTTON 9. INDUCTIVE TRANSMITTER - TURBINE SPEED SENSOR3. DECLUTCH ROCKER SWITCH 10. INDUCTIVE TRANSMITTER - ENGINE SPEED SENSOR4. MANUAL/AUTOMATIC ROCKER SWITCH 11. HALL SENSOR - OUTPUT SPEED SENSOR5. SHIFTER 12. TRANSMISSION CONTROL VALVE CABLE6. SUPPLY SYSTEM CONNECTIONS B+ AND RETURN 13. DECLUTCH LIMIT SWITCH7. TRANSMISSION 14. PLUG

1

234

5

6

7

8

9

11

12

13

14

10

6002-5


BS03A262

COMPONENT LOCATIONS TRANSMISSION LAYOUT

1. CLUTCH SHAFT KR 9. TRANSMISSION PUMP2. POWER TAKE OFF 10. INPUT FLANGE3. CLUTCH SHAFT KV 11. CONVERTER4. CLUTCH SHAFT K2 12. INDUCTIVE TRANSMITTER FOR ENGINE SPEED5. CLUTCH SHAFT K3 13. CLUTCH SHAFT K46. OUTPUT FLANGE REAR 14. CONVERTER RELIEF VALVE7. OUTPUT FLANGE CONVERTER SIDE 15. CLUTCH SHAFT K18. OUTPUT SHAFT

9

10

11

12

1

2

3

4

5

8

7

6

13

14

15

6002-6


BS01A191

COMPONENT LOCATIONS FRONT VIEW

1. ATTACHMENT FOR OIL FILLER PIPE WITH OIL DIPSTICK3. OUTPUT FLANGE CONVERTER

SIDE2. TRANSMISSION SUSPENSION BORES 4. OIL DRAIN PLUG

4

1 3

2

2

2

2

6002-7


BS01A192

COMPONENT LOCATIONS SIDE VIEW

1. CONVERTER BELL HOUSING 6. OUTPUT FLANGE REAR2. BREATHER 7. OIL DRAIN PLUG3. TRANSMISSION CASE COVER 8. OUTPUT FLANGE CONVERTER SIDE4. FILTER HEAD 9. TRANSMISSION CASE5. FILTER 10. PARKING BRAKE

213

4

5

10

7

8

9

6

6002-8


BS01B048

COMPONENT LOCATIONS REAR VIEW

1. LIFTING LUGS 5. OUTPUT FLANGE REAR2. POWER TAKE OFF 6. FILTER3. TRANSMISSION CONTROL VALVE 7. FILTER HEAD4. TRANSMISSION SUSPENSION BORES

11

2

3

44

5

6

7

6002-9


TRANSMISSION OPERATION

GeneralThe transmission is equipped with a TransmissionECM (Electronic Control Module). This modulecontrols modulation and shifting that were normallyassoc ia ted w i th hyd rau l i ca l l y modu la tedtransmissions, providing smoother shifts andenhanced clutch life.

The Transmission ECM relies on signals from severalsensors that are incorporated into the design. Thesesensors measure the speed of several components,as well as other sensors that measure temperature.These solenoids and sensors are further defined inthe following paragraphs.

In addi t ion, the t ransmission incorporates atwo-piece transmission case for ease of transmissionmaintenance, helical cut gears that help reducenoise, and all external hoses have been eliminated(all oil passages are internal).

Transmission ECMModulation and shift ing are controlled by theTransmiss ion E lec t ron ic Con t ro l Modu le(Transmission ECM). This module replaces the oiland springs that are found in hydraulically modulatedtransmissions.

The Transmiss ion ECM con t ro ls the c lu tchengagement, provid ing smoother shi f ts andenhanced clutch life, whether the transmission is setto the automatic or manual shift mode.

The Transmission ECM also informs the InformationCenter, by the use of diagnostic codes, of anytransmission error and the hours of operation that theerror occurred.

Electrical Shift SolenoidsElectrical Shift Solenoids control the modulation ofthe clutches, eliminating the need for a modulationvalve, and providing a smooth shift while maintainingconstant control over clutch engagement as follows:

A. A temperature sensor relays the oiltemperature to the Transmission ECM.

B. The Transmission ECM times the rate thesolenoid energizes and de-energizes.

C. As the transmission changes gears, there isreduced hesitation from one gear to the next.

Transmission ECM TasksThe Transmission ECM performs a variety of tasks inthe overall system. The Transmission ECM:

A. Determines which clutches to engage in thetransmission.

B. Protects the engine and transmission turbinef rom overspeed cond i t i ons dur ingdownloading.

C. Receives speed information from the enginespeed sensor, the turbine speed sensor, theintermediate shaft speed sensor and thetransmission output shaft speed sensor.These speed sensors are checked todetermine if normal sensor operation ispresent. The data is also used to controlmodulation during shifting and to determinethe appropriate shift patterns.

D. Detects system failures and determines theappropriate alternative actions.

E. Provides various diagnostic messages to theInformation Center.

F. Provides other information to the informationcenter, which in turn displays engine speed,wheel speed, gear shift selection, and actualgear selection.

G. Provides a method to calibrate thetransmission clutch control.

H. Establishes clutch modulation pressure duringtransmission shifts.

6002-10


Transmission Sensor Data CollectionThe Transmission ECM collects and uses informationfrom four sensors to accurately shift the transmissionand determine if any clutches are slipping. Thesesensors are:

Engine (Speed) Sensor - monitors engine speed todetermine the load on the engine for shift points andsends the engine rpm to the Transmission ECM,which sends the information to the tachometer in theInformation Center.

Turbine (Speed) Sensor - assists the engine speedsensor in determining the load going into thetransmission and helps determine shift points.

Intermediate (Shaft Speed) Sensor - determinesdifferential gear speed in the transmission to checkfor clutch slippage.

Output (Speed) Sensor - monitors transmissionoutput shaft speed to help determine the load on thetransmission and to assist in determining shift points.Sends output shaft speed to Transmission ECMwhich sends the information to the speedometer inthe Information Center.

The transmission ECM also reviews vol tageinformation from the shifter and transmissionsolenoids to determine if there are any short circuitsor open circuits in the system.

Automatic Problem ModesIf the Transmission ECM detects an error condition inthe transmission system, it will generate a servicecode in the Information Center and will enter one ofthree modes:

A. Clutch Modulation Substitute Mode

B. Limp-Home Mode

C. Transmission/Transmission ECM ShutdownMode

Clutch Modulation Substitute ModeIn this mode, the transmission clutch modulation istime dependant rather than load dependant. Thetransmission will go into the Clutch ModulationSubstitute Mode if any of the four speed sensors fail.

If the output speed sensor is working and thetransmission is in gear, the shift points in Automaticmode will be speed dependant but the modulationwill be a predetermined amount of time.

If the output speed sensor is not working and thetransmission is in gear, the shift points will be loaddependant but the modulat ion wi l l s t i l l be apredetermined amount of time.

If the transmission is shifted from neutral into adirection in the Clutch Modulation Substitute Mode inautomatic, the transmission will shift into 4th gearand shift down until it gets the correct output speedfrom the turbine.

Limp-Home ModeIn this mode, the transmission will go into secondgear, forward or reverse, no matter what gear isselected. If second gear is not obtainable, theTransmission ECM selects a series of prioritizedgears un t i l an operable gear is found. Thetransmission will go into the Limp Home Mode ifthere is a fault on one clutch, a fault on one clutchvalve, or a fault on more than one speed sensor.

Transmission/Transmission ECM Shutdown ModeIn this mode, the Transmission ECM has detected aseve re fa i l u re tha t d i sables con t ro l o f thetransmission. The transmission will go into ShutdownMode if there is a fault on more than one clutch, afault on the solenoid power supply, or invalid voltage.In this mode, the Transmission ECM will shut off allsolenoid valves and the power supply and thetransmission shifts into and stays in neutral.

If the Transmission ECM generates a code, thewrench over the service manual icon wi l l bedisplayed on the Information Center.

6002-11


Transmission Clutch CalibrationThe Transmission ECM has the capability to find theoptimal adjustment of the clutch filling parameters foreach individual transmission, providing the ability toindividually adjust the optimum fill time for theindividual transmission in the machine. Clutch FillingParameter Calibration is performed on each machineat the plant and should be repeated at the first 250hours of use and every 1000 hours thereafter.

Before doing the following transmission clutchcalibration procedures make sure of the following:

1. The machine is running and the transmission oilis warm.

2. Engine low idle speed is correct.

3. The transmission is in neutral.

4. The park brake is applied.

5. If steps 1 through 4 have been accomplished,calibrate the transmission clutches as follows:

A. Press and hold the enter key for 2 to 3seconds and the monitor wil l change toSELECT.

B. Use the down arrow and high light “CONFIG”,press the enter key.

C. Press the down arrow and high light “CALIBG/B”, press the enter key.

D. Monitor will state “CALIB G/B” “CONFIRMPLEASE”, press the enter key.

E. If the conditions are not correct for clutchcalibration the monitor will display the problemthat needs to be corrected.

F. Clutch calibration status will be displayed onthe monitor, “ADJUST K1, K2, K3, K4, KV,KR”.

G.After completing the Clutch Calibrationprocedure, turn the machine OFF for 15seconds. This sets the calibration in thecontroller.

Gear SelectionsThe transmission provides 4 forward and 3 reversegear selections. The transmission ratios weredesigned to give optimized speed and torque foreach gear selection. The torque converter is a singlestage torque converter (one locking unit in the torqueconverter).

Automatic/Manual ModesThe automatic/manual switch is located on the rightcontrol panel. The transmission is in automatic modewhen the top of the automatic/manual switch isdepressed. The Transmission Display Centerindicates when the machine is in the automaticmode.

Upshifting in Automatic ModeUpshifting is determined by machine speed and thetorque on the transmission.

The transmission will shift from first or second gearup to the highest gear selected as the accelerator isdepressed, machine speed increases, and requiredtorque is reduced.

If the machine speed is increasing, but the operatoris not depressing the accelerator (such as whengoing down a hill), the transmission will not upshift.

As the operator depresses the accelerator and thetorque on the t ransmiss ion is lowered, thetransmission will upshift.

Downshifting in Automatic ModeDownshifting is determined directly by machinespeed and transmission torque. The transmission willdownshift to first or second gear as machine speeddecreases and transmission torque increases. Forexample, if the unit begins to climb a hill in forth gearand the machine speed decreases, as the torquerequirement increases, the transmission wi l ldownshift into third, then second, and down to firstgear, if necessary.

Upshifting in Manual ModeIn the manual mode, the transmission starts out inthe selected gear and stays in that gear until theoperator selects another gear or direction. Thetransmission can be upshifted without reducingengine speed or machine speed.

If the gear selected is two or more gears higher thanthe present gear, the transmission will shift upthrough the gears at 2.5 second intervals until theselected gear has been reached.

6002-12


Downshifting in Manual ModeThe transmission can be downshifted in the manualmode without reducing engine speed or machinespeed.

If 1st gear is selected from 3rd or 4th gear, thetransmission will downshift into 2nd gear for 1.2seconds and then will shift into 1st gear.

Downshift ButtonThe downshift button is located on front of thejoystick control lever in machines with a single leverconfiguration, and on top of the control tower inmachines with a three lever configuration.

With the number of different ways the downshiftbutton functions, the operator can tailor the use of themachine to the application at hand.

Automatic ModeIn the Automatic Mode, the downshift button onlyshifts down. The downshift button allows the operatorto downshift through the entire range of gears. This isuseful in long haul applications or roading.

Each time the button is pushed the transmission willinstantly downshift one gear from 4th to 3rd, thenfrom 3rd to 2nd, and then from 2nd to 1st.

The transmission will automatically downshift andthen upshift, as needed, to the last gear that wasselected with the downshift button.

Example: If the downshift button was used to shiftfrom 4th to 3rd gear, the transmission willautomatically shift from 3rd down and then back up to3rd again. It will not shift into 4th until thetransmission has been returned to the full rangeautomatic mode.

The transmission wil l return to the ful l rangeautomatic mode when:

A. Another gear is selected.

B. The shifter is moved into neutral and then intoforward or reverse.

C. The autoshift switch is recycled.

Manual ModeIn the manual mode, the downshift button togglesbetween 1st and 2nd gear. The manual mode isuseful in short haul operations. In this mode, thedownshift button functions in two ways in 1st and 2ndgear.

When the operator is in 2nd gear and pushes thedownshift button, the transmission instantly shifts into1st gear. When the operator pushes the downshiftbutton again, the transmission upshifts into 2nd gear.

If the machine is in 2nd gear and the downshiftbutton is pushed, the transmission instantly shifts into1st gear. When the operator shuttles the shifter, thetransmission upshifts back into 2nd gear.

Cold Start Protection SystemThe transmission has a cold start protection system.When the transmission sump temperature is minus10° C (14° F), the Transmission ECM will keep thetransmission in neutral.

When the transmission sump temperature warms upto minus 10° C (14°F) (within approximately oneminute), the machine will operate in all gears.

Brake Pedal Transmission DeclutchA transmission declutch feature concentrates moreengine power on the loader when digging in heavy ortough conditions, providing smoother stops andstarts. Total disconnection of the transmission fromthe engine is prevented. This feature will function in1st, 2nd, or 3rd gear only. It will not function in 4thgear.

When the transmission declutch switch is in the onposi t ion and the brake pedal is pushed, theTransmission ECM reduces the pressure to thetransmission forward or reverse clutch.

The Transmiss ion ECM wi l l no t comple te lydisconnect the clutch from the engine, but graduallyreduces the forward or reverse clutch pressure downto a lower level.

When the brake pedal is released, the TransmissionECM gradually increases the forward or reverseclutch back up to system clutch pressure.

If the direction is changed while the transmission isdeclutched, the selected forward or reverse clutchwill be filled and maintain a low pressure until thebrake pedal is released. Then the selected forward orreverse clutch pressure will gradually increase up tosystem clutch pressure.

6002-13


TRANSMISSION PRESSURE TEST POINTS DIAGRAM

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

No. IDENTIFICATION/LOCATION CONNECTIONDESIGNATION ON

VALVE BLOCK

Measuring Points for Pressure Oil and Temperature51 Before the Converter - Opening Pressure 8 bar (116 psi) M10x1 H

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 Clutch 16+2 bar (232 + 29 psi) K2 M10x1 A

58 Clutch 16+2 bar (232 + 29 psi) K3 M10x1 C

60 Clutch 16+2 bar (232 + 29 psi) 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 Rates15 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 Sensor21 Inductive Transmitter for Turbine Speed M18x1.5

34 Output Speed Sensor 47 Inductive Transmitter for Central Gear Train Speed M18x1.5

48 Inductive Transmitter for Engine Speed M18x1.5

Connections49 Plug Connection on the Hydraulic Control Unit68 System Pressure M16x1.5 G

69 Pilot Pressure M16x1.5 J

6002-14


BC01B047MEASURING POINTS AND CONNECTIONS

6002-15


CHART FOR RECORDING PRESSURE READINGSUse this chart to record the pressure readings.

P.I.N. Number: Date:

TEST POINTS

ShiftSpeed

P65

V53

R55

156

257

358

460

551

652

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 LP= LUBE PRESSURE

V= FORWARD CLUTCH 2= SECOND GEAR CLUTCH 5= CONVERTER IN

R= REVERSE CLUTCH 3= THIRD GEAR CLUTCH 6= CONVERTER OUT

6002-16


PRESSURE TEST RESULTS

All or Most Pressures Low and/or Flow Test LowPossible 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.

8. Charge pump seals or gaskets leak.

9. Charge pump worn.

10. Oil supply flange not sealing correctly.

Some Pressures LowPossible 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.

Not Enough PowerPossible causes include:

1. Check Electrical Troubleshooting in this Sectionto 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 iscorrect.

3. Engine RPM above Stall Test specified RPM.(Refer to Section 2002 for specifications.)

A. Check converter pressures and flow.

B. Check that torque converter installation iscorrect.

Machine Stops or Hesitates While Shifting - IntermittentPossible causes include:

1. Check orifice and O-ring. (See Section 6007 forreplacing.)

2. Check for foreign material plugging orifices orsticking valves.

3. Check for reduced pressure at test pressurepoints.

4. See Electrical Troubleshooting in this Section forelectrical system problem.

6002-17


CONVERTER OUT PRESSURE CHECK

Test Equipment Required0 to 28 bar (400 psi) gauge with hose long enough totake readings in the cab and CAS-2324 SpecialAdapter.

Test Procedure1. Block the machine tires.

2. Apply the parking brakes.

3. Install the pressure gauge.

4. Heat the oil to an operating temperature of 80 to100° C (176 to 212° F).

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

LUBRICATION PRESSURE CHECK

Test Equipment Required0 to 7 bar (100 psi) gauge.

Test Procedure1. Block the machine tires.


3. Install the pressure gauge in the cooler returnline at the transmission.

4. Heat the oil to an operating temperature of 80 to100° C (176 to 212 ° F).

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

FLOWMETER TEST

Test Equipment RequiredCAS-1808 Flowmeter Kit; CAS-2702 FlowmeterAdapter.

Flowmeter Test Procedure1. Block the machine tires.


3. Heat the oil to an operating temperature of 80 to100° C (176 to 212° F).

4. Remove the filter and install the CAS-2702adapter.

5. Install the flowmeter between the adapter andthe filter.

6. While in the cab, run the engine at full throttle.Put the transmission in NEUTRAL and record theflow measurement. The correct flow is 80 L/min(21 U.S. gpm) at 2000 rpm.

CONSUMPTION TEST PROCEDURE1. Block the machine tires.


3. Heat the oil to an operating temperature of 80 to100° C (176 to 212 ° F).

4. Install the flowmeter to converter outlet line (lineto cooler) in series.

5. While in the cab, run the engine at full throttle.Put the transmission in NEUTRAL and record theflow measurement. The flow must be 9.1 L/min(2 U.S. gpm).

6. Repeat the procedure with the transmission inFORWARD in third gear. The flow must be 9.1L/min (2 U.S. gpm).

7. Repeat the procedure with the transmission inREVERSE in third gear. The flow must be 9.1L/min (2 U.S. gpm).

6002-18


TRANSMISSION OVERHEATING1. 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 theambient 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 arenot within specifications.

5. Refer to Pressure Test Results to determine possible cause of any test results not within specifications.

6002-19


ERROR CODESIn case of possible errors in the system, an amber or red warning appears on the instrument panel, combined witha recorded error number. See section 4005 for error code retrieval procedures and definitions.

TRANSMISSION SHIFTER LOGIC INFORMATION

NOTE: Power is supplied through the fuse A to the transmission shifter via 19A wire. This is 24 Volt. Within theshifter are limit switches to transfer the signal voltages to the outputs. In forward V is high. In reverse R is high. Inneutral 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 lowand B2 is high. In fourth gear, B1 and B2 are high. Downshift, DS, is activated when the end of the shifter isengaged.

RELATIONSHIP BETWEEN TRANSMISSION ECM, VALVES, AND CLUTCHES

Function ShifterShifter Wire

ColorShifter Tower

ConnectorShifter Shroud

ConnectorHarness Wire #

Harnessped/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

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

6002-20


NOTES

Section6003

6003




TRANSMISSION

6003-2


TABLE OF CONTENTS

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3SPECIAL TORQUES (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

6003-3


SPECIAL TOOLS

BS02C093 THRU 096CAS40075 TRANSMISSION TOOL KIT

BS02C097 THRU 104CAS40079 TRANSMISSION OVERHAUL KIT

SPECIAL TORQUESOil 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 shaftOutput 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 pumpTransmission pump screws ......................................................................................... 46 Nm (407 pound inches)Oil feed housing screws .............................................................................................. 25 Nm (221 pound inches)

Engine connection and converterInput 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)

CAS2803 TRANSMISSION TORQUE CONVERTER SEAL

INSTALLATION TOOL

CAS2807 TRANSMISSION INPUT/OUTPUT SHAFT SEAL

INSTALLATION TOOL

CAS2885 TRANSMISSION VALVE ADJUSTMENT TOOL SET

CAS2869 TRANSMISSION OUTPUT SHAFT SEAL INSTALLATION TOOL

(521 AND 621 MODELS ONLY)

CAS2796 NESTING PLATE

CAS2799 CLUTCH PACK H0LDER AND SPRING COMPRESSOR TOOLS

CAS2798 GEAR PULLER COLLET SET

CAS2800 CLUTCH ASSEMBLY HOLDING

KNOB SET

CAS2801 TRANSMISSION MOUNTING BRACKETS

CAS2797 LIFTING EYEBOLT SET

CAS2802 ALIGNMENT DOWEL SET

CAS2868 CLUTCH SPRING COMPRESSOR(521 AND 621

MODELS ONLY)

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)

FilterFilter head screws ....................................................................................................... 25 Nm (221 pound inches)Oil distribution cover screws........................................................................................ 25 Nm (221 pound inches)

Speed sensor and inductive transmitterSpeed 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)

SPECIFICATIONSClutch 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)

6003-5


DISASSEMBLY

STEP 1

GD98M833

Fasten transmission on an assembly stand usingCAS2801 transmission mounting brackets.

STEP 2

GD98M835

Remove and discard oil filter.

STEP 3

GD98M836

Remove hex head screws securing filter head.Remove filter head from transmission.

STEP 4

GD98M837

Remove two socket head screws and instal lCAS2885 transmission valve adjustment tool set.Remove remaining 21 socket head screws securingcontrol valve. Loosen and remove hex rods (part ofCAS2885) from studs then remove control valve.

STEP 5

GD98M838

Remove both gaskets and the intermediate plate.

STEP 6

GD98M839

Remove socket head screws and hex nuts. Removeduct plate. Remove flat gasket.

6003-6


STEP 7

GD98M844

Bend lock plate away from hex head screws.Remove two hex head screws, lock plate, andwasher. Remove input flange from shaft.

STEP 8

GD98M845

Put al ignment marks on conver ter cover andhousing to aid in assembly. Remove 12 nuts andhex head screws.

STEP 9

GD98M846

Connect sui table l i f t ing equipment to shaf t .R e m ove c ove r, s ha f t , a n d c o nve r t e r f r o mtransmission and place in hydraulic press.

STEP 10

GD98M847

Using proper size rod, press input shaft andconverter from cover.

STEP 11

GD98M848

Remove retaining ring then remove bearing.

STEP 12

GD98M849

Remove four hex head screws and removediaphragm and input shaft.

6003-7


STEP 13

GD98M850

Put input shaft and diaphragm in vise as shown.R e m ove 1 2 h ex h e a d s c r ew s t o s e p a ra t ediaphragm and input shaft.

STEP 14

GD98M851

Remove the inductive transmitter.

STEP 15

GD98M852

Remove the hex head screws and remove theconverter housing.

STEP 16

GD98M853

Remove the socket head screws for removal of thetransmission pump.

STEP 17

GD98M854

Apply a bearing separator on the splines shoulder ofthe stator shaft and pull the pump out of the housingbores, using two-leg puller.

NOTE: If traces of wear should be encountered inthe pump housing or the cam disk, the completepump has to be replaced.

STEP 18

GD98M855

Separate the transmission pump from stator.Separate the cam plate from pump.

6003-8


STEP 19

GD98M856

Remove the hex head screws and remove the oilfeed housing. Remove the flat gasket.

STEP 20

GD98M860

Remove the hex head screws, cover, and flat gasket.

STEP 21

GD98M861

Remove the lock plate, hex head screws, and pry theconverter side output flange from the shaft.

STEP 22Pry the shaft seal out of the housing bore.

STEP 23Turn the transmission 180 degrees and remove therear output flange.

STEP 24

GD98M862

Remove the speed sensor and both inductivetransmitters.

STEP 25

GD98M863

Remove the hex nuts and the two covers.

STEP 26

GD98M864

Install CAS2802 alignment dowel set.

NOTE: The following steps describe the commonremoval of all clutches.

6003-9


STEP 27

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 totransmission cover.

STEP 28

BK00D028

Separate the cover along with clutches from thetransmission housing, using lifting device.

STEP 29

BK00D026

Place clutch disc carriers onto CAS2796 nestingplate.

STEP 30Remove CAS2800 clutch assembly holding knobset and lift cover free.

STEP 31

GD98M867

Remove the socket head screws and remove theoutput shaft and both oil baffle plates.

STEP 32

GD98M872

Remove clutch K2.

STEP 33

GD98M873

Remove clutch K1 while lifting clutch K4.

6003-10


STEP 34

GD98M874

Remove clutch K3.

STEP 35

GD98M875

Remove clutch K4 while lifting input shaft slightly.

STEP 36

GD98M876

Remove clutches KV and KR together with inputshaft.

STEP 37

GD98M877

Remove the bearing outer race and pull output shaftout of the housing bore.

STEP 38

GD98M878

Remove the rectangular ring and separate ballbearing from the shaft.

NOTE: The following steps are for the disassemblyof the clutch KV. The disassembly of the clutch KR issimilar.

STEP 39

GD98M979

Remove the sealing ring. Pull the tapered rollerbearing from the shaft. Remove the opposite taperedroller bearing.

6003-11


STEP 40

GD98M881

Separate the clutch disc carrier from the shaft.

STEP 41

GD98M882

Remove the snap ring and remove the clutch discpack.

STEP 42

BK00D018

Preload compression spring using CAS2799 clutchpack holder and spring compressor tool.

STEP 43

BK00D020

Remove snap ring.

STEP 44

BK00D019

Remove the compression spring.

STEP 45

GD98M885

Remove piston from clutch pack holder. Remove anddiscard the O-rings from piston.

6003-12


STEP 46

GD98M886

Remove the snap ring.

STEP 47

GD98M887

GD98M888

Press the idler gear from the shaft using a bearingseparator. Remove released needle bearing.

STEP 48

GD98M889

Remove the snap ring and remove the ball bearing.

NOTE: The following steps are for disassembly ofclutch K3. Disassembly of clutches K1 and K2 issimilar

STEP 49

GD98M890

Remove the rectangular ring. Pull the tapered rollerbearing from the shaft.

STEP 50

GD98M892

Remove the thrust washer, thrust bearing, and thrustwasher.

6003-13


STEP 51

GD98M893

Remove the idler gear.

STEP 52

GD98M894

Remove the needle bearings and thrust bearing.

STEP 53

GD98M895


STEP 54

BK00D018


STEP 55

BKOOD020


STEP 56

BK00D019


6003-14


STEP 57

BS00G001

Remove the sealing ring. Remove bearing usingbearing puller. Tap assembly until piston drops out ofthe clutch pack carrier. Then, remove and discardO-rings from piston.

STEP 58

BK00D022

Remove the clutch disc carrier from the shaft.

NOTE: The following steps are for the disassemblyof the clutch K4.

STEP 59

GD98M800

Remove and discard two sealing rings. Pull twobearings from shaft using bearing puller. Remove thesnap ring and separate the clutch disc carrier fromthe shaft.

STEP 60

GD98M801


STEP 61

BK00D018


6003-15


STEP 62

BK00D020


STEP 63

BK00D019


NOTE: The following two steps are for disassemblyof the input shaft.

NOTE: A snap ring is used to lock turbine shaft ininput shaft. Snap ring will be destroyed when turbineshaft is pressed from input shaft.

STEP 64

GD98M803

If turbine shaft is to be removed from input shaft, useproper size diameter sleeve or rod and press turbineshaft out of input shaft.

STEP 65Remove bearings from input shaft using a bearingpuller.

6003-16


ASSEMBLYNOTE: The following steps are for the reassembly ofthe oil pipes.

STEP 66

GD98M603

Install suction tube (1), pressure pipes (2), andlubrication pressure pipe (3) in housing.

STEP 67Secure suction tube (1) and pressure pipes (2) withsocket head screw and hex nuts. Tighten to a torqueof 23 Nm (204 pound inches)

STEP 68

GD98M605

Tilt the cover 180 degrees. Install the suction tubesand pressure pipes into the housing bores using arolling tool.

NOTE: Pipe end of the pressure pipes must beslightly below the housing plane face.

STEP 69

GD98M607

Install a new O-ring on plug. Tighten the plug to atorque of 51 Nm (38 pound feet).

STEP 70

GD98M608

Install all bearing outer races in housing bores.

STEP 71

GD98M609

Install both oil pipes into the housing cover. Tilt thecover 180 degrees and install pipes into the housingbores using a rolling tool.

NOTE: The pipe end must be slightly below thehousing plane face.

1

3

2

6003-17


STEP 72

GD98M610

Install the studs. Tighten the studs to a torque of 9Nm (80 pound inches).

NOTE: The following steps are for the assembly ofclutches KV and KR, starting with assembly of theclutch disc carrier.

STEP 73

GD98M612

Check that drain hole is clear and free of foreignmatter. Install both O-rings in recesses of the pistonand apply oil.

STEP 74

GD98M613

Install piston in clutch disc carrier.

STEP 75

BK00D019

BK00D018

Install compression spring and two spring cups inclutch disc carrier. Preload compression springusing CAS2799 clutch pack holder and springcompressor tool.

STEP 76

BK00D020

Install the snap ring.

NOTE: The following steps are for the KV and KRclutch disc packs. The disc stacking of clutches KVand KR is identical.

6003-18


STEP 77

225B

Install clutch disc plates in KV and KR clutch disccarriers in position and sequence shown above.Install outer plates (3) with steel faced side facingpiston and end shim (7).

NOTE: Snap rings of different thickness areavailable for adjustment of the running clearance. Toensure correct adjustment, do not apply oil to clutchdiscs until after adjustment is completed.

STEP 78

GD98M616

Install the clutch disc pack.

STEP 79

GD98M617

Install end shim and snap ring.

STEP 80

GD98M618

Adjust running clearance to 2.7 to 2.9 mm (0.106 to0.114 in) . Press down on the end shim withapproximately 10 kg (20 lb). Measure and recorddimension (A) from carrier face to end shim usingdepth gauge as shown.

ExampleDimension A . . . . . . . . . . . . . . . . . 7.25 mm (0.29 in)

1. PLATE CARRIER2. PISTON3. OUTER PLATE - ONE-SIDED COATED4. INNER PLATES5. OUTER PLATES - COATED ON BOTH SIDES6. SNAP RING7. END SHIMA RUNNING CLEARANCE 2.7 TO 2.9 MM (0.106 TO 0.114

IN)

A

6003-19


STEP 81

GD98M619

Use tools to lift the end shim against snap ring(upward) until contact is obtained. Measure andrecord dimension (B) from carrier face to end shimusing depth gauge as shown. Subtract th ismeasurement from the measurement of Step 80. Thedifference is the running clearance.

ExampleDimension 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 (0.106to 0.114 in). Use snap ring(s) of different thickness asnecessary to obtain correct running clearance.

STEP 82Remove clutch disc pack, apply oil to discs, andinstall clutch disc pack, end shim, and snap ring asdetermined in Step 81.

STEP 83

GD98M620

Install idler gear to align and engage all inner discs,then remove idler gear.

STEP 84

GD98M621

Apply Loctite 243 to stud. Tighten stud to a torque of17 Nm (150 pound inches).

STEP 85

GD98M622

Install ball bearing until contact is obtained. Secureusing snap ring.

STEP 86

GD98M623

Install needle bearing.

6003-20


STEP 87

GD98M624

Support the idler gear on the bearing inner race.Press the idler gear against the shoulder.

STEP 88

GD98M625

Secure idler gear using snap ring.

STEP 89

BK00D023

Use heat gun to heat assembled clutch disc carrierinner bore.

STEP 90

BP00G020

Install gear and shaft into heated bore.

STEP 91

BK00D024

Heat bearing.

STEP 92

SM121A

BK00D025

Instal l heated bear ing on shaft against shaftshoulder.

WARNING: Always wear heat protectivegloves to prevent burning your hand whenhandling heated parts.

6003-21


STEP 93Check operation of the clutch using compressed air.

NOTE: The following steps are for assembly ofclutch K1, K2, and K3.

STEP 94

GD98M630

Press bearing against shoulder of shaft. ApplyLoctite 243 to the stud and install the stud. Tightenthe stud to a torque of 17 Nm (150 pound inches).

STEP 95

GD98M631

Install the clutch disc carrier until contact is obtained.

STEP 96

GD98M632

Check that drain hole is clear and free of foreignmatter. Install both O-rings in recesses of piston andapply oil.

STEP 97

GD98M633

Install piston in clutch disc carrier.

STEP 98

GD98M634

Install the compression spring and spring cup.

6003-22


STEP 99

BK00D019

BK00D018


STEP 100

BK00D020

Install the snap ring.

NOTE: The following steps are for K1, K2 and K3clutches. The assembly of clutches K1, K2, and K3 isidentical except for running clearance dimensions.

STEP 101

232A

Install clutch disc plates in K1, K2, and K3 clutch disccarriers in position and sequence shown above.Install outer plate (3) with steel faced side facingpiston.


STEP 102

GD98M636

Install the clutch disc pack.

1. PLATE CARRIER2. PISTON3. OUTER PLATE - ONE-SIDED COATED4. INNER PLATES5. OUTER PLATES - COATED ON BOTH SIDES6. SNAP RING7. END SHIMA. 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)

A

6003-23


STEP 103

GD98M637

Install the end shim and snap ring.

STEP 104

GD98M638

Adjust running clearance for K1 to 2.4 to 2.6 mm(0.094 to 0.102 in); adjust running clearance for K2and K3 to 1.8 to 2.0 mm (0.071 to 0.079 in). Pressdown on the end shim with approximately 10 kg (20lb). Measure and record dimension (A) from carrierface to end shim using depth gauge as shown.

ExampleDimension A . . . . . . . . . . . . . . . . . . 8.2 mm (0.32 in)

STEP 105

GD98M639

Use tools to lift the end shim against snap ring(upward) until contact is obtained. Measure andrecord dimension (B) from carrier face to end shimusing depth gauge as shown. Subtract th ismeasurement from the measurement of Step 104.The difference is the running clearance.

ExampleDimension A . . . . . . . . . . . . . . . . . . .8.2 mm (0.32 in)Dimension B . . . . . . . . . . . . . . . . . . .6.1 mm (0.24 in)

Difference = Running Clearance . . .2.1 mm (0.08 in)

Required running clearance for K1 is 2.4 to 2.6 mm(0.094 to 0.102 in); for K2 and K3 required runningclearance is 1.8 to 2.0 mm (0.071 to 0.079 in). Usesnap ring(s) of different thickness as necessary toobtain correct running clearance.


STEP 107

GD98M640

Install the thrust washer (1), thrust bearing (2), andthrust washer (3).

NOTE: Install the thrust washer (1) with the chamferfacing the thrust bearing.

1

2

3

6003-24


STEP 108

GD98M641

Install both needle bearings.

STEP 109

GD98M642

Install idler gear until all inner discs are engaged.

STEP 110

GD98M643

Install the thrust washer (3), thrust bearing (2), andthrust washer (1). Install the thrust washer (1) withthe chamfer facing the thrust bearing.

NOTE: Ensure the thrust washer (1) is overlappingwith the chaff collar to accommodate all the innerdiscs.

STEP 111

BK00D024

Heat bearing.

STEP 112

SM121A

BK00D025

Place heated bearing on the shaft.


3

2

1


6003-25


NOTE: The following steps are for assembly ofclutch K4.

STEP 114

SM121A

GD98M647

Heat the gear to about 120° C (248° F) and installuntil seated in position.

STEP 115

GD98M648

Install retaining ring to secure gear.

STEP 116

GD98M649

Apply Loctite 243 to the stud and install the stud.Tighten the stud to a torque of 17 Nm (150 poundinches).

STEP 117

GD98M650

Check that drain hole is clear and free of foreignmatter. Install both O-rings in recesses of the pistonand apply oil.

STEP 118

GD98M651

Install piston in clutch disc carrier. Be sure pistonbottoms out.


6003-26


STEP 119

BK00D019

BK00D018


STEP 120

BK00D020

Install snap ring.

NOTE: The following steps are for installing theclutch disc pack in clutch K4.

STEP 121

BS02C131

Install clutch disc plates in K4 clutch disc carrier inposition and sequence shown above. Install outerplate (3) with steel faced side facing piston.


STEP 122

GD98M653

Install clutch disc pack.

1. PLATE CARRIER2. PISTON3. OUTER PLATE - ONE-SIDED COATED4. INNER PLATES5. OUTER PLATES - COATED ON BOTH SIDES6. SNAP RING7. END SHIMA. RUNNING CLEARANCE 1.2 TO 1.4 MM (0.047 TO 0.055

IN)

A

6003-27


STEP 123

GD98M654

Install end shim and snap ring.

STEP 124

GD98M655

Adjust running clearance to 1.2 to 1.4 mm (0.047 to0.055 in) . Press down on the end shim withapproximately 10 kg (20 lb). Measure and recorddimension (A) from carrier face to end shim usingdepth gauge as shown.

ExampleDimension A . . . . . . . . . . . . . . . . . . 7.2 mm (0.28 in)

STEP 125

GD98M656

Use tools to lift the end shim against snap ring(upward) until contact is obtained. Measure andrecord dimension (B) from carrier face to end shimusing depth gauge as shown. Subtract th ismeasurement from the measurement of Step 124.The difference is the running clearance.

ExampleDimension 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 (0.047to 0.055 in). Use snap ring(s) of different thickness asnecessary to obtain correct running clearance.


STEP 127

GD98M657

Install the idler gear until all inner discs are engaged,then remove idler gear.

6003-28


STEP 128

GD98M658

Assemble two thrust washers and thrust bearing.

NOTE: Upper and lower thrust washers are thesame thickness.

STEP 129

GD98M659

Install both needle bearings.

STEP 130

GD98M660

Install the idler gear.

STEP 131

GD98M661

Assemble thrust washer (3), thrust bearing (2), andthrust washer (1). Install the thrust washer (1) withthe chamfer facing the thrust bearing.

STEP 132

GD98M662

Install the assembled clutch disc carrier until all theinner discs are engaged.

STEP 133

GD98M663

Install snap ring to secure clutch disc carrier.

3

2

1

6003-29


STEP 134

BK00D024

Heat bearing.

STEP 135

SM121A

BK00D025

Install heated bearing on the shaft shoulder.

STEP 136Repeat Steps 134 and 135 to install bearing onopposite end of shaft.


NOTE: The following steps are for the reassembly ofthe input shaft.

STEP 138

SM121A

GD98M666

Heat gear to about 120° C (248° F) and install oninput shaft until contact is obtained.

STEP 139

GD98M667

Secure gear with snap ring.

STEP 140

GD98M668

Install snap ring into recess of turbine shaft.



6003-30


STEP 141

GD98M669

Install the turbine shaft until the snap ring snaps intothe recess of the input shaft.

STEP 142

SM121A

BK00D024

Heat bearings and install on turbine shaft untilbearings are against shoulder.

STEP 143

GD98M671

Install bearing then install rectangular ring.

STEP 144

GD98M672

Install output shaft into housing bore until contact ismade.

NOTE: The following steps are for the installation ofthe output shaft and clutches. All clutches have acommon installation.

STEP 145

GD98M673

Install bearing outer races into housing cover untilcontact is obtained.

STEP 146

BK00F003

Install the clutches onto CAS2796 nesting plate.


ABK3

K1

K2

K4AN KR

KV

6003-31


STEP 147

BK00D029

Using CAS2797 lifting eye bolt set and acceptablel i f t ing equipment, instal l housing cover ontoclutches. Install CAS2800 clutch assembly holdingknob set to secure clutch shafts to cover.

STEP 148

GD98M679

The above photo shows the position of the singleclutches in the housing cover.

STEP 149

GD98M866

The above shows the position of the single clutchesand the input and output clutches.

STEP 150

GD98M681

Install the sealing rings and insert rings in theirrespective grooves. Apply grease to the sealing ringsand align the rings centrally.

STEP 151

GD98M692

Install both the O-rings into the annular groove of theoil pipes and apply grease.

STEP 152

Tilt the housing cover 180 degrees.

K3

K2

KV

KR

K4

K1

AB

K3

K2

KVAN

K1

K4

KR

6003-32


STEP 153

BK00D028

Install output gear and shaft in transmission housing.Install alignment screws. Carefully lower the coverand clutches into the gear box housing.

STEP 154Remove CAS2800 clutch assembly holding knob set.

STEP 155

GD98M685

Separate the housing cover from the gearbox, usinga lifting device.

NOTE: The following steps are for the reassembly ofthe output shaft.

STEP 156

GD98M686

Install screen sheet on output shaft. Press front andrear bearings on output shaft until contact withshoulder of output shaft is made.

STEP 157

GD98M688

Install the screening plate.

STEP 158

GD98M689

Install the output shaft.

6003-33


STEP 159

GD98M690

Apply Loctite 243 to the socket head screws andinstall the screws. Tighten the screws to a torque of23 Nm (204 pound inches).

STEP 160

GD98M691

Install rectangular rings in grooves of clutch shafts.Apply grease to rings and align rings.

STEP 161

GD98M696

Position shaft seal with sealing lip facing oil chamber.App ly grease to sea l ing l i p. Use CAS2807transmission output shaft seal installation tool toinstall seal.

STEP 162

GD98M697

Heat the output flange to about 90° C (194° F). ApplyLoctite 574 to the contact area and assemble theflange with the washers and hex head screws.Tighten the screws to a torque of 34 Nm (301 poundinches). Bend corner of lock plate over hex headscrews.

STEP 163Repeat Steps 161 and 162 to install shaft seal andoutput flange on converter side.

NOTE: The following steps are for the assembly ofthe oil feed housing and transmission pump.

STEP 164

GD98M702

Install two alignment studs and install the gasket.

6003-34


STEP 165

GD98M703

Install the oil feed housing with washers and hexhead screws. Screw the hex head screws in only untilcontact is obtained, do not tighten.

STEP 166

GD98M704

Install the two alignment screws and install the statorshaft.

STEP 167

GD98M705

Apply oil and install the O-ring.

STEP 168

GD98M706

Install transmission pump.

STEP 169

GD98M707

Apply grease to new O-rings. Install the O-rings onthe socket head screws.

STEP 170

GD98M708

Secure the transmission pump with the socket headscrews. Tighten screws to a torque of 46 Nm (407pound inches).

6003-35


STEP 171

GD98M709

Install the oil feed housing with the hex head screwsand flat washers. Tighten the screws to a torque of25 Nm (221 pound inches).

STEP 172

GD98M711

Position the gasket and cover. Secure the cover withthe hex head screws. Tighten the screws to a torqueof 23 Nm (204 pound inches).

NOTE: The following steps are for the assembly ofthe engine connection and converter.

STEP 173

GD98M712

Position converter housing. Secure with hex headscrews. Tighten the screws to a torque of 68 Nm (50pound feet).

STEP 174

GD98M713

Put input shaf t in a v ise as shown. Posi t iondiaphragm on input shaft and secure using 12 hexhead screws. Tighten screws to a torque of 115 Nm(85 pound feet).

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 (85pound feet).

6003-36


STEP 176

GD98M715

GD98M716

Position converter. Check and ensure that impulsedisk of converter is centered on the bore for theinductive transmitter.

STEP 177

GD98M717

Position converter cover as shown. Install bearingagainst shoulder in cover. Secure using retainingring.

STEP 178

GD98M718

Position converter cover on converter housing. Makesure alignment marks made during removal of coverare aligned. Install input flange, two hex headscrews, lock plate, and washer. Pull cover againsthousing by tightening two hex head bolts evenly.

STEP 179

GD98M719

Secure converter cover using 12 hex head screwsand nuts. Tighten screws to a torque of 46 Nm (407pound inches).

6003-37


STEP 180

GD98M720

Tighten input flange hex head screws to a torque of34 Nm (301 pound inches). Lock screws by bendingcorners of lock plate over screws.

STEP 181

GD98M724

Install new sealing rings and both plugs in duct plate.

STEP 182

GD98M725

Install the gasket and place the duct plate againstshoulder. Install socket head screws and hex nuts.Tighten to a torque of 25 Nm (221 pound inches).

NOTE: The following steps are for installation oftransmission control valve.

STEP 183

258

Install CAS2885 transmission valve adjustment toolset. Be sure hex rods (par t of tool set) are notinstalled on studs. Mount the gasket (1), intermediateplate (2), and gasket (3).

STEP 184Install the screw plug with new O-ring. Tighten theplug to a torque of 30 Nm (265 pound inches).

STEP 185

GD98M727

Install control valve on duct plate and CAS2885studs. Install hex rods on studs and tighten againstcontrol valve. Install 21 socket head screws. Tightenscrews to a torque of 9.5 Nm (84 pound inches).Remove CAS2885 transmission valve adjustmenttool set. Install remaining two socket head screws.Tighten screws to a torque of 9.5 Nm (84 poundinches).

NOTE: The following steps are for the installation ofthe filter.

6003-38


STEP 186

GD98M729

Install new O-rings in recesses of oil filter head.Position filter head on transmission and secure usingtwo socket head screws. Tighten screws to a torqueof 25 Nm (221 pound inches).

STEP 187

GD98M730

Install a new transmission filter.

STEP 188

GD98M733

Install new O-rings in oil distribution covers. Installthe two oil distribution covers on the housing with hexnuts and flat washers. Tighten to a torque of 25 Nm(221 pound inches).

STEP 189

GD98M735

Apply grease to the new O-ring and install the speedsensor with the socket head screw. Tighten the screwto a torque of 23 Nm (204 pound inches).

STEP 190

GD98M736

With new O-rings, install the inductive transmitters.Tighten to a torque of 30 Nm (265 pound inches).

STEP 191Install the breather.

STEP 192

GD98M737

Install the gasket and the cover plate. Tighten to atorque of 23 Nm (204 pound inches). With a newO-ring, install the screw plug. Tighten to a torque of140 Nm (103 pound feet).

Section6004

6004




FRONT AXLE

6004-2


TABLE OF CONTENTS

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3GEAR TOOTH CONTACT PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6WEAR MEASUREMENT ON MULTI-DISC BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6WHEEL END AND BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

LEAKAGE TEST OF THE BRAKE HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23High Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Low Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

DISASSEMBLY OF DIFFERENTIAL CARRIER AND BRAKE TUBES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24DISASSEMBLY OF LIMITED SLIP DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27DISASSEMBLY OF DRIVE PINION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28DISASSEMBLY OF THE BRAKE TUBES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29ASSEMBLY OF BRAKE TUBES AND DIFFERENTIAL CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30ASSEMBLY OF DIFFERENTIAL CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Determine Shim Thickness for a Perfect Tooth Contact Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Install the Drive Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Adjust Rolling Moment of Drive Pinion Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

ASSEMBLY OF LIMITED SLIP DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Adjust Backlash and Bearing Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

6004-3


SPECIAL TOOLSPlanetary bearing puller collet set ............................................................................................................... CAS2881Brake housing seal installer......................................................................................................................... CAS2880Differential bearing cone puller collet set..................................................................................................... CAS2871Differential bearing preload wrench............................................................................................................. CAS2851Brake housing inner bearing cup installer ................................................................................................... CAS2877Brake housing outer bearing cup installer ................................................................................................... CAS2878Brake housing inner bearing cup installer ................................................................................................... CAS2879Wear ring installer adapter .......................................................................................................................... CAS2874Wear ring installer adapter ......................................................................................................................... CAS2875Pinion depth gauge set................................................................................................................................ CAS2872Pinion depth gauge block ............................................................................................................................ CAS2873Puller body and screw ................................................................................................................................. CAS2882Support bracket ........................................................................................................................................... CAS2883Slide hammer puller adapter ..................................................................................................................... CAS10846Slide hammer ..............................................................................................................................................OEM4252Replacer ...................................................................................................................................................... CAS2297Magnetic base with indicator ................................................................................................................... CAS10066AHeat gun .................................................................................................................................................... CAS10810Lifting sling...................................................................................................................................................OEM4106Engine stand................................................................................................................................................OEM4135Snap ring pliers............................................................................................................................................OEM6484Snap ring pliers............................................................................................................................................OEM6177Snap ring pliers............................................................................................................................................OEM6492Step plate set (includes 8061, 8067, and 8073) ..........................................................................................OEM4288Step plate ............................................................................................................................................................8061Step plate ............................................................................................................................................................8067Step plate ............................................................................................................................................................8073

6004-4


GEAR TOOTH CONTACT PATTERNSIdeal Tooth Contact Pattern

BS01D011

COAST SIDE (CONCAVE)

BS01D012

DRIVE SIDE (CONVEX)

Pinion Distance Must Be Increased

BS01D009

BS01D013


BS01D014

DRIVE SIDE (CONVEX)

6004-5


Pinion Distance Must Be Decreased

BS01D010

BS01D015


BS01D016

DRIVE SIDE (CONVEX)

6004-6


LUBRICATION

BS00M069 BS00M070

WEAR MEASUREMENT ON MULTI-DISC BRAKE

BD00M234 BS00M071

NOTE: A wear measurement on the multi-disc brake has to be made at least once a year, especially in case of achanged 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).

4 54

23

12

4

3

21

2

54

1. OIL DRAIN HOLE (AXLE CASING) 3. OIL FILLER HOLE 5. BLEEDER2. OIL DRAIN HOLE (OUTPUTS) 4. BRAKE BLEEDER

6004-7


WHEEL END AND BRAKES

Disassembly

STEP 1

BD00M235

Fasten the axle on a stand.

STEP 2

BD00M236

BD00M237

Loosen the screw plugs and drain the oil from theaxle casting.

STEP 3

BD00M238

Pry the cover off the wheel end.

STEP 4

BD03B008

Use OEM4252 slide hammer and CAS10846-3adapter, remove the slotted pin from wheel end locknut.

STEP 5

BD03B009

Using CAS2876 locknut socket and CAS2883support bracket, loosen and remove the locknut.

6004-8


STEP 6

BD00M241

Use acceptable lifting equipment and hold the wheelend in place. Loosen and remove the bolts.

STEP 7

BD03B010

Separate the wheel end from the axle casing.

STEP 8

BD00M243

Pull the stub shaft out of the sun gear shaft.

NOTE: Watch for released shim(s).

STEP 9

BD00M244

Remove the shim(s) from the sun gear shaft.

STEP 10

BD00M245

Pull the sun gear shaft out of the planet gears.

STEP 11

BD03B011

Lift planet carrier out of the brake housing usingOEM4054 pulling attachment.

6004-9


STEP 12

BD03B012

Remove the snap rings from the planet gear shaftusing OEM6492 snap ring pliers.

STEP 13

BD03B013

Remove the planet gear using CAS2848 gear pullerand 8061 step plate.

STEP 14

BD03B014

Remove the bearing from the planetary usingCAS2881 collet set, CAS2882 puller body and screw,and 8061 step plate.

STEP 15

BD03B015

Using suitable puller, remove planetary ring gearfrom brake housing.

STEP 16

BD03B016

Remove O-rings from the annular grooves of the ringgear.

STEP 17

BD03B017

Remove O-ring from recess of the brake housing.

6004-10


STEP 18

BD00M253

Remove the brake disc pack from the brake housing.

STEP 19

BD03B019

Drive slotted pins in the support shim until they areflush with the top of the support shim.

STEP 20

BD03B020

Remove the circlip using OEM6484 external pliers.

STEP 21

BD03B021

Use compressed air to raise piston out of the brakehousing.

STEP 22

BD00M257

Remove the support shim out of the piston.

STEP 23

BD03B022

Drive slotted pins out of the support shim.

6004-11


STEP 24

BD00M259

Preload the cup springs using a press and removethe retaining ring.

STEP 25

BD00M260

Pull the pin out of the support shim and remove thereleased cup springs.

STEP 26

BD00M261

Press the gripping rings off of the pins.

STEP 27

BD00M262

Lift the piston out of the brake housing.

STEP 28

BD00M263

Remove and discard the guide ring, support ringsand U-rings from the grooves of the brake housing.

NOTE: If replacing brakes only, go to step 44.

STEP 29

BD03B023

Using CAS2850 puller bridge and 8073 step plate,remove the brake housing from the wheel end shaft.

6004-12


STEP 30

BD03B024

Use acceptable lifting equipment and lift the brakehousing from the wheel end shaft.

STEP 31

BD00M266

If necessary drive both bearing outer rings out of thebrake housing.

STEP 32

BD00M267

Remove the shaft seal from the brake housing.

STEP 33If the wheel end pressure ring or bearing needs to bereplaced, remove the bearing from the wheel endshaft.

STEP 34

BD00M269

If the wheel end pressure ring needs to be replaced,remove the pressure ring from the wheel end shaft.

6004-13


Assembly

STEP 35

BD00M271

Install a new pressure ring on the wheel end shaft.

STEP 36

BD01F107

Install the CAS2874 pressure ring installer adapteron the wheel end shaft.

STEP 37

BD01F105

Press the pressure ring over the collar of the wheelend shaft using CAS2860 pressure ring installer.

SM121A

STEP 38

BD00M273

Heat the bearing inner ring and install it onto thewheel end shaft.

STEP 39

BD03B026

Freeze the bearing outer ring. Press the bearingouter ring into the brake housing using CAS2879.

STEP 40Freeze the bearing outer ring. Press the bearingouter ring into the brake housing using CAS2853.


6004-14


STEP 41

BD03B027

Use a solution of 50% water and 50% mineral spiritsto wet the outer diameter of the shaft seal. UsingCAS2880 install the shaft seal with the sealing lipshowing to the oil chamber. See illustration below.

BS00M073

SHAFT SEAL

STEP 42

BD03B024

Use acceptable lifting equipment and install thebrake housing over the wheel end shaft until contact.

SM121A

STEP 43

BD00M277

Heat the bearing inner ring and install it into thebrake housing until contact.

1. BRAKE HOUSING2. SHAFT SEAL

* GREASE FILLING


6004-15


STEP 44

BD00M263

BS00M072

Install the guide ring, support rings and U-rings in thegrooves of the brake housing.

STEP 45

BD00M279

Clean the groove of the brake housing with solvent.Install the guide ring into the groove and fix it withLoctite 415.

NOTE: Upon installation the guide ring must havecontact on the whole circumference and the orificemust show upwards (12 o’clock).

STEP 46

BD00M280

Apply oil on the sliding surface of the piston. Carefully insert the piston into the brake housing.

1. BRAKE HOUSING 5. U-RING2. GUIDE RING 6. SUPPORT RING3. SUPPORT RING 7. WHEEL END SHAFT4. U-RING

6004-16


STEP 47

BD00M281

Insert the pins into the assembly fixture until contact.

STEP 48

BD00M2821. GRIPPING RINGS

Press the gripping rings onto the pins until contact onthe assembly fixture.

ATTENTION: Observe the installation position,install the gripping rings with the orifices offset by180° to each other.

STEP 49

BD00M283

Install the cup springs onto the pins. See illustrationbelow.

BS00M074

STEP 50

BD00M284

Insert the assembled pins into the support shim andinstall the snap ring.

STEP 51

BD00M285

Insert the assembled support shim into the piston.

1

1. PIN 4. SUPPORT SHIM2. GRIPPING RINGS 5. RETAINING RING3. CUP SPRINGS X. 10.5 MM +0.3 (0.41 IN +0.02)

6004-17


STEP 52

BD00M286

Install the circlip into the brake housing.

STEP 53

BD03B028

BD03B034

Drive slotted pins into the bores of the support shimto lock the circlip.

STEP 54

BD00M2881. SPLINE

Drive the stop bolt into the planet carrier. Then coatthe spline with anti-corrosive antiseize.

STEP 55

BD00M289

Insert the planet carrier into the spline of the wheelend shaft until contact.

1. BRAKE HOUSING 4. SUPPORT SHIM2. CIRCLIP 5. PISTON

X INSTALLATION DIMENSION 5.0 MM ± 0.5 MM

3. SLOTTED PIN

1

6004-18


STEP 56

BS06A166

Install the discs (2), plates (3), and plates (4) asshown. Lubricate the brake disc with clean axle oil.

NOTE: The number of brake discs may vary fromyour machine, the procedure is the same.

STEP 57

BD03B029

Insert O-ring into the recess of the brake housing.

STEP 58

BD03B016

Grease both O-rings.

STEP 59

BD03B030

Install two aligning dowels in the brake housing,install ring gear onto the brake housing.

NOTE: Make sure alignment is correct on ring gear.

STEP 60

BD01C009

Heat the bearing inner rings with a hot air gun.

1. BRAKE PISTON 3. PLATE 4 MM2. BRAKE DISC 4. PLATE 2 MM

1

2

4

3

6004-19


SM121A

STEP 61

BD00M292

Install the bearings with the big radius showing to theplanet carrier (downwards).

STEP 62

BD00M293

Put the planet gears onto the bearing inner rings.

SM121A

STEP 63

BD00M294

Heat the bearing inner rings and install into theplanet gears.

STEP 64

BD03B031

Install the snap rings on the planet gear shafts usingOEM6492 snap ring pliers.



6004-20


Adjust end play of sun gear shaft 0.5 to 2.0 mm (0.02 to 0.08 inch)

STEP 65

BD00M296

Determine dimension I, from the mounting face of thebrake housing up to the face of the stop bolt.Dimension I e.g. . . . . . . . . . . . 46.20 mm (1.82 inch)

STEP 66

BD00M297

Insert the stub shaft into the spline of the axle bevelgear until contact.

STEP 67

BD00M298

Insert the sun gear shaft onto the stub shaft untilcontact.

STEP 68

BD00M299

Determine dimension II from the face of the sun gearshaft 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)

6004-21


STEP 69

BD00M245

Insert the sun gear shaft into the planet carrier.

STEP 70

BD00M244

Install the determined shim(s), e.g. S. = 2.20 mm(0.09 inch) into the sun gear shaft with grease.

STEP 71

BD03B032

Install O-ring and hold into place with grease, installoutput housing onto axle.

STEP 72

BD00M300

Install the washers and bolts by hand.Tightening torque . . . . . . . 390 Nm (288 pound-feet)

STEP 73

BD03B033

Install the locknut by hand and tighten it usingCAS2876 locknut socket and CAS2883 supportbracket.Tighten torque . . . 700+300 Nm (516 +221pound-feet)

STEP 74

BD00M302

Secure the locknut with the slotted pin.

6004-22


STEP 75

BD00M3031. O-RING

Install an O-ring on the cover.

STEP 76

BD00M304

Insert the cover into the wheel end.

1

6004-23


LEAKAGE TEST OF THE BRAKE HYDRAULICSNOTE: Prior to start the test, ventilate the brake hydraulics and then actuate it several times.

High Pressure Test

STEP 77

BD00M305

Increase test pressure up to p =100 bar (1450 psi)maximum and close connection to HD pump bymeans of shutoff valve. During a 5 minute testingtime, a pressure drop of maximum 2 bar (29 psi) isallowed.

ATTENTION: If the maximum pressure of 100 bar(1450 psi) is exceeded, there will be an excessivepiston adjustment and a repeated disassembly of thebrake or the adjusting is required to reset the grippingrings to the adjusting dimension.

Low Pressure TestReduce test pressure to p = 5 bar (72.5 psi) andclose the shutoff valve again.

During a 5 minute testing time a pressure drop is notallowed.

6004-24


DISASSEMBLY OF DIFFERENTIAL CARRIER AND BRAKE TUBES

STEP 1

BD00M235

Fasten the axle on a stand.

STEP 2

BD00M236

BD00M237

Loosen the screw plugs and drain the oil from theaxle casing.

STEP 3

BD00M241

Use acceptable lifting equipment to hold the wheelend in place. Loosen and remove the bolts.

STEP 4

BD03B032

Separate the wheel end from the axle housing.Remove O-ring.

STEP 5

BD00M243

Pull the stub shaft out of the sun gear shaft. Repeatsteps 3 through 5 for the other wheel end.

NOTE: Pay attention to the released shim(s).

6004-25


STEP 6

BD00M395

Remove the bolts from the differential carrier.

NOTE: Mark the location of the differential carrier tothe axle casing.

STEP 7

BD03B035

Use suitable lifting equipment and lift the differentialcarrier out of the axle casing.

STEP 8

BD03B036

Fasten the differential carrier on OEM4135 enginestand using CAS2847 mounting bracket.

STEP 9

BD00M398

Drive out the slotted pins from the differential carrier.

STEP 10

BD01F072

Loosen and remove both adjusting nuts usingCAS2851 wrench.

STEP 11

BD00M400

Heat the axle drive housing with a hot air gun.

NOTE: Bolts are installed with Loctite.

6004-26


STEP 12

BD00M401

Loosen the bolts and take off both bearing brackets.

NOTE: Make an alignment mark between thebearing bracket and the housing.

ATTENTION: Loosen the bolts by hand only.

STEP 13

BD00M402

Remove both bearing outer rings from the differentialcarrier.

STEP 14

BD00M403

Use acceptable l i f t ing equipment and l i f t thedifferential out of the differential carrier.

6004-27


DISASSEMBLY OF LIMITED SLIP DIFFERENTIAL

STEP 15

BD01F089

Using CAS2294 cone puller and 8065 step plate,remove the bearing inner ring from the differentialhousing.

STEP 16

BD01F096

Remove the bearing inner ring from the housingcover using CAS2294 cone puller and 8065 stepplate.

STEP 17

BD00M406

Place the differential in a press to prevent it fromturning. Remove the bolts and the released housingcover.

STEP 18

BD00M407

Remove all the single parts from the differentialhousing.

STEP 19

BD00M408

Press off the ring gear from the differential housing.

6004-28


DISASSEMBLY OF DRIVE PINION

STEP 20

BD00M409

Heat the pinion shaft locknut with a hot air gun.

NOTE: Locknut is held with Loctite Type No. 262.

STEP 21

BD01F091

Using CAS1579A yoke holding wrench, loosen thelocknut and remove the washer behind it.

STEP 22

BD00M411

Pull the input yoke from the drive pinion shaft.

STEP 23

BD00M412

Remove the shaft seal from the differential carrier.

STEP 24Use a rubber hammer to remove the drive pinion outof the differential carrier.

STEP 25Take off the spacer ring and pull the bearing innerring from the drive pinion shaft.

STEP 26

BD00M414

If necessary drive out both bearing outer rings fromthe differential carrier.

6004-29


DISASSEMBLY OF THE BRAKE TUBES

STEP 27

BD00M334

Remove the screw plug with the vent valve from theaxle casing.

STEP 28

BD00M335

Loosen and remove the hexagon screw from theaxle.

STEP 29

BD00M336

Loosen and remove the union screw from the axle.

STEP 30

BD00M337

Disconnect the pipe union and remove the releasedbrake tube from the axle casing.

STEP 31

BD00M338

Remove the vent valve from the connection part.

STEP 32

BD00M339

Loosen the connection part and remove it from theaxle. Repeat steps 28 to 32 for the other wheel end.

6004-30


ASSEMBLY OF BRAKE TUBES AND DIFFERENTIAL CARRIER

STEP 33

BD00M340

Assemble the part as shown in the photo above.

STEP 34

BD00M341

Install the connection part on the axle casing. Tightening torque . . . . . . . . .130 Nm (96 pound feet)

STEP 35

BD00M342

Install the union screw with a new O-ring on the axle.Tightening torque . . . . . . . 190 Nm (140 pound-feet)

STEP 36

BD00M3431. O-RING

Install an O-ring into the groove of the brake tube.

STEP 37

BD00M3441. BRAKE TUBE2. UNION SCREW

Insert the brake tube into the axle casing, assemblingthe connection part through the union screw.

1. VENT VALVE

2. CONNECTION PART

3. O-RING 4. RECTANGULAR RING

1 23

4

1

1

2

6004-31


STEP 38

BD00M345

Fasten the brake tube with the hexagon nut andunion nut.Tightening torque . . . . . . . . . 70 Nm (52 pound-feet)

STEP 39

BD00M346Tightening torque . . . . . . . . . 80 Nm (60 pound-feet)

NOTE: Repeat steps 33 to 39 for the other wheelend.

STEP 40

BD00M3471. O-RING2. SCREW PLUG3. VENT VALVE

Assemble the screw plug as shown in the abovephoto.

STEP 41

MD00M348

Install the screw plug on the axle casing.Tightening torque . . . . . . . . 70 Nm (52 pound-feet)

12

3

6004-32


ASSEMBLY OF DIFFERENTIAL CARRIERNOTE: If the ring gear or drive pinion are damaged,both parts have to be replaced together. For newinstallation of a complete bevel gear set pay attentionto the same pair number of drive pinion and ringgear.

Determine Shim Thickness for a Perfect Tooth Contact PatternNOTE: Make the following measuring steps atmaximum accuracy. In exact measurements result ina faulty tooth contact pattern and require a repeateddisassembly and assembly of the drive pinion as wellas of the differential.

STEP 42Install the CAS2873 pinion depth gauge block andCAS2289-1 gauge tube on the differential carrier.

STEP 43

BD01F106

Determine the gap between the measuring shaft andthe measuring pin with a feeler gauge.Dim. B e.g. . . . . . . . . . . . . . . . 1.00 mm (0.039 inch)Example A.:

STEP 44

BD00M350

Determine Dimension I (bearing width).Dimension I e.g. . . . . . . . . . . 36.00 mm (1.417 inch)

STEP 45

BD00M3511. 168.0 +0.05

Read Dimension II (dimension for pinion).Dimension II e.g. . . . . . . . . . 168.05 mm (6.62 inch)Example B:

Example C:

Dimension A (tool constant)204.25 mm

------(8.041 inch)

Dimension B (gap)+ 1.00 mm

------(0.039 inch)

Results in Dimension Xs = 205.25 mm -----(8.08 inch)

Dimension I36.00 mm

------(1.417 inch)

Dimension II+ 168.05 mm

------(6.616 inch)

Results in Dimension Ys = 204.05 mm -----(8.04 inch)

Dimension X 205.25 mm (8.081 inch)Dimension Y − 204.05 mm (8.033 inch)Difference = Shim e.g. s = 1.20 mm (0.048)

1

6004-33


Install the Drive Pinion

STEP 46

BD00M352

Place the determined shim e.g. S. =1.20 mm (0.05inch) into the bearing bore in the differential carrier.

STEP 47

BD01F063

Freeze the bearing outer ring and insert into thedifferential carrier using CAS2293-1, CAS2293-2,and 8073 step plate.

STEP 48

BD01F087

Freeze the bearing outer ring on the input side andinstall using CAS2293-2 and 8073 step plate.

STEP 49

BD01F065

Press the bearing inner ring on the drive pinion shaftusing CAS2297 and 8073 step plate.

6004-34


Adjust Rolling Moment of Drive Pinion Bearing

STEP 50

BD00M356

Install the spacer ring on the pinion shaft.

NOTE: As per experience the required rollingmovement 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 movementmust be done.

SM121A

STEP 51

BD00M357

Insert the assembled drive pinion into the differentialcarrier and install the heated bearing inner ring.

STEP 52

BD01F101

Press the dust shield onto the input yoke usingCAS2882 puller tube.

STEP 53

BD00M359

Install the input yoke on the pinion shaft.

STEP 54

BD00M360

Install the washer on the pinion shaft.


6004-35


STEP 55

BD01F091

Install the locknut by hand. Using CAS1579A yokeholding wrench tighten the locknut. Tightening torque . . . . . . . 700 Nm (516 pound-feet)

NOTE: When tightening rotate the drive pinion inboth directions several times.

STEP 56

BD00M362

Check rolling movement. Rolling movement shouldbe 1.5 to 3.0 Nm (1.10 to 2.21 pound-feet).

NOTE: For new bearings it should be tried toachieve the maximum value of the rolling movement.

ATTENTION: If the required rolling movement is notobtained, correct it with an adequate spacer ring,according to the following indications:Rolling movement too low - install a thinner spacerring.Rolling movement too high - install a thicker spacerring.

STEP 57Remove the locknut again and pull off the input yokefrom the drive pinion shaft.

STEP 58

BD01F098

Using CAS2288 and CAS2299, install the shaft sealwith the sealing lip showing to the oil chamber(downwards).

ATTENTION: Just before the installation wet theouter diameter of the shaft seal with a solution of50% water and 50% mineral spirits. Fill the spacebetween the sealing and dust lip with grease.

STEP 59

BD01F091

Put the input yoke in place and install the washer andlocknut. Using CAS1579A yoke holding wrenchtighten the locknut.Tighten torque . . . . . . . . . 700 Nm (516 pound-feet)

ATTENTION: Apply Loctite, Type No. 262, onto thethread of the locknut.

6004-36


ASSEMBLY OF LIMITED SLIP DIFFERENTIAL

STEP 60

BD00M427

Place both thrust washers into the differentialhousing.

STEP 61

BD00M428

Starting with an outer clutch disc install alternatelythe outer and inner clutch discs.

ATTENTION: Thickness of the disc pack must beidentical on both sides.

STEP 62

BD00M429

Insert the pressure ring into the differential housing.

STEP 63

BD00M430

Insert the axle bevel gear and slide the splined shaftinto the clutch discs.

STEP 64

BD00M431

Assemble the differential spider and insert it into thedifferential housing.

STEP 65

BD00M432

Insert the second axle bevel gear.

6004-37


STEP 66

BD00M433

Insert the second pressure ring into the differentialhousing.

STEP 67

BD00M434

Starting with an inner clutch disc install alternatelythe inner and outer clutch disc.

ATTENTION: The thickness of the clutch disc packmust be identical on both sides.

Determine the Disc Clearance

STEP 68

BD00M435

Determine dimension I, from the mounting face of thedifferential housing to the plane face of the outerclutch disc.Dimension I e.g. . . . . . . . . . . 38.05 mm (1.50 inch)

STEP 69

BD00M436

Determine dimension II, from the contact surface ofthe outer clutch disc to the mounting face of thehousing cover.Dimension II e.g. . . . . . . . . . . 37.75 mm (1.48 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 thedifference in thickness between the left and the rightdisc pack must only be 0.1 mm (0.004 inch) at amaximum.

Dimension I38.05 mm

-------(1.50 inch)

Dimension II+ 37.75mm

-------(1.49 inch)

Difference = Disc clearance = 0.30 mm

------(0.01 inch)

6004-38


STEP 70

BD00M437

Fix the thrust washer with grease into the recess ofthe differential housing cover.

STEP 71

BD00M438

Put the housing cover in place on the differentialhousing. Heat the ring gear and install onto thedifferential housing.

STEP 72

BD00M439

Put the differential in a press to prevent it fromturning and install the bolts on the ring gear.Tightening torque . . . . . . . 410 Nm (302 pound-feet)

ATTENTION: Use new locking bolts.

STEP 73

BD00M440

Press both bearing inner rings onto the differentialhousing.

STEP 74

BD00M441

Use acceptable lifting equipment and insert thedifferential into the differential carrier.

STEP 75

BD00M442

Place the bearing outer ring into the differentialcarrier.

6004-39


STEP 76

BC00M443

Install the adjusting nut by hand on the differentialcarrier.

STEP 77

BD00M444

Install the ring gear sided bearing outer ring.

STEP 78

BD00M445

Install the adjusting nut by hand on the differentialcarrier.

STEP 79

BD00M446

Install both bearing brackets and install the bolts andwashers.Tighten torque . . . . . . . . . 280 Nm (207 pound-feet)

ATTENTION: Apply Loctite Type No. 262 ontothreads of the bolts.

6004-40


Adjust Backlash and Bearing Preload

STEP 80

BD00M447

Place a dial indicator right-angled at the outerdiameter of the tooth flank (ring gear).

Adjust the pinion to ring gear backlash to the low sideof specifications (see value etched on the outerdiameter of the ring gear) by alternately turning eachof the adjusting nuts to move the ring gear closer toor further away from the pinion. Backlash is checkedusing a dial indicator against a tooth on the ring gear.

NOTE: Rotate the differential several times andrecheck the backlash.

STEP 81

BD01F072

Go to the adjusting nut opposite the ring gear andloosen the nut approximately one turn to releasepressure on the bearing. It should be very noticeablethat pressure is released on the bearing, as theadjusting nut will turn much easier.

STEP 82Tighten the adjusting nut slowly until firm contact ismade with the bearing.

NOTE: As the adjusting nut makes firm contact withthe bearing, the adjusting nut will immediately beginto turn much harder.

STEP 83To adjust the bearing preload, note the position of theadjusting nut. Now tighten the nut two additionalnotches.

STEP 84As the bearing preload is adjusted as described insteps 81, 82 and 83, pinion to ring gear backlashmay increase slightly. Check pinion backlash toconfirm that it is within specifications. If backlash isoutside of specified range, repeat step 80 through 84again.

STEP 85

BD00M449

Coat several teeth on the ring gear with marking inkand roll the ring gear in both directions over the drivepinion.

Compare the obtained tooth contact pattern with theexamples on page 4 and 5.

ATTENTION: If the tooth contact pattern differs,there has been a measuring error at determination ofthe shim. This must be corrected.

6004-41


STEP 86

BD00M450

Install both adjusting nuts with the slotted pins on thedifferential carrier.

STEP 87

BD03B035

Use suitable l i f t ing equipment and inser t thedifferential carrier into the axle casing.

NOTE: Align the two alignment marks together.

ATTENTION: Apply sealing compound on themounting surface.

STEP 88

BD00M452

Install new bolts on the differential carrier.Tighten torque . . . . . . . . . 250 Nm (185 pound-feet)

1.

BD00M453

Insert the stub shaft into the spline of the axle bevelgear.

STEP 89

BD00M454

Install the thrust washer removed at disassembly inthe sun gear shaft with grease.

6004-42


STEP 90

BD03B032

Install O-ring and hold into place with grease. Useacceptable lifting equipment and place the wheel endon the axle housing.

STEP 91

BD00M456

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, fillwith oil. See section 1002.

Section6004

6004




REAR AXLE

6004-2


TABLE OF CONTENTS

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3GEAR TOOTH CONTACT PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6WEAR MEASUREMENT ON MULTI-DISC BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6WHEEL END AND BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

BRAKE HYDRAULICS LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24High Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Low Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

REPLACE HUB SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Drive Pinion Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Drive Pinion Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Drive Pinion Bearing Rolling Torque Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Setting Backlash and Bearing Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Contact Pattern Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

6004-3


SPECIFICATIONSLubricant 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 TORQUESBolts 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 TOOLSSlide hammer puller adapter . . . . . . . . . CAS10846-3Slide hammer . . . . . . . . . . . . . . . . . . . . . . OEM4252Pressure Ring Installer . . . . . . . . . . . . . . . CAS2860Planetary Bearing Puller . . . . . . . . . . . . . . CAS2881Planetary Bearing Puller . . . . . . . . . . . . . . CAS2849Bearing Cone Puller . . . . . . . . . . . . . . . . . CAS2843Bearing Cone Puller Body . . . . . . . . . . . . . CAS2844Pinion Shaft Seal Installer . . . . . . . . . . . . . CAS2841Seal Driver. . . . . . . . . . . . . . . . . . . . . . . . . CAS2859Step Plate . . . . . . . . . . . . . . . . . . . . . . . . . CAS2510Lifting Bracket . . . . . . . . . . . . . . . . . . . . . . OEM4106Wheel Nut Socket . . . . . . . . . . . . . . . . . . 380100000Bearing Cup Installer . . . . . . . . . . . . . . . . 380100001

6004-4


GEAR TOOTH CONTACT PATTERNSIdeal Tooth Contact Pattern

BS01D011


BS01D012

DRIVE SIDE (CONVEX)

Pinion Distance Must Be Increased

BS01D009

BS01D013


BS01D014

DRIVE SIDE (CONVEX)

6004-5


Pinion Distance Must Be Decreased

BS01D010

BS01D015


BS01D016

DRIVE SIDE (CONVEX)

6004-6


LUBRICATION

BC06G003

NOTE: Refer to section 1002 of this service manual for proper lubricant.

WEAR MEASUREMENT ON MULTI-DISC BRAKE

BD00M234 BS00M071

NOTE: A wear measurement on the multi-disc brake must be made at least once a year. Wear measurementshould also be made if brake noise is heard, if braking power is reduced, or anytime it is suspected that brakingfunction 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 orequal to 4.0 mm (0.16 inch) the lined discs on both output sides must be replaced. Replace O-ring when installingthe plug. Tighten plug to a torque of 50 Nm (40 pound feet).

1. OIL DRAIN HOLE (AXLE HOUSING) 3. OIL FILL PLUG & DIPSTICK 5. BREATHER2. OIL DRAIN HOLE (OUTPUTS) 4. BRAKE BLEEDER 6. BRAKE INLET

4

4

6

3

2

1

2

5

6

5

A

6004-7


WHEEL END AND BRAKE

DisassemblyNOTE: Tools and axle shown in the followingphotographs may appear slightly different than thetools and axle you may have. The use of the toolsand disassembly/assembly of axle is the sameregardless of appearance.

STEP 1

BD06G001

Fasten axle on a stand.

STEP 2

BD06G002

BD06G003

Remove drain plugs and drain oil from axle housing.

STEP 3

BD06G004

Use lifting bracket, OEM4106, to hold wheel end.Loosen and remove the bolts and washers.

STEP 4Carefully pull the wheel end from the axle housing.Remove and discard O-ring from axle housing wheelend.

STEP 5

BD06G005

Mount the wheel end on a stand.

6004-8


STEP 6

BD06G006

Using pry bar, remove cover from output shaft.Remove and discard O-ring from cover.

STEP 7

BD06G007

Remove pin from lock nut using OEM4252 slidehammer and CAS10846-3 adapter.

STEP 8

BD06G008

Remove lock nut using socket 380100000.

STEP 9

BD06G009

Using OEM4054 pulling attachment, remove theplanetary carrier.

STEP 10

BD06G012

Remove retaining ring.

STEP 11

BD06G013

Using CAS2848 planetary gear puller and step plate8061, remove planetary gear and outer bearing fromplanetary carrier shaft. Using a suitable puller,remove the inner bearing from carrier shaft.

6004-9


STEP 12

BD06G014

Remove the bearing from the planetary usingCAS2881 collet set, CAS2849 puller body and screw.

STEP 13Repeat Steps 10, 11, and 12 to remove theremaining three retaining rings, planetary gears, andsix bearings.

STEP 14

BD06G015

Inspect the stop pin for wear, if necessary drill a holeinto the pin, use CAS10846-3 adapter and OEM4252striker and remove the pin.

STEP 15

BD00M250

Put alignment marks on planetary ring gear andbrake housing to aid in assembly. Using suitablepuller, remove planetary r ing gear from brakehousing.

STEP 16

BD00M251

Remove and discard two O-rings from planetary ringgear.

STEP 17

BD06G017

Remove and discard O-ring from brake housing port,remove the brake disc pack from brake housing.

6004-10


STEP 18

BD06G018

Using suitable tool, push the three pins down untilpins are even with top surface of shim.

STEP 19

BD06G047


STEP 20

BD06G019

WEAR FACE PROTECTION WHEN USINGCOMPRESSED AIR. Apply compressed air to brakehousing por t to push brake piston from brakehousing.

STEP 21

BD06G020

Remove the support shim from the brake piston.

STEP 22

BD06G022

Remove three pins from support shim.

STEP 23

BD06G023

Put support shim in a press and compress Bellevillewashers. Remove retaining ring and pull pin withBelleville washers and rings installed from supportshim. Repeat this step to remove the remaining fiveretaining rings and pins from support shim.

6004-11


STEP 24

BD00M260

Remove seven Belleville washers from each pin.

STEP 25

BD06G024

Using a press, remove four gripping rings from eachpin.

STEP 26

BD00M262

Lift and remove the piston from the brake housing.

STEP 27

BD00M263

BS00M072

Remove the guide ring (2), support rings (3 and 6),and U-rings (4 and 5) from the grooves of the brakehousing.

1. BRAKE HOUSING 5. GROOVED RING2. GUIDE RING 6. SUPPORT RING3. SUPPORT RING 7. WHEEL END SHAFT4. GROOVED RING

6004-12


STEP 28

BD01F102A

Using the CAS2850 brake housing puller bridge andCAS2510 step plate, pull the brake housing from thewheel end shaft and remove the inner bearing.

STEP 29

BD06G026

Use acceptable lifting equipment and lift the brakehousing from the wheel end shaft.

STEP 30

BD06G027

If replacement of bearing cups is necessary, driveboth bearing cups out of the brake housing.

STEP 31

BD06G028

Remove the face seal from the brake housing.

STEP 32

BD06G029

Remove and discard the face seal metal ring fromthe wheel end shaft.

STEP 33If the wheel end pressure ring or bearing need to bereplaced, remove the bearing from the wheel endshaft.

6004-13


Cleaning and InspectionIMPORTANT: Do not use compressed air to drybearings. Allow bearings to air dry.

STEP 34Clean all parts except friction plates in brake discpack us ing c lean ing so lven t . WEAR FACEPROTECTION WHEN USING COMPRESSED AIR.Use compressed air to clear passages in planetaryring gear and brake housing.

STEP 35Inspect bear ing ro l le rs for p i t t ing, scor ing ,deformation, or other damage. Check inner face andbearing cage for deformation, dents, and otherdamage. Check associated bear ing cups forscratches, grooves, or cracks. Check bearings forrough spots or binding by holding bearing androtating. If bearing binds or action is not smooth,replace the bearing.

STEP 36Inspect bearing cups for pitting, scoring, cracks, orother damage. Replace if any of these conditions areseen.

NOTE: If a bearing or bearing cup requiresreplacement, the associated part must also bereplaced.

STEP 37Check planetary ring gear, planetary gears, andplanetary carrier gear teeth for cracks, breaks,chipping, or other damage. Replace the part if any ofthese conditions are seen. Check planetary carriershaft spl ines for broken, cracked, or twistedcondition. Replace if necessary.

STEP 38Check wheel end shaft for cracked, broken, ortwisted splines. Replace if any of these conditionsare seen.

Assembly

STEP 39

BD06G033

Apply Loctite 574 to the seal ring mounting surface.

SM121A

STEP 40

BD06G034

Heat the seal ring to approximately 120° C (248° F),place the face seal ring on the wheel end shaft.


6004-14


STEP 41

BD06G035

Use special tool CAS2860 and drive the busing intoposition onto the hub.

NOTE: Only use the special tool to install the sealingring to ensure proper seating.

STEP 42

SM121A

BD06G036

Heat the wheel end shaft outer bearing to 120° C(248° F) in a bearing oven. Wearing heat resistantgloves or mittens, install the bearing on the wheelend shaft until the bearing is against the shoulder onthe wheel end shaft.

STEP 43

BD06G037

Using CAS2877 inner bearing cup installer, press theinner bearing cup into the brake housing until seatedagainst the shoulder in the brake housing.

STEP 44Using CAS2878 outer bearing cup installer press theouter bearing cup into the brake housing until seatedagainst the shoulder in the brake housing. WARNING: Always wear heat protective

gloves to prevent burning your hand whenhandling heated parts.

6004-15


STEP 45

BD06G032

BS00M073

Wet the outer diameter of the face seal with asolution of 50% water and 50% mineral spirits. UseCAS2880 seal installer to install the face seal withthe seal lip positioned as shown. Apply grease toseal as indicated by (A) above.

STEP 46

BD06G038

Use acceptable lifting equipment and install thebrake housing on the wheel end shaft.

STEP 47

SM121A

BD06G039

Heat the wheel end shaft inner bearing to 120° C(248° F) in a bearing oven. Wearing heat resistantgloves or mittens, install the bearing on the wheelend shaft until the bearing is against the bearing cupin the brake housing.

1. FACE SEAL2. BRAKE HOUSINGA FILL WITH GREASE

1

2

A

A A


6004-16


STEP 48

BD00M278

BC06G002

GUIDE RING, SUPPORT RINGS AND U-RINGS LOCATION

Install the support rings and U-rings in the grooves ofthe brake housing.

STEP 49

BD00M279

Clean the groove of the brake housing with cleaningsolvent. Install the guide ring in the groove. Makesure the ends (A) of the guide ring are facing uptowards the top (B) of the brake housing and theguide ring is installed completely in its groove in thebrake housing. Apply Loctite 415 to ID of guide ringto secure guide ring in its groove.

STEP 50

BD00M280

Apply oil on the sliding surface of the piston, supportrings, U-rings and guide ring. Carefully install pistonin the brake housing.

1. SUPPORT RING 4. SUPPORT RING2. GROOVED RING 5. GUIDE RING3. GROOVED RING A. BRAKE HOUSING

A B

6004-17


STEP 51

BD00M2821. GRIPPING RINGS

Press the gripping rings on the pins. Ends of grippingrings must be 180° opposite from each other.

STEP 52

BD00M283

BS00M074

Install the Belleville springs on the pins. Make suredimension (A) is 10.5 to 10.8 mm (0.41 to 0.43 inch).

STEP 53

BD00M284

Put the assembled pins into the support shim andinstall the snap ring.

STEP 54

BD00M285

Put the assembled support shim in the piston.

STEP 55

BD00M286

Install the snap ring to secure the support shim, slotof the snap ring must be between two pins.

1. PIN 4. SUPPORT SHIM2. GRIPPING RINGS 5. RETAINING RING3. BELLEVILLE SPRINGS A. 10.5 TO 10.8 MM (0.41 TO 0.43

INCH)

1

A

1

2

3

45

6004-18


STEP 56

BD00M287

BS00M075

Install the six pins (3) in the support shim (4) to lockthe 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).

STEP 57

BD06G049

Apply oil to the clutch discs. Install the outer andinner clutch discs alternately starting with an outerclutch disc.

STEP 58

BD06G051

Apply grease to new O-ring and install in the brakehousing port.

STEP 59

BD00M251

Apply grease to new O-rings and install on planetaryring gear.

STEP 60

BD06G052

Install two alignment studs in the brake housing.Posit ion the planetary r ing gear on the brakehousing. Make sure alignment marks made duringdisassembly are aligned. Use a soft faced hammerand tap the planetary ring gear into brake housing.

1. BRAKE HOUSING 4. SUPPORT SHIM2. SNAP RING 5. PISTON3. PIN A. 4.0 TO 4.5 MM

(0.15 TO 0.18 INCH)

A

6004-19


STEP 61

BD06G053

If removed, drive the stop bolt into the planetarycarrier until contact.

STEP 62

SM121A

BD06G054

Heat the planetary gears inner bearings to 120° C(248° F) in a bearing oven. Wearing heat resistantgloves or mittens, install the bearings on the shaftsuntil the bearing is against the bottom of the shaft.

STEP 63Install the planetary gears on the bearings.

STEP 64

SM121A

BD06G055

Heat the planetary gears outer bearings to 120° C(248° F) in a bearing oven. Wearing heat resistantgloves or mittens, install the bearings on the shaftsuntil the bearing is against the gear.

STEP 65

BD06G056

Install the retaining rings on the planetary gearshafts.



6004-20


STEP 66

BD06G057

Coat the spline with Loctite No. 767 antiseizelubricant.

STEP 67

BD06G058

Align the slots of the brake disks.

STEP 68

BD06G059

Install the planet carrier into the spline of the wheelend shaft using OEM4054.

STEP 69

BD06G060

Rotate the housing until the planet carrier gears areflush with the ring gear.

STEP 70

BD06G061

Pivot the housing on the stand and install the locknut.

STEP 71

BD06G062

Tighten the lock nut to a torque of 1000 Nm (737pound feet) using socket 380100000, rotate thebrake housing several time in both directions andrecheck torque.

6004-21


STEP 72

BD06G063

Install a new slotted pin into the wheel end lock nut.

NOTE: If the slot is not aligned tighten the nut toalign the slot, never loosen the nut to align the slot.

STEP 73

BD06G064

Install a new O-ring on the wheel end cover.

STEP 74

BD06G065

Install the cover into the wheel end.

6004-22


Sun Gear Shaft End Play Adjustment

STEP 75

BD06G066

Using two M18 bolts of suitable length, secureplanetary ring gear to brake housing.

STEP 76Take a measurement from the straight edge to theface of the planetary gear r ing, the differencebetween this measurement and the measurement inthe next step will be dimension A.

STEP 77

BD06G067

Mount the sun gear into the planet gears. Then,determine dimension A, from the inner face of thesun gear to the face of the planetary ring gear.

Example:Dimension A . . . . . . . . . . . . . 97.90 mm (3.85 inch)

STEP 78Install the stub shaft in the spline of the axle bevelgear. Make sure the stub shaft is installed all the wayinto the axle bevel gear.

STEP 79

BD06G068

Determine dimension B from the face of the stubshaft to the mounting face of the axle housing.

Example:Dimension B . . . . . . . . . . . . . 100.20 mm (3.95 inch)

STEP 80Subtract dimension A from dimension B. Thensubtract 1.30 mm (0.05 inch) from the difference. Thedifference is the required shim size.Example:

STEP 81

BD06G069

Install the shim set (size as determined in Step 80above) into the sun gear shaft with grease.

Dimension B 100.20 mm (3.94 inch)Dimension A − 97.90 mm (3.85 inch)Difference 2.30 mm (0.09 inch)Required end play − 1.30 mm (0.05 inch)Difference = shim size

1.00 mm (0.04 inch)

6004-23


STEP 82

BD06G070.

Remove the two M18 bolts securing the planetaryring gear to brake the housing.

STEP 83

BD06G071

Apply grease to a new O-ring and install O-ring inbrake port.

STEP 84

BD06G072

Use l i ft ing bracket, OEM4106, and install theassembled wheel end onto the axle housing.

NOTE: Turn the input flange to align splines of thestub shaft into the sun gear.

STEP 85

BD00M300

Install the washers and bolts to secure the wheel endto the axle housing. Tighten the bolts to a torque of440 Nm (325 pound feet).

6004-24


BRAKE HYDRAULICS LEAKAGE TESTIMPORTANT: DO NOT EXCEED 100 BAR (1450PSI) PRESSURE IN THE FOLLOWING STEPS. Ifthe maximum pressure of 100 bar (1450 psi) isexceeded, the piston will move too much changingthe gripping rings adjustment. If the gripping ringsadjustment changes, the wheel end must beremoved and disassembled and the gripping ringsadjusted to the correct dimension (Step 51).

STEP 86

BD00M305

Connect a hand pump with pressure gauge to thebrake port as shown above. Fill the hand pump withhydraulic oil. Build up pressure in the axle internalbrake lines then bleed air from the lines. After air isbled, actuate the brakes a minimum of 5 times to apressure of 100 bar (1450 psi) by operating the handpump.

High Pressure Test

STEP 87Operate the hand pump to increase pressure to 100bar (1450 psi) maximum. Close connection to handpump using the shutoff valve. During a 5 minuteperiod, pressure shall not drop more than 2 bar (29psi).

Low Pressure Test

STEP 88Reduce pressure to 5 bar (72.5 psi) and close theshutoff valve. During a 5 minute period pressure shallnot drop.

6004-25


REPLACE HUB SEAL

Removal

STEP 89

BD06G074

Remove drain plug and drain oil from the brakehousing.

STEP 90

BD06G075

Use pry bar and remove the end cover.

STEP 91

BD06G076

Use a slide puller and remove the slotted pin from thelock nut.

STEP 92

BD06G077

Loosen and remove the lock nut using socket380100000.

STEP 93

BD06G078

Use lifting bracket, OEM4106, to hold wheel end.Separate the output shaft using a puller.

STEP 94

BD06G079

Use a pry bar and remove the seal form the brakehousing.

6004-26


STEP 95

BD06G080

Inspect the bushing for wear marks where the sealmakes contact, if required remove the bushing.

Installation

STEP 96

BC06G005

Install the seal as shown above with wipers (3) facingout towards bushing (4).

STEP 97

BD06G081

Lubricate the outer diameter of the seal with water,use driver CAS2859 and install the seal.

STEP 98

BD06G082

Put a bead of Loctite 574 on the bushing mountingsurface.

STEP 99

SM121A

BD06G083

Heat the bushing to 120° C (248° F) and place thebushing onto the output shaft.


6004-27


STEP 100

BD06G084

Use special tool CAS2860 and drive the busing intoposition onto the hub.

NOTE: Only use the special tool to install the sealingring to ensure proper seating.

STEP 101

BD06G085

Heat the inner bearing to 120° C (248° F).

STEP 102

BD06G086

Grease the seal lip of the shaft seal, use liftingbracket, OEM4106, and install the wheel end ontothe brake housing.

STEP 103

BD06G087

Install the lock nut, tighten the lock nut to a torque of1000 Nm (737 pound feet) using socket 380100000,rotate the brake housing several t ime in bothdirections and recheck torque.

STEP 104

BD06G088

Install a new slotted pin into the wheel end lock nut.

NOTE: If the slot is not aligned tighten the nut toalign the slot, never loosen the nut to align the slot.

STEP 105

BD00M304

Install a new O-ring on the wheel end cover, installthe cover into the wheel end.

6004-28


DIFFERENTIAL

Removal

STEP 106

BD06G002

BD06G003

Remove drain plugs and drain oil from axle.

STEP 107

BD06G126

Fasten the axle to a stand, support the center of theaxle as shown, facing the input shaft attach suitablelifting equipment to the left axle housing, remove themounting bolts and axle half.

ATTENTION: Differential can fall out of housingwhen axle half is removed.

STEP 108

BD06G127

Connect lifting equipment to the differential andremove the differential from axle housing.

NOTE: Make sure that the right axle stub shaftreleases from the differential.

DisassemblySTEP 109

BD01F059

Remove the bearing from the differential housingusing CAS2848 puller, OEM4175 pulling attachment,1103 puller legs, and 8065 step plate.

6004-29


STEP 110

BD01F075

Remove the bearing from the housing cover usingCAS2871 collet set, CAS2882 puller body, and 8067step plate.

STEP 111

BD00M323

Place the differential in a press to prevent it fromturning. Remove the bolts.

STEP 112

BD00M324

Remove the housing cover from the differentialhousing.

STEP 113

BD06G129

Remove all parts from the differential housing.

STEP 114

BD00M326

Press the ring gear from the differential housing.

STEP 115

BD06G131

Pull the outer bearing ring and shims from both axlehousings.

NOTE: Make sure to identify the shims into whichaxle housing they were removed.

6004-30


BC06G001

1. BEARING 5. OUTER CLUTCH 9. PINION, BEVEL2. HOUSING 6. PLATE 10. SHAFT3. WASHER, THRUST 7. DIVIDER 11. COVER4. SHIM 8. GEAR, BEVEL 12. BOLT, M15 X 45

1

23 4

56

78

9

10

9

8 7

3 411

12 1

65

6004-31


AssemblyNOTE: The ring gear and the drive pinion are amatched gear set and cannot be serviced separately.

STEP 116

SM121A

BD06G149

Heat the ring gear to 120° C (248° F) in a bearingoven. Wearing heat resistance gloves or mittens,install the ring gear on the differential.

NOTE: Make sure to align the bolt holes.

STEP 117

BD06G150

Install both thrust washers into the differential carrier,the brass thrust washer must be towards the bevelgear as shown, refer to illustration on page 30.

NOTE: Be sure to apply oil to all parts beforeassembly.

STEP 118

BD06G151

Install the disk package starting with an outer clutch,refer to illustration on page 30.

STEP 119

BD06G152

Install the divider in the differential housing.

STEP 120

BD06G153

Install the axle bevel gear. Make sure axle bevel gearsplines mate with splines of all inner clutch plates.


6004-32


STEP 121

BD06G154

Assemble the differential spider and install into thedifferential housing.

STEP 122

BD06G155

Install the second axle bevel gear.

STEP 123

BD06G156

Install the second divider in the differential housing.

STEP 124

BD06G157

Starting with an clutch plate, install alternately theplate and outer clutch.

NOTE: Thickness of disc packs must be the sameon both sides.

Determine Disc Clearance

STEP 125

BD06G158

Determine dimension A, from mounting face of thedifferential housing to face of the outer clutch disc.Dimension A (Example). . . . . . 38.05 mm (1.50 inch)

6004-33


STEP 126

BD06G159

Determine dimension B, from contact surface of theouter clutch disc to mounting face of the housingcover.Dimension B (Example). . . . . . 37.65 mm (1.48 inch)Example B:

NOTE: If required disc clearance of 0.040 mm (0.02inch) is not obtained, install new outer clutch discs ofthickness necessary to obtain 0.040 mm (0.002 inch)disc clearance. The left and right clutch packs mustbe the same thickness. Outer clutch discs areavailable in following thicknesses: 2.9 mm (0.114inch), 3.0 mm (0.118 inch), 3.1 mm (0.122 inch).

STEP 127

BD06G160

Install the thrust washers with grease in the recess ofthe housing cover.

NOTE: Mount the brass thrust washer (on top)towards the bevel gear.

STEP 128

BD06G161

Place the differential in a press to prevent it fromturning. Install new bolts and tighten bolts to a torqueof 390 Nm (288 pound feet).

NOTE: Use new bolts only.

STEP 129

BD06G162

Press both bearings on the differential.

Dimension A38.05 mm

-------(1.50 inch)

Dimension B+ 37.65 mm

-------(1.48 inch)

Difference = Disc clearance = 0.40 mm

------(0.02 inch)

6004-34


Drive Pinion RemovalSTEP 130Heat lock nut securing flange with a hot air blower toloosen Loctite, approximately 120° C (248° F).

STEP 131

BD06G132

Install holding wrench on input flange. Hold flangeusing holding wrench, CAS1579A, and remove locknut and washer. Remove holding tool from flange.

STEP 132Remove the input flange from the drive pinion.

STEP 133

BD06G133

Remove the shaft seal from the axle drive housing.

STEP 134

BD06G134

Press the input pinion out of the housing.

STEP 135

BD06G135

Remove the spacer ring from the drive pinion.

STEP 136

BD06G136

Press the bearing inner ring from the drive pinionusing CAS2843 and CAS2844 puller body and colletset.

STEP 137Drive out both bearing cups from the differentialcarrier.

6004-35


Drive Pinion Installation

STEP 138

BD06G137

Find and record the housing dimension “X”.Dimension X (Example). . . . . 205.30 mm (8.08 inch)

STEP 139

BD06G138

Measure the thickness of the inner bearing andrecord its measurement, dimension “I”.Dimension I (Example) . . . . . 36.13 mm (1.422 inch)

NOTE: Deduct the thickness of the gauge blocksbeing used to support the bearing from the overallmeasurement,IE: overall measurement 106.13 mm (4.178 inch)minus gauge block thickness 70 mm (2.756 inch) willequal dimension I.

STEP 140

BD06G1391. 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 nodistance deviation is indicated the pinion basicdimension 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 141Calculation example A:

Calculation example B:

NOTE: Shims are available in 0.10 mm (0.004 inch),round up or down to the next available shimthickness, s = 1.20 (0.044 inch)

Dimension I36.13 mm

-------(1.422 inch)

Dimension II+ 167.95 mm

-------(6.612 inch)

Results in dimension Y = 204.08 mm ------(8.034 inch)

Dimension X205.30 mm

-------(8.080 inch)

Dimension Y− 204.08 mm

-------(8.034 inch)

Difference = shim thickness

= 1.22 mm ------(0.046 inch)

1

2

3

6004-36


STEP 142

BD06G140

Heat the bearing hole to approximately 120° C (248°F) and install the outer bearing until contact is madeusing the outer bearing cup installer of 380100001.

STEP 143

BD06G141

Install the shim set determined in Step 141 in thebearing bore on the differential carrier.

STEP 144

BD06G142

Heat the bearing hole to approximately 120° C (248°F) and pull the bearing into to the bearing hole using380100001.

STEP 145

BD06G143

Press the inner bearing on the drive pinion shaft.

Drive Pinion Bearing Rolling Torque Adjustment

STEP 146

BD06G144

Install an 9.03 mm (0.35 inch) thick spacer on thepinion shaft.

6004-37


STEP 147

SM121A

BD06G145

Heat the pinion shaft outer bearing to 120° C (248°F) in a bearing oven. Wearing heat resistance glovesor mittens, install the bearing on the pinion shaft untilcontact.

NOTE: Prior to mounting the input flange andtightening the nut, allow the bearing to cool toambient temperature.

STEP 148

BD06G146

Press the dust shield on the input flange.

STEP 149

BD06G147

Install the input flange on the pinion shaft.

STEP 150Put the washer in place on the pinion shaft.

STEP 151Install holding wrench, CAS1579A, on input flange.Hold flange using holding tool and tighten nut to atorque of 700 Nm (515 pound feet). Remove holdingwrench.

NOTE: When tightening rotate the pinion shaft inboth directions several times.

STEP 152

BD06G148

Check the rolling torque of the drive pinion bearing.The rolling torque should be 1.5 to 3.0 Nm (13.3 to26.5 lb-inch). If rolling torque is too low, install athinner spacer (Step 146); if rolling torque is too high,install a thicker spacer (Step 146).

STEP 153Remove the nut and input yoke from the drive pinionshaft.


6004-38


Setting Backlash and Bearing Preload

STEP 154

BD06G163

Record the deviation value on the ring gear, the valuewill be a + or -, use the table to determine shimthicknesses needed.

Example: Deviation value of +10 requires thefollowing shims:Shim A = 0.90Shim B = 1.10

STEP 155

BC06G004

STEP 156

BD06G164

Insert shim A (0.90 mm) and install the bearing outerring until seated.

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

1. DIFFERENTIAL 5. AXLE HOUSING2. DRIVE HOUSING A. RING GEAR SIDE3. AXLE HOUSING B. CARRIER SIDE4. INPUT PINION

A

1 2

B

354

6004-39


STEP 157

BD06G165

Insert shim B (1.10 mm) and install the bearing outerring until seated.

Contact Pattern Check

STEP 158

BD06G166

Apply marking ink on several teeth of the ring gear.

STEP 159

BD06G167

Position the differential assembly in the axle drivehousing.

STEP 160

BD06G168

Position the axle housing on the drive housing, install4 bolts, top center, bottom center, front center, rearcenter, torque bolts evenly to 390 Nm (285 poundfeet).

STEP 161

BD06G169

Roll the input pinion several times in both directionsover the ring gear. Remove the differential andcompare the contact pattern with examples on page4 and page 5.

NOTE: If the tooth contact pattern differs, the wrongshim size was selected in Step 143. Removedifferential and repeat Steps 138 though 144.

6004-40


Installation

STEP 162

BD06G170

Install a new O-ring on the axle housing. Position theaxle housing on the drive housing, install bolts andtorque bolts evenly to 290 Nm (215 pound feet).

STEP 163

BD06G171

Loosen and remove the nut and input flange.

STEP 164

BD06G172

Install the shaft seal with the sealing lip towards oilsump using pinion shaft seal install CAS2841.

NOTE: Wet the outer diameter of the seal with asolution of 50% water and 50% mineral spirits. Fillthe space between the sealing and dust lip withgrease.

STEP 165

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 andlocknut by hand. Hold flange using holding tool andtighten nut to a torque of 700 Nm (516 pound feet).

NOTE: Rotate the input pinion several times in bothdirections when tightening.

Section6005

6005




DRIVE SHAFTS, CENTER BEARING, AND UNIVERSAL JOINTS

6005-2


TABLE OF CONTENTS

SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3FRONT DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3FRONT DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4CENTER BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5CENTER BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6CENTER DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

REAR DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

ENGINE DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

UNIVERSAL JOINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

6005-3


SPECIAL TORQUESCoupler 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 1

BD03A166

Loosen and remove the bolts and straps that fastenthe center drive shaft to the yoke of the front driveshaft.

STEP 2

BD03A183

Remove the lock nut that fastens the yoke to the frontdrive shaft.

STEP 3Make an alignment mark on the yoke and the end ofthe front drive shaft to make sure that the yoke isinstalled correctly.

STEP 4Use an acceptable puller and remove the yoke fromthe end of the front drive shaft.

STEP 5Loosen the set screws that secure the center bearingto the front drive shaft.

STEP 6Remove any paint or rust from the rear of the frontdrive shaft and apply WD40 or similar oil to loosenany rust between the inner race and the front driveshaft.

STEP 7

BD03A167

Loosen and remove the bolts and straps that fastenthe front drive shaft to the front axle.

STEP 8Use a prybar to disengage the front drive shaft fromthe front axle and remove the front drive shaft fromthe machine.

NOTE: If necessary, use a brass hammer to drivethe front drive shaft out of the center bearing.

6005-4


FRONT DRIVE SHAFT

Installation

STEP 9Apply antiseize compound to the bearing area of thefront drive shaft.

STEP 10Place the front drive shaft into position in the centerbearing of the machine.

STEP 11

BD03A167

Install the bolts and straps that fasten the front driveshaft to the front axle. Tighten the bolts to a torque of75 to 81 Nm (55 to 60 pound feet).

STEP 12Apply antiseize compound to the splines on the frontdrive shaft.

STEP 13Install the yoke to the front drive shaft, making surethe alignment marks made during removal arealigned.

NOTE: If a new front drive shaft has been installed,make sure the yoke being installed is 90° to the yokeon the other end of the front drive shaft.

STEP 14

BD03A183

Install the lock nut and washer which fastens theyoke to the front drive shaft. Tighten the lock nut to atorque of 339 to 375 Nm (250 to 275 pound feet).

STEP 15Tighten the set screws that secure the center bearingto the front drive shaft alternately until they stopturning and the hex head socket wrench starts tospring.

STEP 16

BD03A166

Install the bolts and straps that fasten the front driveshaft to the center drive shaft. Tighten the bolts to atorque of 75 to 81 Nm (55 to 60 pound feet).

6005-5


CENTER BEARING

Removal

STEP 17

BD03A166

Loosen and remove the bolts and straps that fastenthe center drive shaft to the front drive shaft.

STEP 18

BD03A183

Loosen and remove the lubrication hose from thecenter bearing

STEP 19

BD03A183

Loosen and remove the lock nut that fastens the yoketo the front drive shaft.

STEP 20Make an alignment mark on the yoke and the frontdrive shaft to be sure that the yoke is installedcorrectly.

STEP 21Use an acceptable puller and remove the yoke fromthe end of the front drive shaft.

STEP 22Remove any paint or rust from the rear of the frontdrive shaft and apply WD40 or similar oil to loosenany rust between the inner race and the front driveshaft.

STEP 23Loosen the set screws that secure the center bearingto the front drive shaft.

STEP 24

BD03A183

Loosen and remove the bolts, washers and nuts thatfasten the bearing housing to the front frame.

STEP 25Install two longer bolts, at least 3 inches, to hold thebearing housing during removal. Use an acceptablepuller to remove the bearing housing from the frontdrive shaft.

6005-6


CENTER BEARING

InstallationNOTE: The center bearing and the bearing housingare not serviced separately. If the center bearing isworn or damaged or if the bearing housing iscracked, a new center bearing and bearing housingmust be used.

STEP 26Apply antiseize compound to the bearing area of thefront drive shaft.

STEP 27Install the bearing housing so that the lubricationfitting is at the top.

STEP 28

BD03A183

Apply Loctite 242 to bolt threads. Install the bolts,washers and nuts that fasten the bearing housing tothe front frame. Tighten the bolts to a torque of 99 to128 Nm (73 to 94 pound feet).

STEP 29

BC05M214

Turn the set screw down to the shaft and then back itoff 1/4th turn and lock it with the jam nut. Repeat theprocedure with the other set screw.

STEP 30Apply antiseize compound to the splines on the frontdrive shaft. Install the yoke to the front drive shaft,making sure the alignment marks made duringremoval are aligned.

STEP 31

BD03A183

Install the washer and lock nut that fasten the yoke tothe front drive shaft. Tighten the lock nut to a torqueof 339 to 375 Nm (250 to 275 pound feet).

STEP 32

BD03A166

Install the straps and bolts that fasten the centerdrive shaft to the yoke on the front drive shaft.Tighten the bolts to a torque of 75 to 81 Nm (55 to 60pound feet).

STEP 33Install the lubrication hose into the fitting on thebearing housing.

STEP 34Lubr icate the center bear ing with the greasespecified in Section 1002.

6005-7


CENTER DRIVE SHAFT

Removal

STEP 35

BD03A166

Loosen and remove the bolts and straps that fastenthe center drive shaft to the yoke of the front driveshaft.

STEP 36Use a prybar to disengage the center drive shaft fromthe yoke of the front drive shaft.

STEP 37

BD03A165

Loosen and remove the bolts and straps that fastenthe center drive shaft to the transmission.

STEP 38Hold the center drive shaft and remove from themachine.

Installation

STEP 39

BD03A165

Hold the center drive shaft in position and install thebolts and straps that fasten the center drive shaft tothe transmission. Tighten the bolts to a torque of 75to 81 Nm (55 to 60 pound feet).

STEP 40

BD03A166

Install the bolts and straps that fasten the centerdrive shaft to the yoke of the front drive shaft. Tightenthe bolts to a torque of 75 to 81 Nm (55 to 60 poundfeet).

6005-8


REAR DRIVE SHAFT

Removal

STEP 41

BD01D323

Loosen and remove the bolts and straps that fastenthe rear drive shaft to the transmission.

STEP 42Use a prybar to disengage the rear drive shaft fromthe transmission.

STEP 43

BD01F304

Loosen and remove the bolts and straps that fastenthe rear drive shaft to the rear axle.

STEP 44Hold the rear drive shaft and remove from themachine.

Installation

STEP 45

BD01F304

Hold the rear drive shaft into position and install thebolts and straps that fasten the rear drive shaft to therear axle. Tighten the bolts to a torque of 75 to 81 Nm(55 to 60 pound feet).

STEP 46

BD01D323

Install the bolts and straps that fasten the rear driveshaft to the transmission. Tighten the bolts to atorque of 75 to 81 Nm (55 to 60 pound feet).

6005-9


ENGINE DRIVE SHAFT

Removal

STEP 47

BD01D342

Remove and discard the bolts and straps that fastenthe engine drive shaft to the transmission.

IMPORTANT: The bolts and straps that fasten theengine drive shaft to the transmission must bereplaced when removed.

STEP 48

BD03A172

Loosen and remove the six bolts that fasten theengine drive shaft to the engine.

STEP 49Remove the engine drive shaft from the machine.

Installation

STEP 50

BD01D342

Place the engine drive shaft into position on thetransmission and install new straps and bolts.Tighten the bolts to a torque of 61 to 81 Nm (45 to 60 pound feet).

STEP 51

BD03A172

Apply Loctite 242 to bolt threads. Install the six boltsthat fasten the engine drive shaft to the engine.Tighten the bolts to a torque of 53 to 62 Nm (39 to 46pound feet)

6005-10


UNIVERSAL JOINTS

Removal

STEP 52Remove the drive shaft from the machine.

STEP 53

BD01F304

Remove the ring (1) and the bearing (2) from thedrive shaft.

NOTE: The above photo shows the drive shaft onthe machine and is for reference of the ring andbearing only.

STEP 54Remove the universal joint from the drive shaft.

InstallationNOTE: The bearing race and journal that make upthe universal joint are not serviced separately. If thebearing race or journal is worn or damaged, a newuniversal joint must be used.

STEP 55Clean the slots in the yoke of the drive shaft.

STEP 56Install the universal joint and install the bearings (2)and the rings (1). Refer to the photo in Step 53.

STEP 57Install the drive shaft.

1. RING 2. BEARING

12

Section6006

6006




WHEELS AND TIRES

6006-2


TABLE OF CONTENTS

WHEELS AND BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Torque Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

TIRE PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3CHANGING TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3INSTALLING A WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Wheel Bolt Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

6006-3


WHEELS AND BOLTS

General InformationThe wheel bolts must be tightened after every 20hours of operation until the wheel bolts stay tight:

A. If the machine is new.

B. If a wheel has been removed and installed.

Torque SpecificationTighten the wheel bolts to 298 Nm (220 pound-feet)in the sequence shown in Figure 1. Then a finaltorque of 640 to 720 Nm (475 to 530 pound-feet) inthe same sequence.

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 TIRES1. Have a qualified tire mechanic service the split

rim wheels used on this machine.

2. The correct tire equipment, especially a tireinflation cage, is required. Using the wrongprocedure for a split rim wheel can result indeath.

IMPORTANT: When installing a Michelin tire,lubricate the tire with a tire mounting lubricant andinflate the tire to 551 kPa, 5.5 bar (80 psi) to makesure that the tire is seated on the rim. Then decreasethe pressure to the specified pressure.

INSTALLING A WHEEL1. 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 wheelbolts.

3. Use a hand wrench (not an impact) to tighten thewheel bolts to pul l the wheel against theplanetary housing. DO NOT use an impactwrench to tighten the wheel bolts.

4. Tighten the wheel bolts to 298 Nm (220pound-feet) in the sequence shown in Figure 1.Then t ighten the wheel bolts in the samesequence to 640 to 720 Nm (475 to 530pound-feet).

The split rim wheels used on this machinecan be dangerous. When inflating a tire onthe machine, use a self-locking nozzle andstand at the front or rear of the tire.

When inflating a tire off the machine, putthe wheel in a t ire inflation cage. Theretaining ring and rim can come off withenough force to result in death to a personin front of the rim.

48-44

6006-4


BS06G052

WHEEL BOLT TORQUE SEQUENCE

Section6007

6007


Printed in U.S.A.Issued March, 2006

CNH America LLC.245 E NORTH AVENUECAROL STREAM, IL 60188 U.S.A. Bur 6-81450

TRANSMISSION CONTROL VALVE

6007-2


TABLE OF CONTENTS

Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

6007-3


CONTROL VALVE

Disassembly

STEP 1

BD06A007

Mark the installation position of the wiring harness tothe valve block.

STEP 2

BD06A008

Loosen and remove the cap screws that secure thedistribution plate and intermediate plate to the valvebody, remove the intermediate plate and distributionplate.

STEP 3

BD06A009

Remove the wiring harness retaining clamp.

STEP 4

BD06A010

Loosen and remove the cap screws, remove thecover. Remove the opposite cover.

STEP 5

BD06A011

Remove the wiring harness.

STEP 6

BD06A012

Loosen and remove the retaining plate cap screws,remove the retaining plates and solenoids.

6007-4


STEP 7

BD06A013

Loosen and remove two cap screws, install twoadjusting screws. Loosen and remove the remainingcap screws.

STEP 8

BD06A014

Separate the housing from the valve body by equallyloosening the adjusting screws.

STEP 9

BD06A015

Remove the components.

STEP 10

BD06A016

Remove the opposite solenoids, housing, andcomponents.

6007-5


Inspection1. Clean all metal parts in cleaning solvent.

2. Immerse end housings, valve housing, valveplate, and distribution plate in cleaning solventand agitate cleaning solvent. WEAR EYEPROTECTION WHEN USING COMPRESSEDAIR. Use compressed air to remove foreignmatter from interior of housings and plates and toensure that all bores are clear of foreign matter.

3. WEAR EYE PROTECTION WHEN USINGCOMPRESSED AIR. Use compressed air toensure 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 forcorrosion, cracks, breaks, chipping or otherdamage. Check bores in housings for deepscratches, gouges, and other damage. Replacea housing or cover if any of the above conditionsare seen.

6. Check pressure regulators for cracks, breaks, orother damage. Check connector contacts forlooseness or signs of corrosion. Replace apressure regulator if any of these conditions areseen. Check resistance of pressure regulatorsusing a multimeter. Replace a pressure regulatorif resistance is not 17 to 21 ohms.

7. Check wiring harness connectors for signs ofbreaks, cracks, or other damage. Check contactsfor foreign matter or corrosion. Check harnesswiring for signs of broken or cracked insulationand broken or frayed wiring at connection toconnectors. Replace wiring harness if any ofthese conditions are seen.

8. Check springs for cracks, breaks, distortion, orsigns of permanent set. Replace a spring if anyof these conditions are seen.

9. Inspect pistons for cracks, breaks, chipping,grooves, or other damage. Replace if any ofthese conditions are seen.

Assembly NOTE: Apply clean engine oil (15W-40) to pistonsand springs, orifices, new O-rings, and filter screensbefore assembly.

STEP 11

BD06A017

Place the valve body on the bench with the orificesup.

STEP 12

BD06A018

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).

1. VIBRATION DAMPER 3. PRESSURE REDUCING VALVE2. PISTONS

12

3

12

6007-6


STEP 14

BD06A020

Install the adjusting screws, gasket, and housingcover.

STEP 15

BD06A021

Tighten the adjusting screws equally until the cover isflush on the valve body.

STEP 16

BD06A022

Push the pistons down through the pressurecontroller wholes and remove the roll pins.

STEP 17

BD06A023

Install the cap screws and torque in a criss crosspattern to 7.5 Nm (66.3 pound-inch).

STEP 18

BD06A024

Install the solenoids and secure them with theretaining plates and cap screws. Torque the capscrews to 5.5 Nm (48.5 pound-inch).

NOTE: Install the retaining plate with the necktowards valve body, install controllers withconnectors as shown.

STEP 19

BD06A025

Install components in positions shown.

1. VIBRATION DAMPER 3. MAIN PRESSURE VALVE2. PISTONS

1

2

31

2

6007-7


STEP 20

BD06A026

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 housingcover.

STEP 21

BD06A023

Install the cap screws and torque in a criss crosspattern to 7.5 Nm (66.3 pound-inch).

STEP 22

BD06A027

Install the solenoids and secure them with theretaining plates and cap screws. Torque the capscrews to 5.5 Nm (48.5 pound-inch).

NOTE: Install the retaining plate with the necktowards valve body, install controllers withconnectors as shown.

STEP 23

BD06A028

Install the wiring harness with connector on side ofvalve body marking made during disassembly.Connect wiring harness to the solenoids.

STEP 24

BD06A029

Install the gasket, install the wiring harness plug inthe cover. Install the cap screws and torque in a crisscross pattern to 7.5 Nm (66.3 pound-inch).

STEP 25

BD06A030

Install the wiring harness retaining clamp.

6007-8


STEP 26

BD06A031

Install the screens into the bores of the intermediateplate towards the distribution plate.

STEP 27

BD06A032

Install two adjusting screws. Place the intermediateplate with the screens facing up.

STEP 28

BD06A033

Install the distribution plate, install the cap screwsand torque in a criss cross pattern to 9.5 Nm (84pound-inch).

STEP 29

BD06A034

Install new o-rings on the plugs, install and torqueplugs to 6 Nm (53 pound-inch).




SECTION INDEX

BRAKES

Removal and Installation of Brake Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7001

Hydraulic Brake Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7002

Brake Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7003

Brake Accumulators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7004

Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7008


Section7001

7001




REMOVAL AND INSTALLATION OF BRAKE COMPONENTS

7001-2


TABLE OF CONTENTS

BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE BRAKE AND PARKING BRAKE ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

BRAKE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

7001-3


BC05M136

COMPONENT LOCATION ILLUSTRATION

1. FRONT AXLE 5. FRONT ACCUMULATOR2. REAR AXLE 6. REAR ACCUMULATOR3. BRAKE VALVE 7. BRAKE PUMP4. PARKING BRAKE ACCUMULATOR 8. CONNECTOR TO FAN VALVE

1

2

4

5

6

3

7

8

7001-4


BRAKE VALVE

Removal 1. Park the machine on a level surface and lower

the loader bucket to the floor. Stop the engine.

2. Put blocks on both sides of each tire to preventmachine movement.

3. Make sure the brake accumulators arecompletely discharged. Push down and releasethe brake pedals at least 30 times.

4. Turn the master disconnect switch to the OFFposition.

5. Remove the cab skirts located under the cab orcanopy.

6. To release the pressure on the parking brakeaccumulator, the line at the accumulator must beSLOWLY cracked open. A pan will be needed tocatch the hydraulic oil.

7. Connect a drain hose to the quick disconnectcouplings in each brake circuit to release anypressure in the brake circuit.

8. Clean the brake valve (1) and lines, refer to theillustration on page 5.

9. Put identification tags on all electrical andhydraulic lines that are connected to the brakevalve (1).

10. Connect a vacuum pump to the hydraulicreservoir. Start the vacuum pump

11. Disconnect the lines from the brake valve (1) andput plugs in each line.

12. Remove the brake valve (1).

Installation 1. Install the brake valve (1) in the cab or canopy.

Refer to the illustration on page 5.

2. Remove the plugs from the hydraulic lines andconnect the hydraulic lines to the brake valve (1).

3. Stop the vacuum pump and remove.

4. Connect all of the electrical connections.

5. Turn the master disconnect switch to the ONposition.

6. Bleed the brake system. See Section 7002.

7. Install the cab skirts.

8. Check the hydraulic reservoir oil level and add oilas required. See Section 1002 for the correct oil.

7001-5


BC05M137

BRAKE VALVE ILLUSTRATION

1. BRAKE VALVE 6. FRONT BRAKE LINE2. REAR ACCUMULATOR LINE 7. REAR BRAKE LINE3. PARKING BRAKE LINE 8. FRONT ACCUMULATOR4. BRAKE PUMP INPUT 9. RETURN TO TANK5. BRAKE VALVE DISCHARGE 10. PARKING BRAKE ACCUMULATOR

1

2

3

4

5

6

7

8

910

7001-6


SERVICE BRAKE AND PARKING BRAKE ACCUMULATORS

Removal1. Park the machine on a level surface and lower



3. Make sure the service brake accumulators (1)and the parking brake accumulator (2) arecompletely discharged. Push down and releasethe brake pedal at least 30.


5. Remove the left cab skirt located under the cabor canopy to gain access to accumulators.

6. To release the pressure on the parking brakeaccumulator, the line at the accumulator must beSLOWLY cracked open. A pan will be needed tocatch the hydraulic oil.

7. Connect a drain hose to the quick disconnectcouplings in each brake circuit to release anypressure in the brake circuit.

8. Clean the brake accumulators (1), parking brakeaccumulator (2) and lines. Refer to illustration onpage 7.

9. Put identification tags on the line that isconnected to the parking brake accumulator (2).


11. Disconnect the tubes from both brakeaccumulators (1).

12. Loosen the clamp stud (8) on the accumulatorclamp (7).

13. Remove the accumulators (1) from theaccumulator clamps (7).

14. Install plugs in the tubes.

15. Disconnect the hose from parking brakeaccumulator (2).

16. Remove the nut (3), remove the parking brakeaccumulator (2).

17. Install a plug in the hose.

Installation1. 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 thebracket.

5. Install the nut (3) and tighten.

6. Connect the line to the parking brakeaccumulator (2).


8. Install the left cab skirt.



11. Refer to Section 7008 and perform the ParkingBrake Test Procedure.


7001-7


BC05M138

BRAKE AND PARKING BRAKE ACCUMULATORS ILLUSTRATION

1. BRAKE ACCUMULATORS 5. TUBE FRONT BRAKE ACCUMULATOR2. PARKING BRAKE ACCUMULATOR 6. TUBE REAR BRAKE ACCUMULATOR3. MOUNTING NUT 7. CLAMP ACCUMULATOR4. HOSE PARKING BRAKE ACCUMULATOR 8. CLAMP STUD

1

2

7

4

3

6

5

1

7

8

8

7001-8


BRAKE PUMP

Removal1. Park the machine on a level surface and lower




4. Clean the brake pump (1) and lines, refer to theillustration on page 9.

5. Put identification tags the lines that areconnected to the brake pump (1).


7. Disconnect the lines from the brake pump (1)and put plugs in each line.

8. Remove the mounting bolts (2) and washers (3)from the brake pump (1) and remove the brakepump (1).

Installation1. Install gear (6) onto the pump shaft, install

washer (7) and slotted nut (8), torque nut to 70 to79 Nm (52 to 58 pound feet). Refer to theillustration on page 9.

2. Install the cotter pin (9).

3. Install the brake pump (1), mounting bolts (2) andwashers (3).

4. Torque mounting bolts (2) to 57 to 65 Nm (42 to48 pound feet).

5. Remove the plugs or caps and connect the linesto the brake pump (1).





7001-9


BC05M139

BRAKE PUMP ILLUSTRATION

1. BRAKE PUMP 4. SUCTION HOSE 7. WASHER2. MOUNTING BOLT (2) 5. PRESSURE HOSE 8. SLOTTED NUT3. WASHER (2) 6. DRIVE GEAR 9. COTTER PIN

1

23

4

5

76

9 8

7001-10


NOTES

Section7002 70

02




HYDRAULIC BRAKE TROUBLESHOOTING

7002-2


TABLE OF CONTENTS

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TROUBLESHOOTING THE HYDRAULIC BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5CHARGING THE ACCUMULATOR WITH DRY NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5BLEEDING THE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6BRAKE MODULATION PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Testing the Brake Modulation Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Adjusting the Brake Modulation Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

CHECKING THE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9BRAKE PUMP OUTPUT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Brake Valve Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

7002-3


SPECIFICATIONSBrake 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

94L95

CAS-10899 NITROGEN CHARGING KIT USED TO CHECK AND CHARGE THE ACCUMULATOR WITH NITROGEN.

BC04A001

380001168 ACCUMULATOR CHARGING ADAPTER

G

7002-4


TROUBLESHOOTING THE HYDRAULIC BRAKE SYSTEMNOTE: The hydraulic brake schematic is included inthe hydraulic schematic. Refer to the rear pocket ofthis manual.

1. Check the oil level in the hydraulic reservoir; addoil as necessary.

2. Push and release the brake pedal many timeswith the engine stopped to remove all hydraulicpressure from the brake system until there is nopressure on the pedal.

3. Install two 207 bar (3000 psi) pressure gauges tofront and rear hydraulic brake accumulator testports, refer to page 7 for the locations of the testports.

4. Make sure that the pressure gauge hoses arelong enough so the gauges can be read whilesitting in the operators seat.

NOTE: The gauges can not be connected to the testports if hydraulic pressure remains in the system.

5. Start the engine. Run the engine at low idle whilereading the pressure gauges. The alarms(buzzer, master warning light and brake pressurewarn ing l igh t ) shou ld shut o f f when theaccumulator with the lowest pressure reaches106 to 115 bar (1530 to 1670 psi), approximately40 seconds at any engine speed.

6. After the alarms stop, run the machine at highidle to finish charging the accumulators. Thepressure must increase on both gauges until 190to 196 bar (2757 to 2843 psi) is reached. This isthe accumulator valve cut-out pressure. It isnormal for the pressure to drop slightly once thecut-out pressure is reached.

7. With the engine running at high idle, push andrelease the brake pedal rapidly while reading thedrop in pressure on the gauges. The pressuredrops may not be equal, but as the lowestpressure reaches 157 to 167 bar (2280 to 2420psi), the system pressure must start to increase.This is the valve cut in pressure.

NOTE: The brake cut-in and cut-out pressures of thebrake system charge valve are factory preset and arenot adjustable.

NOTE: If the pressure on one of the pressuregauges is lower than specified, the problem can be abad accumulator valve.

8. Stop the engine. Turn the ignition switch to theON position. Push and release the brake severaltimes while reading the pressure on the gauges.Each push and release of the pedal will result ina slight drop in pressure, but not necessarilyequal on the two gauges. As the lowest pressurereaches 106 to 115 bar (1530 to 1670 psi) thebrake warning lamp and alarm buzzer mustactuate. If the warning lamp and alarm buzzer failto work, test the low brake pressure warningswitches and electrical circuit. If the warninglamp and alarm buzzer actuate at a higher orlower pressure than specified, test the low brakepressure warning switches and replace asneeded.

9. As the lowest pressure reaches 106 to 115 bar(1530 to 1670 psi) the brake warning lamp andalarm buzzer must actuate. If the warning lampand alarm buzzer fail to work, test the low brakepressure warning switches and electrical circuit.If the warning lamp and alarm buzzer actuate ata higher or lower pressure than specified, testthe low brake pressure warning switches andreplace as needed.

10. After the low brake pressure light activates, pressthe 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 (700to 850 psi), the test is complete.

13. If the pressures are not within the requiredspecifications, then the brake system must bebled.

14. After bleeding the brake system, perform thebrake system check again.

15. Continue to slowly push and release the brakepedal several times until the gauge pressuresuddenly drops to zero. The last pressurereading before the drop to zero is the nitrogencharge pressure in the accumulator. Test thepressure in both accumulators. If the pressure isbelow 48 to 59 bar (700 to 850 psi), charge orreplace the accumulator(s) (see page 5).

NOTE: Nominal temperature of 20° C (68° F), coldertemperature will reduce pressure, hotter temperaturewill increase pressure.

7002-5


CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR1. 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 manytimes to release the pressure.

2. Connect a drain hose to the test connector ineach brake circuit to release any pressure in thebrake circuit.

3. Close valves B and C on the nitrogen chargingkit, refer to the illustration.

4. Turn the stem out of valve F until the stem stops.

5. Remove the cap screws and guard from theaccumulator.

6. Remove the cap from the accumulator valvestem.

7. Connect valve F to the accumulator valve stem.

94L95

NITROGEN CHARGING KIT

8. Make sure that valve D is open.

9. Turn the stem into valve F and read the pressuregauge E.

10. The pressure must be 48 to 59 bar (700 to 850psi). If the pressure is too low, charge theaccumulator with dry nitrogen.

CHARGING THE ACCUMULATOR WITH DRY NITROGENNOTE: Check the pressure in the accumulatoraccording to the instructions in Checking theNitrogen Charge in the Accumulator. Keep thenitrogen charging kit connected to the accumulator.

1. Close (turn counterclockwise) valve A and openvalve B. Close valves C and D.

2. Turn the stem out of valve F until the stem stopsmov ing . D isconnec t va lve F f rom theaccumulator valve stem.

3. Connect the nitrogen charging kit to a drynitrogen tank.

4. Slowly turn valve A clockwise and read gauge Euntil 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 andread gauge E. If the pressure is still too high,close valve A (turn counterclockwise) a smallamount and quickly open and close valve D. Thepressure shown on gauge E is the chargepressure.

6. Connect valve F to the accumulator valve stem.Turn the stem into valve F until the stem stopsmov ing and open va lve D to charge theaccumulator.

7. After the accumulator stops charging, turn thestem out of valve F until the stem stops moving.

8. Close valve B and disconnect the nitrogencharging kit from the accumulator valve stem.

9. Install the cap on the accumulator valve stem.Insta l l the guard and cap screws on theaccumulator.

C

F

D B A

E

7002-6


BLEEDING THE BRAKE SYSTEM1. Check the level of hydraulic fluid in the reservoir.

Add fluid to the reservoir if necessary.


BD03A092

2. Raise loader arms and install the safety link (1)for safe access to the front axle bleed screws.


4. Keep the engine speed at high idle until bothbrake accumulators are fully charged.

NOTE: This will be approximately 30 seconds afterthe low brake pressure light goes out.

5. Stop the engine.

6. Pump the brake pedal until there is no hydraulicpressure in the brake system (approximately 20pumps).

7. Remove the plastic and rubber caps from eachwheel end and slowly open all four bleed screws.

NOTE: Attach a hose to the bleed screws to preventspilling any fluids.

8. Start the engine and run at low idle.

9. Push the brake pedal all the way down andslowly release for one cycle.

10. Close all four wheel end bleed screws.

11. Fully depress the brake pedal three times in 5second cycles.

12. With the brake pedal partially depressed, openthe bleed screw on the left front axle. Hold thebrake pedal in position until the oil is clear (nobubbles). Close the bleed screw.

13. Open the bleed screw on the right front axle.Repeat step 12.

14. Open the bleed screw on the left rear axle.Repeat step 12.

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.

1. SAFETY LINK

1

7002-7


BRAKE MODULATION PRESSURE CHECK

BD06F145

Testing the Brake Modulation Pressure

1. Make sure the hydraulic accumulator cut-in andcut-out pressures are correct. Refer to page 4 ofthis section.

2. Stop the engine. Pump the brake pedal untilthere is no pressure in the brake system.

3. Remove the cab skirts to gain access to thebrake test ports.

4. Connect two 207 bar (3000 psi) pressure gaugesto the front brake test port (1) and the rear braketest port (2).

5. Connect two 207 bar (3000 psi) pressure gaugesto the front brake accumulator test port (4) andthe rear brake accumulator test port (3).

6. Start the engine.

7. Operate the machine at low idle and watch thepressure gauges on the brake accumulators untilthe gauges rise above 170 bar (2645 psi).

8. Apply and hold the brakes for 10 to 15 seconds.

9. Make a note of the pressure on the gauges forthe front and rear brakes.

10. The front brake pressure should read 80 to 87bar (1160 to 1260 psi). This is the modulationpressure for the front axle.

11. The rear brake pressure should read 78 to 85 bar(1130 to 1230 psi). This is the modulationpressure for the rear axle

12. If the pressures are not within the specifiedrange, i t wi l l be necessary to ad just themodulation pressures.

1. FRONT AXLE TEST PORT 3. FRONT BRAKE ACCUMULATOR TEST PORT2. REAR AXLE TEST PORT 4. REAR BRAKE ACCUMULATOR TEST PORT

32

4

1

7002-8


Adjusting the Brake Modulation PressureNOTE: The adjusting bolt to adjust the modulationpressure is located in the cab, under the brake pedal.

BD00N121

1. Remove the tamper evident cover (1).

NOTE: This is a tamper evident cover and it will benecessary to install a new cover after the modulationpressure is adjusted.

2. Turn the adjusting bolt (2) to adjust themodulation pressure.

NOTE: The rear brake modulation pressure cannotbe adjusted separately from the front brakemodulation pressure.

3. Repeat steps 5 through 10 in the Testing theBrake Modulation Pressure procedure.

4. Repeat these steps until the brake modulationpressure is within the specified range.

1. TAMPER RESISTANT COVER2. ADJUSTING BOLT

2

1

7002-9


SERVICE BRAKE SYSTEM PERFORMANCE (STORED ENERGY)

BD06F145

NOTE: Prior to doing this procedure make sure thatthe accumulator pressures are correct.

1. Check the level of the hydraulic fluid in thereservoir, add as needed.

BD00M030

2. Install the articulation lock (1) before doing thistest.

3. Remove the left side cab skirt to gain access tothe brake accumulator test ports.

4. Pump the brake pedal until there is no hydraulicpressure in the brake system (approximately 20pumps).

5. Connect two 207 bar (3000 psi) pressure gaugesto the test ports 3 and 4.

6. Start the engine and let idle until both the frontand rear accumulators 3 and 4 are fully charged.The accumulators are fully charged at 190 to 196bar (2755 to 2842 psi).

7. Stop the engine.

8. Push the brake pedal down slowly, allowing forfull piston actuation.

NOTE: Depress the brake pedal at the rate of threestrokes per minute.

9. Continue pressing the brake pedal down. Thelow brake pressure light should activate when thepressure reaches 106 to 115 bar (1530 to 1670psi). After the low brake pressure light activates,press the brake pedal eight more times.

10. Record the readings on the pressure gauges.The pressure gauges should read at or above 48 to 59 bar (700 to 850 psi).

11. If the pressures are at or above 48 to 59 bar (700to 850 psi), the test is complete.

12. If the pressures are not within the requiredspecifications, then the brake system must bebled.

13. After bleeding the brake system, perform thebrake system check again.

1. FRONT AXLE TEST PORT 3. FRONT BRAKE ACCUMULATOR TEST PORT2. REAR AXLE TEST PORT 4. REAR BRAKE ACCUMULATOR TEST PORT

32

4

1


1

7002-10


BRAKE PUMP OUTPUT TEST1. Connect the flowmeter to the brake pump as

shown, refer to the illustration below.

2. Make sure the load control of the flowmeter isopen. Start the engine. Run the engine at fullthrott le. Make sure the oi l is at operatingtemperature.

3. Measure the flow at 0 bar (0 psi). Record the flowreading. Slowly close the load valve on theflowmeter and read the flow at 170 bar (2500psi). Record the flow reading.

4. Divide the flow reading at 170 bar (2500 psi) bythe reading at 0 bar (0 psi). Multiply the result by100. This is the percent efficiency of the pump. Ifthe efficiency of the pump is less than 85%,repair or replace the pump.

BS03B021

1. BRAKE PUMP 3. FLOWMETER INLET HOSE 5. FILTER INLET MANIFOLD2. 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

1

2

3

4

6

NOTE

5

7002-11


NOTES

7002-12


BC05G011

BRAKE VALVE EXPLODED VIEW

33

32

31

5

3

2

1

1

2

4

5

6

5

7

8

9

10

12

11

13

2

5

14

5

14

14

15

16

17

18 19

20

15

21

21

23

22 5

24 25

26

2728

15

29

30

30

534

235

36

7002-13


1. CAP SCREW (T 22 NM (16 LB-FT)) 13. CAP (T 60 NM (44 LB-FT)) 25. CHECK VALVE2. O-RING 14. SPOOL 26. CARTRIDGE3. BUSHING 15. PLUG (T 10 NM (88.5 LB-IN)) 27. PLUG (T 60 NM (44 LB-FT))4. SLEEVE 16. PLUG (T 60 NM (44 LB-FT)) 28. JET5. SPRING 17. PLUG (T 22NM (16 LB-FT)) 29. WVI UNIT6. SPRING RETAINER 18. VALVE SEAT 30. PLUG (T 60 NM (44 LB-FT))7. SPRING RETAINER 19. THROTTLE SCREW 31. PLUG (T 100 NM (74 LB-FT))8. CIRCLIP 20. PLUG (T 22NM (16 LB-FT)) 32. RV UNIT9. SHAFT SEAL 21. CAP 33. SPRING RETAINER

10. SLEEVE LVE 22. SLEEVE 34. SLEEVE11. GUIDE RING 23. SPRING RETAINER 35. THRUST RING12. O-RING 24. SLEEVE 36. SLEEVE LVV

7002-14


NOTES

Section7003

7003




BRAKE PUMP

7003-2


TABLE OF CONTENTS

BRAKE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

7003-3


BC06F594

PUMP ILLUSTRATION

1. RETAINING RING 8. BACKUP SEAL 14. WASHER2. SEAL RETAINER 9. CHANNEL SEAL 15. BOLT3. 0-RING 10. DOWEL PIN 16. DRIVEN GEAR4. OUTER LIP SEAL 11. THRUST PLATE 17. DRIVE GEAR5. INNER LIP SEAL 12. GEAR HOUSING 18. DRIVE SCREW6. SHAFT END COVER HOUSING 13. PORT END COVER HOUSING 19. NAME PLATE7. QUAD RING

10

16

17 1514

12

34

56

78 9 10

12

11

98

713

10

11

19

18

7003-4


BRAKE PUMP

Disassembly1. Secure the pump by the port end cover (13) in a

soft jawed vise.

2. Draw a line the length of the pump to assistduring assemble.

3. Loosen and remove bolts (15).

4. Tap the shaft end cover housing (6) with softhammer to loosen it, remove the shaft end coverhousing (6).

5. Remove the backup seal (8), channel seal (9),and thrust plate (11).

6. Remove the drive gear (17) from the gearhousing (12).

7. Remove the driven gear (16) from the gearhousing (12).

8. Tap the gear housing (12) with a soft hammer toloosen 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 endcover housing (6).

11. Remove the seal retainer (2), O-ring (3), andouter l ip seal (4) from the shaft end coverhousing (6).

12. Remove the inner lip seal (5) from the shaft endcover housing (6).

Inspection

1. Discard all seals and quad rings. Clean all partsin cleaning solvent. Check all machined surfacesfor damage or wear.

2. Hold a straightedge across each gear housingand use a feeler gauge to measure the amountof wear caused by the gear teeth in the gearpocket. If the wear in any gear pocket is morethan 0.18 MM. (0.007 inch), use a new gearhousing.

3. Inspect the thrust plates for scoring, pitting, orother damage.

4. Inspect the gears for wear and damage. Theremust be no scoring on the gear hubs or on theoutside edges of the gear teeth. There must beno more than 0.05 MM. (0.002 inch) wear in theseal area of the drive shaft. If any gear must bediscarded, 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 thegears when the seal retainer (2) is installed intothe shaft end cover housing (6).

2. Install a new lip seal (4) into the shaft end coverhousing (6) with the lip of the seal facing towardsthe 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 endcover 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 coverhousing (6).

IMPORTANT: Be sure to place the thrust plate (11)onto the shaft end cover housing (6) in the positionshown 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 placeeither in the gear housing (12) or the shaft endcover housing (6).

11. Align the marks made during disassembly,carefully place the gear housing (12) onto thegears.

12. Slide the thrust plate (11) onto the shafts of thegears.

IMPORTANT: Be sure to place the thrust plate (11)onto the gears in the position shown in the illustrationon page 3.

13. Install a new quad ring (7) into the gear housing(12). Check that dowel pins (10) are in placeeither in the gear housing (12) or the port endcover housing (13).

14. Align the marks made during disassembly, placethe 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).

Section7004

7004


Printed in U.S.A.Issued April, 2003/Revised February, 2004

CNH America LLC.700 State StreetRacine, WI 53404 U.S.A. Bur6-47761

BRAKE ACCUMULATORS

7004-2


TABLE OF CONTENTS

SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3CHARGING THE ACCUMULATOR WITH DRY NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Temperature/Charge Pressure Brake Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

7004-3


SPECIAL TOOL

94L95 BC04A001

DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR1. Remove cover from accumulator charge port.

Loosen the Allen screw in the charge port.

NOTE: Do not turn the Allen screw more than 1/8 ofa turn or gas will escape uncontrolled.

2. Install adapter on accumulator, use theCAS10899 nitrogen charging kit to discharge theaccumulator, refer to illustrations above. The toolmust be disconnected from the nitrogen tank.

3. Close valves B, C and D.

4. Adjust the regulator A to the minimum pressuresetting by turning the knob counterclockwise.

5. Turn the T-handle on valve F fully out.

6. Connect valve F to the valve stem on theadapter.

7. Turn the T-handle inward on valve F to engagethe pin in the valve stem, open valve G.

8. Open valve D and check the charge pressure ongauge E.

9. To discharge the accumulator, partially openvalve B. The accumulator charge will bleed downthrough the regulator.

10. Once the accumulator is fully discharged,disconnect valve F from the valve stem andremove adapter.

CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR1. 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 21times to release the pressure.

2. Connect a drain hose to the test connector ineach brake circuit to release any pressure in thebrake circuit.

3. Close valves B and C on the nitrogen chargingkit, refer to the illustration.

4. Turn the stem out of valve F until the stem stops.

5. Remove the cap from the accumulator. Loosenthe Allen screw in the charge port.

NOTE: Do not turn the Allen screw more than 1/8 ofa 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 pressuregauge E.

NOTE: See chart below for pressure readings.

10. If the pressure is too low, charge the accumulatorwith dry nitrogen.

CAS10899 NITROGEN CHARGING KIT

EC

F

D B A

380001168 ACCUMULATOR CHARGING ADAPTER

G

7004-4


CHARGING THE ACCUMULATOR WITH DRY NITROGENNOTE: Check the pressure in the accumulatoraccording to the instructions in Checking theNitrogen Charge in the Accumulator. Keep thenitrogen charging kit connected to the accumulator.

1. Close (turn counterclockwise) valve A and openvalve B. Close valves C, D, and G.

2. Turn the stem out of valve F until the stem stopsmoving. Disconnect valve F from the adaptervalve stem.

3. Connect the nitrogen charging kit to a drynitrogen tank.

4. Slowly turn valve A clockwise and read gauge Euntil the pressure is equal to charge pressurerequired for accumulator being charged. Stopturning valve A.

5. If the pressure increases above requiredpressure, quickly open and close valve D andread gauge E. If the pressure is still too high,close valve A (turn counterclockwise) a smallamount and quickly open and close valve D. Thepressure shown on gauge E is the chargepressure.

6. Connect valve F to the adapter valve stem. Turnthe stem into valve F until the stem stops movingand open va lve G and D to cha rge theaccumulator.

7. After the accumulator stops charging, turn thestem out of valve F until the stem stops movingand close valve G.

8. Close valve B and disconnect the nitrogencharging kit from the adapter valve stem, removethe adapter.

9. Torque the Allen screw to 20 Nm (15 lb-ft), installthe cover on the accumulator valve stem.

TEMPERATURE/CHARGE PRESSURE BRAKE ACCUMULATOR

TEMPERATURE CHARGE PRESSURE0° C 32° F 51.2 BAR 743 PSI5° C 41° F 52.2 BAR 757 PSI

10° C 50° F 53.1 BAR 770 PSI15° C 59° F 54.1 BAR 784 PSI20° C 68° F 55.0 BAR 798 PSI25° C 77° F 55.9 BAR 811 PSI30° C 86° F 56.9 BAR 825 PSI35° C 95° F 57.8 BAR 839 PSI40° C 104° F 58.8 BAR 852 PSI

Section7008

7008




PARKING BRAKE

7008-2


TABLE OF CONTENTS

PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

PARKING BRAKE TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

7008-3


PARKING BRAKE

Disassembly

STEP 1Park the machine on a hard level surface and lowerthe loader bucket to the ground.

STEP 2Place wheel chocks on each wheel to preventmachine movement.

STEP 3

BD01F143

Install the articulation lock.


STEP 5Pump the brake pedal at least 30 times to dischargethe accumulators.

STEP 6

BD03A184

Loosen and remove the cover from the parkingbrake.

STEP 7

BD03A185

Loosen the jam nu t , tu r n ad jus t ing bo l tcounterclockwise until the brake pads are loose.

STEP 8

BD03A186

Remove the retainer pin and brake pin.

STEP 9

BD03A187

Remove the two brake pads from the parking brakeassembly.

7008-4


Inspection

STEP 10Clean and inspect all parts for wear and damage.

Inspect the brake disc for wear and damage.

Replace all parts that are worn or damaged.

Assembly

STEP 11

BD03A187

Install the two brake pads in the parking brakeassembly.

STEP 12

BD03A186

Install the brake pins and retainer pins.

STEP 13Start the machine and run the engine at low idle withthe bucket resting on the ground.

IMPORTANT: It will be necessary to have anassistant help for this procedure. An operator mustbe present in the cab at all times to apply the servicebrakes and shut down the machine in the event ofmechanical failure.

STEP 14Disengage the parking brake.

NOTE: Hydraulic pressure will not be applied to theparking brake until the parking brake rocker switch isturned off, the service brakes applied and thetransmission is put into gear.

A. Place the parking brake rocker switch in theOFF position.

B. Apply the service brake and put the machineinto gear.

C. The parking brake light on the cluster will turnoff at this time.

Place the transmission back into neutral beforeproceeding.

STEP 15

BD0CA185

Turn the adjusting bolt clockwise until both brakepads contact the brake disc, then turn the adjustingbolt counterclockwise one turn. Tighten the jam nutto secure the adjusting bolt.

STEP 16Install the cover on the parking brake.

STEP 17Perform the Parking Brake Test Procedure asdescribed in this section.

STEP 18Remove the articulation lock.

STEP 19Place the master disconnect switch to the ONposition.

7008-5


PARKING BRAKE TEST PROCEDURE

STEP 20While testing, the machine must be on a clear levelsurface with the bucket in the travel position.

SA015

STEP 21Start the machine and run the engine at low idle inthird gear neutral.

STEP 22Place the Transmission-Auto switch to the manualposition.

STEP 23Place the Parking Brake switch to the ON position.

STEP 24

BD06F141

Press and hold the enter key for 2 to 3 seconds untilthe instrument cluster monitor display changes to theselect screen.

STEP 25

BD06F142

Use up or down arrow and highlight config, press theenter key to select the config menu.

STEP 26

BD06F143

Press the up or down arrow and high light brake test,press the enter key.

WARNING: Always know the location of allworkers in your area. Warn them before youstart working the machine. Always keep allother persons away from your area. Seriousinjury or death can result if you do not followthese instructions.

7008-6


STEP 27

BD06F144

Monitor will display Test Park Brake if all conditionsare met to test the brake, press the enter key.

NOTE: If all conditions are not met to test the brakethe monitor will display the condition that needscorrected prior to proceeding.

STEP 28Monitor will display Test Park Brake Ready.

STEP 29Shift the gear selector into third gear forward andslowly increase the engine speed to wide openthrottle.

STEP 30Verify that the machine does not move.

STEP 31Reduce the engine speed to low idle and return thetransmission neutral.

STEP 32Shift the gear selector to third gear reverse andslowly increase the engine speed to wide openthrottle.

STEP 33Verify that the machine does not move.

STEP 34Reduce the engine speed to low idle and return thetransmission to neutral.

STEP 35

BD06F141

Press the escape switch on the key pad to exit thetest mode.

STEP 36If any machine movement was detected, the parkingbrake must be adjusted, see procedures this section.




SECTION INDEX

HYDRAULICS

Removal and Installation of Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8001

Hydraulic Specifications, Troubleshooting, and Pressure Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8002

Cleaning the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8003

Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8004

Loader Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8005

Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8006

Coupler Solenoid Locking Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8007

Ride Control Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8013

Ride Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8014


Section8001

8001




REMOVAL AND INSTALLATION OF HYDRAULIC COMPONENTS

8001-2


TABLE OF CONTENTS

LOADER CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Hydraulic Valve Pilot Line Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Loader Control Valve Line Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6REMOTE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8


Joystick and 2 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Joystick and 1 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Joystick Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

LIFT CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

BUCKET CYLINDER - Z-BAR LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

BUCKET CYLINDERS - XT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

XT Loader Bucket Cylinder Removal And Installation Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

RIDE CONTROL ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

RIDE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

FAN REVERSING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

THERMAL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

8001-3


LOADER CONTROL VALVE

Removal

STEP 1Park the machine on a level surface.


STEP 2

BD03A092

Raise the lift arms and install the safety link on the liftarm cylinder.

STEP 3Stop the engine and apply the parking brake.

IMPORTANT: With the engine NOT running, pumpthe brake repeatedly to be sure the brakeaccumulators have no hydraulic pressure, put theignition switch in the ON position then move theloader control valve back and forth several times torelease any hydraulic pressure in the pilot controlcircuit, turn ignition switch OFF.


STEP 5

BD06H198

Relieve the pressure in the ride control accumulatorwith the manual bleeder valve located on the top ofthe ride control valve. Remove the plug and turn thevalve two turns counter-clockwise.

STEP 6Loosen the filler cap on the reservoir to release theair pressure in the reservoir.

STEP 7Drain the hydraulic reservoir.

STEP 8

BD03A093

Loosen and remove the bolts and washers thatfasten the access cover plate for the loader controlvalve. Remove the cover plate.

8001-4


BC05M094

HYDRAULIC VALVE PILOT LINE CONNECTIONS

1. GREEN WHITE GREEN 4. ORANGE BLACK GREEN 7. GREEN BLACK GREEN2. RED WHITE GREEN 5. GREEN WHITE GREEN 8. RED BLACK GREEN3. YELLOW BLACK GREEN 6. RED WHITE GREEN 9.

REAR OF MACHINE

13

42

57

8

6

8001-5


BC05M093

LOADER CONTROL VALVE LINE CONNECTIONS

1. DUMP LINE 4. RAISE LINE RIGHT 6. LOWER LINE RIGHT2. ROLLBACK LINE 5. LOADER VALVE 7. RAISE LINE LEFT3. LOWER LINE LEFT

1 2

6

4

7

3

5

8001-6


STEP 9Disconnect the hoses (3, 4, 7, 8 if equipped 1, 2, 5,and 6) from the remote control valve(s) at the loadercontrol valve. Refer to the illustration on page 4 forcolor coding. Install a plug in each hose and a cap oneach fitting.

NOTE: Line 1, 2, 5, and 6 will need to be tagged asright or left of valve.

STEP 10Loosen and remove tilt cylinder lines (1 and 2). Installa plug in each line and a cap on each fitting.

STEP 11Loosen and remove lines (3 and 4). Install a plug ineach line and a cap on each fitting.

STEP 12Loosen and remove lines (6 and 7). Install a plug ineach line and a cap on each fitting.

STEP 13Loosen and remove supply and return lines. Install aplug in each line and a cap on each fitting.

STEP 14Attach proper lifting equipment to lift loader controlvalve.

STEP 15

BC05M096

Loosen and remove the three bolts and washers thathold the loader control valve to the valve mountingplate. Remove the loader control valve.

InstallationIMPORTANT: Before installing the fittings orconnecting the tubes to the fittings, install newO-rings on the fittings.

STEP 16

BC05M096

Install and align the loader control valve with thevalve mounting plate.

STEP 17Install the bolts and washers that fasten the loadercontrol valve to the valve mounting plate. Tighten thebolts.

STEP 18Tighten the left lift cylinder lines (6 and 7).

STEP 19Install and tighten the supply and return lines.

STEP 20Install and tighten right lift cylinder lines (3 and 4).

STEP 21Install and tighten tilt cylinder lines (1 and 2).

STEP 22Connect the hoses (3, 4, 7, 8 if equipped 1, 2, 5, and6) to the remote control valve(s) at the loader controlvalve. Refer to the illustration on page 4 for colorcoding.

8001-7


STEP 23Fill the hydraulic reservoir with oil. Refer to Section1002 for the correct oil.

STEP 24Tighten the accumulator manual bleeder valvelocated on the top of the ride control valve to a torqueof 3.5 Nm (31 lb-in). Install the plug and torque to 7 Nm (62 lb-in).

STEP 25Place the master disconnect switch in the ONposition.

STEP 26

BD03A092

Raise the loader arms and remove the safety link.

STEP 27Run engine at half throttle.

STEP 28Slowly and completely extend and retract al lcylinders at least 10 times to remove any air from thecircuits.

STEP 29Stop the engine and check for leaks.

STEP 30Install the access cover on the front of the machine.

STEP 31Check the level of the hydraulic oil and add hydraulicoil as required.

8001-8


REMOTE CONTROL VALVE

Removal




STEP 34Unlatch and open the right hand side access door.

STEP 35Lift the access door up and remove the access doorfrom the pins.

STEP 36

BD06F207

Unlatch and open the window on the right hand side.

STEP 37

BD06F208

Open and remove the access panel.

STEP 38

BD06F209

Remove the front access panel.

STEP 39

BD06F210

Disconnect the electrical connectors for the remotecontrol valve.

STEP 40Loosen the filler cap on the reservoir to release anyair in the reservoir. Connect a vacuum pump to thehydraulic reservoir, turn on the pump.

8001-9


STEP 41Put identification tags on each hose and disconnectone at a time from the remote control valve. Installplugs in the hoses and caps on the fittings.

STEP 42Loosen and remove the screws and washers holdingthe hydraulic control tower cover. Remove the cover.

STEP 43Loosen and remove the screws that fasten theremote control valve to the hydraulic control tower.

STEP 44Remove the remote control valve from the hydrauliccontrol tower.

Installation

STEP 45Install new O-rings on the adapters for the remotecontrol valve.

STEP 46Install the remote control valve and screws in thehydraulic control tower and tighten the screws.

STEP 47Install the cover over the remote control valve andinstall the screws and washers.

STEP 48Remove the plugs from the hoses and the caps fromthe fittings and connect the hydraulic hoses to thefittings according to the identification tags. (Refer toillustrations on pages 11, 12, and 13 as necessary.

STEP 49Turn off the vacuum pump and disconnect from thehydraulic reservoir.

STEP 50

BD06F210

Connect the electrical connectors for the remotecontrol valve.


STEP 52Start the engine and run the engine at low idle.

STEP 53Check to see that the remote control valve workscorrectly.

8001-10


STEP 54Check for hydraulic oil leakage at the remote controlvalve.

STEP 55Check the level of hydraulic oil in the reservoir andadd as required.

STEP 56

BD06F209

Position the access panel on the ROPS cab or theROPS canopy and install and tighten the screw.

STEP 57

BD06F208

Install and close the access panel.

STEP 58

BD06F207

Close the right hand window.

8001-11


BC05M092

JOYSTICK AND 2 LEVER HOSE COLOR CODING

1. PILOT TANK HOSE 4. ORANGE BLACK GREEN 7. GREEN WHITE GREEN2. PILOT PRESSURE HOSE 5. GREEN BLACK GREEN 8. RED WHITE GREEN3. YELLOW BLACK GREEN 6. RED BLACK GREEN

1 2

2

1

3

4

8

6

87

57

8

5

4

6

3

7

8001-12


BC05M091

3 LEVER HOSE COLOR CODING JOYSTICK AND 1 LEVER HOSE COLOR CODING

7 77

71

23

6

54

12

36

54

21

5

6

4

3

7

3

1

26

5

4

7

1. PILOT TANK HOSE2. PILOT PRESSURE HOSE3. RED BLACK GREEN4. ORANGE BLACK GREEN5. YELLOW BLACK GREEN6. GREEN BLACK GREEN7. RED WHITE GREEN


8001-13


BC05M090

2 LEVER HOSE COLOR CODING JOYSTICK HOSE COLOR CODING

12

36

54

3

1

2

6

54

2

1

5

64

3

12

36

54

1. PILOT TANK HOSE2. PILOT PRESSURE HOSE3. RED BLACK GREEN4. ORANGE BLACK GREEN5. YELLOW BLACK GREEN6. GREEN BLACK GREEN


8001-14


HYDRAULIC PUMP

BC05M095

1. PUMP MAIN HYDRAULIC 5. SPLIT FLANGE 9. STEERING HIGH PRESSURE 13. LOADER HIGH PRESSURE2. MOUNT BOLTS 6. TUBE 10. CLAMPS 14. STEERING PRIORITY MANIFOLD3. DRAIN HOSE 7. HOSE SUCTION 11. STEERING LOAD SENSE HOSE 15. CLAMPS4. BOLT 8. HOSE CASE DRAIN 12. LOADER LOAD SENSE HOSE 16. FITTINGS

14

13

12

11

4

5

4

6

6

5

2

1

8

9

10

7

3

15

15

16

8001-15


RemovalNOTE: When disconnecting hydraulic fittings, plughoses and cap fittings to prevent entry of foreignmatter into hydraulic system.




STEP 62Refer to Section 9007 and remove the ROPS cab orROPS canopy.

STEP 63Remove eight bolts (4) and washers. Remove foursplit flanges (5). Disconnect tubes (6) with suctionhoses (7) from hydraulic pump. Remove and discardO-ring face seals from flange heads of tubes.

STEP 64Loosen clamps (10). Tag and disconnect suctionhoses (7) from hydraulic reservoir and remove frommachine.

STEP 65Tag and disconnect case drain hoses (8) from fittings(16); remove hoses (8). Remove and discard O-ringface seals from fittings.

STEP 66Tag and disconnect load sense hoses (11 and 12).Remove and discard O-ring face seals from fittings.

STEP 67Tag and disconnect drain hose (3). Remove anddiscard O-ring face seals from fittings.

STEP 68Tag and disconnect pump pressure hoses (9 and 13)from steering priority manifold (14). Remove anddiscard O-ring face seals from flange heads ofhoses.

STEP 69Connect lifting equipment to hydraulic pump (1). Takeup all slack in lift ing equipment. Remove fourmounting bolts (2) and washers securing pump totransmission. Pull hydraulic pump from transmissionand remove from loader. Remove and discard O-ringfrom pump.

InstallationNOTE: Install new O-rings where required.

STEP 70Install new O-ring on hydraulic pump flange. Movepump into position and install in transmission. Installfour washers and bolts (2) to secure pump (1) totransmission, tighten the bolts. Disconnect liftingequipment from pump.

STEP 71Connect pump pressure hoses (9 and 13) to steeringpriority manifold (14).

STEP 72Connect drain hose (3).

STEP 73Connect load sense hoses (11 and 12).

STEP 74Install and connect case drain hoses (8).

STEP 75Install suction hoses (7), tighten clamps (10) to 10 to11 Nm (90 to 100 pound inches).

STEP 76Install four split flanges (5). Install eight bolts (4) andwashers, tighten bolts (4) to 73 to 90 Nm (53.8 to66.3 pound feet).

STEP 77Refer to Section 9007 and install the ROPS cab orROPS canopy.



8001-16


STEP 80Start the engine and run the engine at low idle for twominutes.

NOTE: If any unusual vibration is heard coming fromthe pump, stop the machine immediately and checkfor obstructions in the pump suction line.

STEP 81Stop the engine and check for hydraulic oil leakage atthe hydraulic pump.

STEP 82Check the level of the hydraulic oil in the reservoirand add hydraulic oil as required.

8001-17


LIFT CYLINDERS

Removal



STEP 84Relieve the pressure in the ride control accumulatorwith the manual bleeder valve located at the rear ofthe front chassis.

STEP 85Loosen the filler cap on the hydraulic reservoir torelease any pressure.

STEP 86

BD01D708

Tag and disconnect the hoses on each side of the liftcylinder. Install plugs in the hoses and caps on thefittings.

STEP 87

BD01D709

Loosen and remove the bolt, washer and spacer thathold the pivot pin for the yoke.

STEP 88

BD01D711

Use a proper lifting device and secure a strap aroundthe lift cylinder.

STEP 89

BD01D712

Remove the pivot pin from the yoke end of the liftcylinder.

8001-18


STEP 90

BD01D710

Loosen and remove the bolt, washer and spacer thathold the pivot pin at the closed end of the lift cylinder.

STEP 91

BD01D713

Remove the pivot pin from the closed end of the liftcylinder.

STEP 92Remove the lift cylinder from the machine

Installation

STEP 93Apply antiseize compound to the bores in the frontframe and the yoke on the piston rod.

STEP 94

BD01D714

Use a proper lifting device and position the liftcylinder on the machine.

STEP 95

BD01D713

Align the closed end of the lift cylinder with the frontframe and install the pivot pin.

8001-19


STEP 96

BD01D710

Align the pivot pin with the front frame and install thespacer, washer and bolt. Tighten the bolt.

STEP 97

BD01D708

Remove the caps and plugs and connect the hosesto the lift cylinder.

STEP 98If the yoke of the lift cylinder is not aligned with theloader frame, have another person start and run theengine at low idle and use the loader control lever toSLOWLY move the yoke into alignment with theloader frame.

STEP 99

BD01D712

Install the pivot pin for the yoke. Stop the engine.

STEP 100

BD01D709

Align the pivot pin with the yoke and install thespacer, washer and bolt. Tighten the bolt.

STEP 101SLOWLY extend and retract the piston rod threetimes to remove any air from the lift cylinders.

STEP 102Lubricate the pivot pins with molydisulfide grease.

STEP 103Check the level of hydraulic oil in the reservoir andadd as required. Tighten the fi l ler cap on thehydraulic reservoir.

8001-20


BUCKET CYLINDER - Z-BAR LOADER

Removal


STEP 105With the engine stopped, move the bucket controllever to release pressure in the bucket circuit.

STEP 106

BD01D694

Disconnect the proximity switch connector from thewiring harness connector.

STEP 107

BD01D696

Loosen and remove the two bolts that fasten thetarget bar to the mounting bracket. Remove thetarget bar.

STEP 108

BD01D695

Loosen and remove the two bolts that fasten themounting bracket to the machine. Remove themounting bracket.

STEP 109

BD01D697

Loosen and remove the two bolts that fasten themounting bracket for the proximity switch to thebucket cylinder. Remove the mounting bracket andswitch.

8001-21


STEP 110

BD01D699

Disconnect the hoses from each side of the bucketcylinder. Install plugs in the hoses and caps on thefittings.

STEP 111

BD01D700

Use acceptable equipment to hold the bucketcylinder.

STEP 112

BD01D698

Loosen and remove the bolt, washer and spacer thatfasten the pivot pin from both ends of the bucketcylinder.

STEP 113

BD01D701

Remove the pivot pin from the rod end of the bucketcylinder.

STEP 114

BD01D704

Remove the pivot pin from the head end of the bucketcylinder.

NOTE: It is not necessary to remove the grease linefrom the pivot pin unless the pivot pin is to bereplaced.

STEP 115

BD01D706

Raise the bucket cylinder and remove the cylinderfrom the machine.

8001-22


Installation

STEP 116Apply antisieze compound to the bores in the frontframe and the bores in the loader arm for the bucketcylinder.

STEP 117

BD01D706

Use acceptable lifting equipment to lower the bucketcylinder into position.

STEP 118

BD01D704

Install the pivot pin to the head end of the bucketcylinder.

STEP 119Install the spacer, washer and bolt that fasten thepivot pin to the front frame. Tighten the bolt.

NOTE: If a new pivot pin is being installed, connectthe grease line to the pivot pin.

STEP 120

BD01D699

Connect the hoses to each side of the bucketcylinder.

STEP 121If the rod end of the bucket cylinder is not alignedwith the bellcrank, have another person start theengine and run the engine at low idle and use thebucket control lever to SLOWLY move the piston rodeye into alignment with the bellcrank.

STEP 122Install the pivot pin and stop the engine.

STEP 123

BD01D698

Install the spacer, washer and bolt that fasten thepivot pin to the bellcrank. Tighten the bolt.

8001-23


STEP 124

BD01D697

Install the two bolts that fasten the mounting bracketfor the switch to the bucket cylinder.

STEP 125

BD01D695

Install the two bolts for the mounting bracket for thetarget bar.

STEP 126

BD01D696

Install the two bolts that fasten the target bar to themounting bracket.

STEP 127

BD01D694

Connect the proximity switch connector to the wiringharness connector.

STEP 128See Section 9006 for the adjustment procedure foradjusting the proximity switch.

STEP 129Start and run the engine at low idle.

STEP 130SLOWLY extend and retract the piston rod threetimes to remove any air from the bucket cylinder.

STEP 131Lubricate the pivot pins with molydisulfide grease.

STEP 132Check the level of the hydraulic oil in the reservoirand add as required. Tighten the filler cap on thehydraulic reservoir.

8001-24


OIL COOLER

Removal

STEP 133Park the machine on a level surface and lower thebucket to the ground. Stop the engine and apply theparking brake.


STEP 135Raise the engine hood and remove the shield on theright side of the machine between the tire and the oilcooler.

STEP 136

BD03A120

Have assistant hold side panel in raised position,remove two mounting screws, remove side panel.

STEP 137Loosen the filler cap on the hydraulic reservoir torelease the air pressure in the reservoir. Connect avacuum pump to the hydraulic reservoir, turn on thepump.

STEP 138

BD03A154

Disconnect the top hose and install a plug in the hoseand a cap on the fitting.

STEP 139

BD03A179

Loosen and remove the bolt and washer that fastenthe 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 coolerfrom the machine.

8001-25


Installation

STEP 141

BD06H195

Place the oil cooler in position in the cooling frame.Connect the lower hose to the oil cooler, install andtighten the two mounting nuts.

STEP 142

BD03A179

Install the bolt and washer that fasten the oil cooler tothe cooling frame

STEP 143

BD03A154

Connect the hose to the top of the oil cooler.

STEP 144

BD03A120

Have assistant hold side panel in raised position,install and tighten two mounting screws.



STEP 147Start the engine and run the engine at low idle for twominutes. Stop the engine and check for hydraulic oilleakage at the ports on the oil cooler.

STEP 148Install the shield between the right rear tire and theoil cooler and tighten the two bolts holding the shield.

STEP 149Check the level of the hydraulic oil in the reservoirand add hydraulic oil as required.

8001-26


RIDE CONTROL ACCUMULATOR

Removal



STEP 151

BD06H198



STEP 153

BD06H196

Disconnect the hose from the elbow at the bottom ofthe ride control accumulator. Install a plug in the hoseand a cap on the fitting.

STEP 154

BD06H197

Loosen and remove the nuts and washers from theU-bolt. Remove the U-bolt.

STEP 155Loosen and remove the two bolts that fasten theaccumulator bracket to the front frame. Remove theride control accumulator from the machine.

8001-27


Installation

STEP 156Place the ride control accumulator in position on thefront frame.

STEP 157Install the two bolts that fasten the accumulatorbracket to the front frame. Tighten the bolts.

STEP 158

BD06H197

Install the U-bolt, washers and nuts. Tighten the nuts.

STEP 159

BD06H196

Remove the caps and plugs and install the hose onthe e lbow a t the bot tom of the r ide cont ro laccumulator.

STEP 160Turn off and disconnect the vacuum pump from thehydraulic reservoir.

STEP 161Tighten the accumulator manual bleeder valvelocated on the top of the ride control valve to a torqueof 3.5 Nm (31 lb-in). Install the plug and torque to 7 Nm (62 lb-in).

STEP 162Refer to Section 8002 Testing the Ride Control forthe proper charging of the accumulator to check forleaks.


8001-28


RIDE CONTROL VALVE

Removal



STEP 165

BD06H198




STEP 168Disconnect the electrical connector on top of the ridecontrol valve.

STEP 169Tag and disconnect the hoses from the ride controlvalve. Install a plug in the hoses and caps on fittings.

STEP 170Loosen and remove the two bolts and washers thatfasten the ride control valve to the frame.

STEP 171Remove the ride control valve from the machine.

STEP 172Remove and discard all O-rings.

8001-29


Installation

STEP 173Install the ride control valve in position on the frontframe.

STEP 174Install the washers and bolts through the frame andinto the ride control valve. Tighten the bolts.

STEP 175

BD06H198

Tighten the accumulator manual bleeder valvelocated on the top of the ride control valve to a torqueof 3.5 Nm (31 lb-in). Install the plug and torque to 7 Nm (62 lb-in).

STEP 176Lubricate and install new O-rings.

STEP 177Connect the hoses to the ride control valve.

STEP 178Connect the electrical connector to the ride controlvalve.



STEP 181Start and run the engine at low idle for two minutes.

STEP 182Stop the engine and check for hydraulic oil leakage atthe ride control valve.


STEP 184Refer to Section 8002 and perform the Ride ControlTest Procedure.

8001-30


FAN REVERSING VALVE

Removal




STEP 187

BD03A174

Disconnect the electrical connector for the fanreversing valve.

STEP 188

BD03A174

Tag and disconnect the fan forward hose (1) from thefan reversing valve. Install a plug in the hose and acap on the fitting. Tag and disconnect the fan reversehose (2) from the fan reversing valve. Install a plug inthe hose and a cap on the fitting.

STEP 189

BD03A173

Tag and disconnect the fan valve return hose (3) fromthe fan reversing valve. Install a plug in the hose anda cap on the fitting. Tag and disconnect the fan valvesupply hose (4) from the fan reversing valve. Install aplug in the hose and a cap on the fitting.

STEP 190Loosen and remove the nuts, washers and bolts.

STEP 191Remove the fan reversing valve from the machine.

STEP 192Remove and discard all O-rings from the fittings.

1

2

34

8001-31


Installation

STEP 193Place the fan reversing valve into position on themachine.

STEP 194Lubricate and install new O-rings in the fittings.

STEP 195Install the bolts, washers and nuts. Tighten the nuts.

STEP 196

BD03A173

Connect the fan valve supply hose (4) to the fitting onthe fan reversing valve. Connect the fan valve returnhose (3) to the elbow on the fan reversing valve.

STEP 197

BD03A174

Connect the fan reverse hose (2) to the fitting on thefan reversing valve. Connect the fan forward hose (1)to the fitting on the fan reversing valve.

STEP 198

BD03A174

Connect the electrical connector for the fan reversingvalve.


STEP 200Check the level of the hydraulic oil in the reservoir.


STEP 202Stop the engine and check for hydraulic oil leakage atthe fan reversing valve.

STEP 203Check the level of the hydraulic oil in the reservoirand add as required. Tighten the filler cap on thereservoir.

34

1

2

8001-32


THERMAL VALVE

Removal




STEP 206

BD06F211

Tag and disconnect the hoses from the thermal valve.Install a plug in the hose and a cap on the fitting.

STEP 207Remove the mounting bolts from the thermal valve,remove the valve from the machine.

Installation

STEP 208Place the thermal valve into position on the machine.

STEP 209Lubricate and install new O-rings in the fittings.

STEP 210Install the bolts, washers and nuts. Tighten the nuts.

STEP 211Connect the hoses to the thermal valve, remove anddiscard tags.


STEP 213Check the level of the hydraulic oil in the reservoir.


STEP 215Stop the engine and check for hydraulic oil leakage atthe thermal valve.

STEP 216Check the level of the hydraulic oil in the reservoirand add as required. Tighten the filler cap on thereservoir.

Section8002 80

02




HYDRAULIC SPECIFICATIONS, TROUBLESHOOTING, AND PRESSURE CHECKS

8002-2


TABLE OF CONTENTS

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Problems in All Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Problem in All Loader Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Problem in the Braking Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Problem in a Single Loader Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Problem in the Steering Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Problem in the Ride Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

TESTING AND ADJUSTING THE HIGH PRESSURE PUMP DIFFERENTIAL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Adjusting the High Pressure Pump Differential Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

TESTING AND ADJUSTING THE LOW PRESSURE PUMP DIFFERENTIAL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Adjusting the Low Pressure Pump Differential Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

TESTING AND ADJUSTING THE LOADER LIMIT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Adjusting the Loader Limit Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

TESTING AND ADJUSTING THE STEERING LIMIT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Adjusting the Steering Limit Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

TESTING AND ADJUSTING THE LOADER PUMP CUTOFF PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Adjusting the Loader Pump Cutoff Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

TESTING THE HYDAULIC CONTROLLER PILOT SUPPLY PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

HIGH PRESSURE PUMP FLOW TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18TESTING AND ADJUSTING THE CIRCUIT RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

TESTING THE RIDE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21HYDRAULIC COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

8002-3


SPECIFICATIONSManufacturer........................................................................................................................................ 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 settingAuxiliary 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 5002Brake accumulator pressure .......................................................................................................... See Section 7002

NOTE: Both pump sections provide flow for both the steering and loader functions.

8002-4


SPECIAL TOOLS

633L95

CAS-1904 PRESSURE FITTING KIT

632L95


B785789M

CAS-10280 FLOWMETER

B877168V

CAS-1808 FLOWMETER FITTING KIT

B877895M

CAS-10090 HAND PUMP

B877558M


8002-5


TROUBLESHOOTING PROCEDURE

Visually check the machine for oil leakage anddamaged or missing parts. Repair or replaceany damaged or missing parts.

Check the oil level in the hydraulic reservoir. Is the oil level correct?.

NoFill the hydraulic reservoir with the hydraulic oilspecified in Section 1002.

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 ifthe engine is good.

See Section 8003 and check for contaminated oil. Is the oil contaminated?

NoSee Page 18. Do the flow meter test of thehydraulic pump.

Yes

See Section 8003 and clean or replace the oil.

Problem in All Loader Circuits

See Page 11 and check the pressure settingof the limit pressure in the loader controlvalve. Is the pressure setting correct?

NoAdjust the limit pressure. See page 11 in thissection.

Problem in the Braking Circuit

See Section 7002 and check the braking circuit.

8002-6


Problem in a Single Loader Circuit

Star t and run the engine at full throttle.Operate the control for the bad circuit. Doesthe cylinder move in both directions?

NoThe loader control valve is damaged. SeeSection 8005 and repair the loader controlvalve

Yes

Check the cylinder piston packing. Is the packing good?

No See Section 8006 and repair the cylinder.

Yes

See Page 20. Check and adjust the circuit relief valves. Then check the operation of the circuit again. Does the circuit work correctly?

NoSee Section 8005. Disassemble the loaderc o n t r o l va l ve a n d c h e ck fo r wo r n o rdamaged parts.

Yes

The problem is repaired.

Problem in the Steering Circuit

See Section 5002 and check the steeringcircuit. Is the steering circuit good? No Repair the component as necessary.

Yes

See Page 13. Do the Steering Pump LimitPressure Test and Adjustment

Problem in the Ride Control

Lift arms rapidly and continuously sinktowards the ground. No

See the Ride Control Test Procedure page21 in this section.

Yes

Check the manual bleed valve for the ridecontrol accumulator to be sure that it isclosed.

8002-7


TESTING AND ADJUSTING THE HIGH PRESSURE PUMP DIFFERENTIAL PRESSURE

Pressure Check

STEP 1

BD00M041

Install articulation lock (1).

STEP 2Make sure that the temperature of the hydraulic oil isat least 54°C to 57°C (129°F to 135°F). The followingis the procedure for heating the hydraulic oil.

● To measure the oil temperature with the instrumentcluster:



● To heat the hydraulic oil do the following:

A. Start the engine and run at full throttle.

B. Hold the bucket control lever in theROLLBACK posi t ion whi le ra is ing andlowering the lift arms from ground level to fullheight.

C. Continue this procedure until the temperatureof the hydraulic oil is 54° to 57°C (129° to135°F).

After heating oil to operating temperature, lowerbucket to the ground, turn off the engine, and relieveall pressure in the hydraulic system.

STEP 3

BD06G180

BD06F148

Connect two 69 bar (1000 psi) test gauges, one tothe test port (2) located on the priority valve, and oneon the pump load-sense pressure tap (1 closest totransmission).

IMPORTANT: Do not steer or operate loader controlswhile the gauges are connected, gauges could bedamaged.

STEP 4Start the engine and run at low idle.

STEP 5Make sure all of the controls are in the neutralposition and record the readings on the test gauges(1) and (2).

STEP 6Subtract the reading of the test port (1) from thereading of the test port (2).


1

1. TEST PORT (LOAD SENSE)2. TEST PORT (PUMP PRESSURE)

1

2

8002-8


STEP 7The difference between the two readings should be24 to 27 bar (350 to 390 psi).

STEP 8If this reading is more or less than specified, it will benecessary to adjust the pump load-sense pressure.

Adjusting the High Pressure Pump Differential Pressure

STEP 9The load-sense adjusting screw is directly below theload-sense pressure tap. Turn the screw clockwise toincrease the load-sense pressure. Turning the screwcounterclockwise will decrease the load-sensepressure.

NOTE: One turn of the adjustment screw will changethe pressure approximately 16 bar (230 psi).

8002-9


TESTING AND ADJUSTING THE LOW PRESSURE PUMP DIFFERENTIAL PRESSURE

Pressure Check

STEP 1

BD00M041











STEP 3

BD06G180

BD06F148

Connect two 69 bar (1000 psi) test gauges, one tothe test port (2) located on the priority valve, and oneon the pump load-sense pressure tap (1 furthestfrom the transmission).

IMPORTANT: Do not steer of operate loader controlswhile the gauges are connected, gauges could bedamaged.

STEP 4Start the engine and run at low idle.

STEP 5Make sure all of the controls are in the neutralposition and record the readings on the test gauges(1) and (2).

STEP 6Subtract the reading of the test port (1) from thereading of the test port (2).


1

1. TEST PORT (LOAD SENSE)2. TEST PORT (PUMP PRESSURE)

1

2

8002-10


STEP 7The difference between the two readings should be25 to 28 bar (360 to 400 psi).

STEP 8If this reading is more or less than specified, it will benecessary to adjust the pump differential pressure.

Adjusting the Low Pressure Pump Differential Pressure

STEP 9The differential adjusting screw is directly below theload-sense pressure tap. Turn the screw clockwise toincrease the load-sense pressure. Turning the screwcounterclockwise will decrease the differentialpressure.


8002-11


TESTING AND ADJUSTING THE LOADER LIMIT PRESSURE

Pressure Check

STEP 1

BD00M041


STEP 2

BD06F148

Connect a 345 bar (5000 psi) test gauge to the testport (1), located on the priority valve.










STEP 4Run the engine at full throttle.

STEP 5Roll the loader bucket back against the stops.

STEP 6Record the reading on the test gauge.

STEP 7Reading should be 248 to 255 bar (3600 to 3700 psi).

STEP 8If this reading is more or less than specified, it will benecessary to adjust the pump limit pressure.


1. TEST PORT (LOAD LIMIT)

1

1

8002-12


Adjusting the Loader Limit Pressure

BD06H193

STEP 9The limit adjusting screw is located on the left side ofthe loader valve. Turn the screw clockwise toincrease the limit pressure. Turning the screwcounterclockwise will decrease the limit pressure.


8002-13


TESTING AND ADJUSTING THE STEERING LIMIT PRESSURE

Pressure Check

STEP 1

BD00M041


STEP 2

BD06F148

Connect a 345 bar (5000 psi) test gauge to the testport (1), located on the priority valve.










STEP 4Start the engine and run at full throttle.

STEP 5Steer hard in either direction over relief pressure.



STEP 8If this reading is more or less than specified, it will benecessary to adjust the steering limit pressure.


1. TEST PORT (LOAD LIMIT)

1

1

8002-14


Adjusting the Steering Limit Pressure

BD06F147

STEP 9The steering priority valve is located on the hydraulicpump, the adjust ing valve is located on thetransmission side of the priority valve. Turning thescrew clockwise to increase the limit pressure.Turning the screw counterclockwise will decrease thelimit pressure.

1. STEERING LIMIT VALVE

1

8002-15


TESTING AND ADJUSTING THE LOADER PUMP CUTOFF PRESSURE

Pressure Check

STEP 1

BD00M041


STEP 2

BD06F148

Connect two 345 bar (5000 psi) test gauge to the testport (1) located on the large hydraulic tube on thebottom of the pump.










STEP 4Start the engine and run at full throttle.

STEP 5Roll the loader bucket back against the stops.



STEP 8If this reading is more or less than specified, it will benecessary to adjust the pump cutoff pressure.


1. TEST PORT (PUMP PRESSURE)

1

1

8002-16


Adjusting the Loader Pump Cutoff Pressure

STEP 9

BD06G179

The unloading adjuster is the longer of the twoadjusters on the loader pump. Turn the screwclockwise to increase the cutoff pressure. Turning thescrew counterclockwise will decrease the cutoffpressure.

NOTE: The adjusting screw is located just above thesteering priority valve on the pump furthest from thetransmission.

8002-17


TESTING THE HYDAULIC CONTROLLER PILOT SUPPLY PRESSURENOTE: This pressure is factory preset and is notadjustable.

Pressure Check


● To measure the oil temperature with theinstrument cluster:







STEP 2Raise lift arms to the top and turn off the engine. Turnthe ignition switch to the “RUN” position.

STEP 3Repeatedly put the loader control lever into “FLOAT”position and back to neutral.

STEP 4The system should allow a minimum of 10 actuationsinto float and still cause the lift arms to come down.

NOTE: If 10 full actuations cannot be made, aninternal hydraulic leak exists, proceed to next step.

STEP 5Start machine and lower the bucket to the groundand turn off the engine. Turn the ignition switch to the“RUN” posit ion, operate the pi lots controls aminimum of 30 strokes to relieve any pressure in thesystem.

STEP 6Open the right side compartment to gain access tothe loader control handle.

STEP 7Attach a gauge capable of reading 70 bar (1000 psi)to the test port under loader control handle.

STEP 8Start and run the machine at low idle, hold the bucketcontrol lever in the ROLLBACK position to increasethe system pressure.

STEP 9A pressure reading of 29.5 to 39.5 bar (425 to 575psi) should be obtained, if pressure is not asspecified do the following steps.

STEP 10Lower the bucket to the ground and turn off theengine. Turn the ignit ion switch to the “RUN”position.

STEP 11Operate the pilot controls several times until thegauge pressure suddenly drops to zero. The lastpressure reading before the drop to zero is thenitrogen charge pressure in the accumulator. If thepressure is below 13 to 15 bar (188 to 218 psi),replace the accumulator. If accumulator test is good,go to next step.

STEP 12Replace the pilot controls, see section 8001, retestthe system, if test fails go to next step.

STEP 13Replace the loader control valve, see section 8001,retest the system.

8002-18


HIGH PRESSURE PUMP FLOW TESTNOTE: The pump differential pressure must be setbefore attempting any other tests. Refer to page 7 ofthis section.

STEP 1Connect the flow meter (3) by disconnecting the inlethose (6) to the valve supply tube (13), installing a cap(12) on the fitting at the valve supply tube (13). Referto illustration on page 19.

STEP 2Disconnect the load sense hose (7) and install a cap(12) the fitting at the loader valve (15).

NOTE: This is the line that returns to the pumpcompensator valve.

STEP 3Connect a “T” fitting (10) into the loader control valveinlet hose (6) and to the flow meter inlet hose (11).

STEP 4Use a union (9) and connect an in line needle valve(8) to the open port in the “T” fitting (10), connect theload sense hose (7) to the needle valve (8).

STEP 5Make sure that the flow meter valve and the installedneedle valve are in the open position. Start and runthe engine at high idle, slowly close the flow metervalve until a pressure reading of 103 bar (1500 psi) isobtained.

STEP 6Using the temperature gauge on the flow meter,continue to run the engine at high idle until thetemperature of the hydraulic oil is at least 52°C to60°C (125°F to 140°F).

STEP 7Run the engine at low idle, fully open the flow metervalve.

STEP 8Open the needle valve (8) and operate the engine at2000 rpm. At 0 bar (0 psi) the flow should be 250 to255 L/min (66 to 67.4 gpm).

STEP 9Close the flow meter valve slowly and read the flowat 34.5 bar (500 psi) the flow should be 249 to 255L/min (65.8 to 66.8 gpm).

STEP 10Close the flow meter valve slowly and read the flowat 2000 psi @ 2000 rpm. The flow should read 244.5to 247.5 L/min (64.6 to 65.4 gpm).

STEP 11Continue to close the flow meter valve slowly, atapproximately 2900 psi the f low should dropsignificantly, this will be the low pressure pumpdestroking.

STEP 12Continue slowly closing the flow meter valve until3500 psi is reached. The flow should read between120 to 122 L/min (31.6 and 32.1 gpm).

STEP 13If any of the pump flow readings are not withinspecifications, the pump may be out of calibrationand Techn ica l Suppor t Ser v ices shou ld becontacted.

8002-19


BS06G117

1. HYDRAULIC RETURN MANIFOLD 6. HOSE M42 ORB 11. FLOW METER INLET HOSE2. FLOW METER RETURN HOSE 7. LOAD SENSE HOSE M14 ORB 12. CAP3. FLOW METER 8. NEEDLE VALVE 13. VALVE TUBE SUPPLY4. PUMPS 9. UNION 14. ELBOW M14 ORB5. 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

1

2

35

4

6

7

8

9

10

11

1213

12

14

15

8002-20


TESTING AND ADJUSTING THE CIRCUIT RELIEF VALVES

Pressure Check

STEP 1Circuit relief valves are located as shown below.

BS03B022

STEP 2Raise the lift arms and install the safety link on the liftarm cylinder.

STEP 3Loosen and remove the bolts and washers thatfasten the access cover plate for the loader controlvalve. Remove the cover plate.

STEP 4Remove the safety strut and lower the bucket to thefloor. Shut off the engine. Find an easy place todisconnect the line for the circuit to be tested.

STEP 5Connect the hand pump to the disconnected line thatgoes to the loader control valve.

STEP 6Make sure that the hand pump is full of hydraulic oiland that the temperature of the oil is approximately21°C (70°F).

STEP 7Operate the handle of the hand pump and read thehighest pressure. Repeat this step several times tobe sure of the reading.

STEP 8Compare the reading to the specifications on Page 3.

STEP 9If the pressure is not correct, adjust the circuit reliefvalve.

Adjustment

STEP 1Loosen the lock nut. Turn the adjustment screwc lockw ise to i nc rease the p ressure o rcounterclockwise to decrease the pressure.

NOTE: One turn of the adjusting screw will changethe pressure approximately 138 bar (2000 psi).

STEP 2Check the pressure again. Repeat the adjustment asnecessary.

1. CIRCUIT RELIEF VALVES2. PUMP LIMIT PRESSURE ADJUSTMENT3. BUCKET SPOOL4. LIFT SPOOL5. AUXILIARY SPOOL6. LOADER CONTROL VALVE

3

1

2

1

3

4

451

5

1

6

8002-21


TESTING THE RIDE CONTROL

STEP 1Move the machine to a clear level surface withclearance for full lift arm and bucket movement.

STEP 2Install the ar ticulation lock, star t the machine,activate the parking brake.

STEP 3With the pilot controller in neutral, set the ride controlrocker switch on the right side console to the “AlwaysOn” position and observe the switch lamp, the lampshould illuminate.

STEP 4Set the ride control rocker switch to the “Off” positionand observe the switch lamp, the lamp should go out.

NOTE: This indicates that the switch is operatingcorrectly and has power, if the switch does notilluminate see section 4002 and troubleshoot theelectrical system for the ride control.

STEP 5Raise the lift arms to the top of their travel and dumpthe bucket.

STEP 6Dump the bucket until it hits the dump stops. Hold thebucket in the dump position for 5 to 10 seconds.

NOTE: This will charge the ride control accumulator.

STEP 7Lower the lift arms and roll the bucket back to a carryposition. Do not leave the lift arms or the bucket ontheir stops, place the pilot control lever in the neutralposition.

STEP 8Set the ride control rocker switch to the “Always On”position. The lift arms should rise 15 to 30 cm (6 to12 inches) with an empty bucket.

NOTE: Test results will be for a machine with aempty factory bucket and no attachments.

STEP 9If there is little or no lift arm raise, the test may havebeen done too slowly. The elapsed time betweenstep 6 and step 8 should not exceed six seconds.

NOTE: If test was done to slowly repeat in theallotted time.

STEP 10If test was completed in the allotted time and the liftarms still do not rise, test the nitrogen charge in theaccumulator, see section 8013.

8002-22


HYDRAULIC COMPONENT LOCATIONS

BC00N140

NOTE: The hydraulic schematic is located in the rear pocket. All numbers are coordinated with the hydraulicschematic for reference.

1. REAR BRAKE CYLINDERS 11. FRONT BRAKE CYLINDERS2. BRAKE ACCUMULATOR PRESSURE DIAGNOSTIC

COUPLER12. RIDE CONTROL ACCUMULATOR BLEEDER VALVE AND

RIDE CONTROL VALVE (OPTIONAL) 3. BRAKE ACCUMULATORS 13. PARKING BRAKE CYLINDER4. FRONT AND REAR AXLE BRAKE PRESSURE

DIAGNOSTIC COUPLERS14. STEERING PRESSURE DIAGNOSTIC COUPLER15. STEERING PRIORITY VALVE 16. STEERING CYLINDERS17. AUXILIARY STEERING PUMP AND MOTOR 18. AUXILIARY STEERING PRIORITY VALVE 19. AUXILIARY STEERING PRESSURE SWITCH

5. BRAKE LIGHT PRESSURE SWITCH6. BRAKE WARNING PRESSURE SWITCH7. BRAKE AND ACCUMULATOR CHARGING VALVE8. LIFT CYLINDERS9. BUCKET CYLINDER (TILT CYLINDER)

10. RIDE CONTROL ACCUMULATOR

12

8

8

9

1516

1918

17

14

7

2

6

3

1

11

13

4

5

10

8002-23


BC00N140

NOTE: The hydraulic schematic is located in the rear pocket. All numbers are coordinated with the hydraulicschematic for reference.

20. FAN DRIVE MOTOR 28. PUMP PRESSURE DIAGNOSTIC COUPLER21. HYDRAULIC RESERVOIR BREATHER 29. LOAD SENSING DIAGNOSTIC COUPLER22. HYDRAULIC RESERVOIR 30. IMPLEMENT HYDRAULIC PUMP23. PILOT PRESSURE DIAGNOSTIC COUPLER 31. HYDRAULIC FILTER24. PILOT CONTROL VALVE 32. HYDRAULIC COOLER25. PILOT PRESSURE ACCUMULATOR 33. BRAKE HYDRAULIC PUMP26. LOADER CONTROL VALVE 34. FAN VALVE 27. PARKING BRAKE ACCUMULATOR

20

32

21

22

23

28

24

2625

29

34

30

3127

33

8002-24


NOTES

Section8003

8003


Printed in U.S.A.Issued April, 2003 Revised August, 2006


CLEANING THE HYDRAULIC SYSTEM

8003-2


TABLE OF CONTENTS

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4TYPES OF CONTAMINATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4CLEANING THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5FLUSHING WATER FROM THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

8003-3


SPECIAL TOOLS

806127

CAS101162A, filter unit, portable.

TR98H032

CAS10192, vacuum pump.

806128

CAS10508, fitting kit.

8003-4


GENERAL INFORMATIONContamination in the hydraulic system is a majorcause of the malfunction of hydraulic components.Contamination is any foreign material in the hydraulicoil. Contamination can enter the hydraulic system inseveral ways.

1. When you drain the oil or disconnect any line.

2. When you disassemble a component.

3. From normal wear of the hydraulic components.

4. From damaged or worn seals.

5. From a damaged component in the hydraulicsystem.

A l l hyd rau l i c sys tems opera te w i th somecontamination. The design of the components in thishydraulic system permits efficient operation with asmall amount of contamination. An increase in thisamount of contamination can cause problems in thehydraulic system. The following list includes some ofthese problems.

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.

5. Pump gears, housing, and other parts wearrapidly.

6. Relief valves or check valves held open by dirt.

7. Quick failure of components that have beenrepaired.

8. Cycle times are slow; machine does not haveenough power.

If your machine has any of these problems, check thehydraul ic oi l for contaminat ion. See types ofcontamination below. If you find contamination, usethe Portable Filter to clean the hydraulic system.

TYPES OF CONTAMINATIONThere are two types of contamination, microscopicand visible.

1. Microscopic contamination occurs when very fineparticles of foreign material are in suspension inthe hydraulic oil.

2. These particles are too small to see or feel.Microscopic contamination can be found byidentification of the following problems or bytest ing in a laborator y. Examples of theproblems:

A. Cylinder rod seal leak.

B. Control valve spools do not return toNEUTRAL.

C. The hydraulic system has a high operatingtemperature.

3. Visible contamination is foreign material that canbe found by sight, touch, or odor. Visiblecontamination can cause a sudden failure ofcomponents. Examples of visible contamination:

A. Particles of metal or dirt in the oil.

B. Air in the oil

C. The oil is dark and thick.

D. The oil has an odor of burned oil.

E. Water in the oil. See page 7.

8003-5


CLEANING THE HYDRAULIC SYSTEM1. Prepare the portable filter on page 3 by doing the

following steps:

A. Remove all the hydraulic oil from the inlet andoutlet hoses for the portable filter.

B. Remove the filter element from the portablefilter.

C. Remove all hydraulic oil from the portablefilter.

D. Clean the inside of the housing for the filterelement.

2. You must know whether the contamination ism ic roscop ic o r v is ib le . See t ypes o fcontamination on page 4.

3. If the contamination is microscopic:

A. Check the maintenance schedule for themachine to learn if the hydraulic oil must bechanged. If needed, change the hydraulic oil.See Section 1002 for specifications. Changethe hydraulic filter.

B. Do steps 6 through 35.

4. If the contamination is visible:

A. Change the hydraulic oil and hydraulic filter.See Section 1002 for specifications.

B. Do steps 5 through 35.

5. Check the amount of contamination in thehydraulic system by doing the following steps:

A. Disassemble one cylinder in two differentcircuits. Check for damage to seals, scoring ofthe cylinder wall, etc. Repair the cylinders asnecessary.

B. If, in your judgment, the damage to thecylinders was caused by sever contaminationand is not the result of normal wear, it isnecessary to remove, clean and repair valves,pump, lines, cylinders, hydraulic reservoir, etc.in the hydraulic system.

6. Remove the breather from the reservoir andconnect the vacuum pump to the opening. Startthe vacuum pump.

7. Loosen and remove the drain plug from thereservoir.

8. Using the fitting kit shown on page 3, install thevalve in the hole for the drain plug. Make surethat the valve is closed.


10. Connect the inlet hose for the portable filter tothe valve that is installed in the hole for the drainplug.

11. Disconnect the vacuum pump from the hydraulicreservoir air breather hose. Remove the fillercap.

12. Install the outlet hose for the portable filter in thehydraulic reservoir filler neck.

13. Open the valve that is installed in the hole for thedrain plug.

14. Move the switch for the portable filter to the ONposition. 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 theengine speed to full throttle. Heat the oil tooperating temperature by doing the followingsteps:

A. Hold the blade control lever in the TILTposition for five seconds.

B. Return the blade control lever in theNEUTRAL position for five seconds.

C. Repeat steps A and B until the oil in thehydraulic 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 completelyextend and retract the cylinders. Continue tooperate each hydraulic circuit two times, oneafter the other for 45 minutes.


20. Continue to run the portable filter for 10 minutes.

21. Stop the portable filter.


23. Remove the hose from the hydraulic reservoir.

8003-6


24. Close the valve that is installed in the hole for thedrain plug.

25. Disconnect the inlet hose for the portable filterfrom the valve. Remove the outlet hose from thereservoir filler neck and replace filler cap.

26. Connect a vacuum pump to the breather hose ofthe hydraulic reservoir.

27. Start the vacuum pump.

28. Remove the valve from the hole for the drainplug.

29. Install the drain plug.

30. Stop the vacuum pump. Disconnect the vacuumpump from the opening in the reservoir andinstall the breather.

31. Remove the hydraulic filter elements from themachine.

32. Install new hydraulic filter elements on themachine.

33. Start the engine. Check for oil leakage aroundthe new hydraulic filters.


35. Check the oil level in the hydraulic reservoir. Addo i l as requ i red . See Sec t ion 1002 fo rspecifications.

8003-7


FLUSHING WATER FROM THE HYDRAULIC SYSTEM1. Start and run the engine at 1500 rpm (r/min).

2. Completely retract the cylinders of allattachments on the machine. Angle the blade tothe right, the right cylinder will be fully retractedand the left will be fully extended. Stop theengine.

39-4

NOTE: Any attachment or part of an attachment thatis raised must be supported with acceptableequipment to prevent the attachment from falling.

3. Move each control lever in both directions torelease pressure in the hydraulic circuits.

4. Loosen and remove the filler cap from thereservoir.

5. Drain the hydraulic oil from the reservoir.

A. See Section 1002 for capacity specifications.

B. Have available acceptable equipment to drainthe hydraulic oil.

C. Remove the drain plug from the bottom of thereservoir.



8. Install the drain plug in the bottom of thereservoir.

9. Fill the hydraulic reservoir with hydraulic fluid.See Section 1002 for specifications.

10. Disconnect the line from the OPEN end andCLOSED end of each cylinder.

11. Be sure all control levers are in the NEUTRALposition.

12. Start and run the engine at low idle.

IMPORTANT: Check the oil level in the hydraulicreservoir frequently while doing step 13. Haveanother person hold a container under the hydrauliclines while you do step 13.

13. Slowly move each control lever in both directionsuntil oil begins to flow from the open line. Holdthe control lever in place until clean oil flows fromthe open line.


15. Connect the system line to the CLOSED end ofeach cylinder.

16. Connect a suitable drain line to the OPEN end ofeach cylinder and place the other end in anacceptable container for contaminated oil.


18. Slowly and completely extend all cylinders. Asthe piston rod comes in/out of the cylinder, oil willbe pushed out of the OPEN end of the cylinders.

NOTE: Any attachment or part of an attachment thatis raised must be supported with acceptableequipment to prevent the attachment from falling.

19. Support any attachments that will be in theRAISED position.


21. Disconnect the drain lines and connect thesystem lines to the cylinders.

22. Check the oil level in the hydraulic reservoir. Addo i l as requ i red . See Sec t ion 1002 fo rspecifications.

23. Install the filler cap on the reservoir.



26. Start and run the engine at 1500 rpm (r/min),operate each hydraulic circuit to completelyextend and retract the cylinders.

27. Stop the engine and check for leaks. Check theoil level in the hydraulic reservoir. Add oil asrequired. See Section 1002 for specifications.

WARNING: If retracting the cylinder rodscauses the attachments to be raised, blockthe attachments in place before proceedingto the next step!

8003-8


NOTES

Section8004

8004




HYDRAULIC PUMP

8004-2


TABLE OF CONTENTS

PUMP SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3PREPARING THE EQUIPMENT PUMP FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3EQUIPMENT PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

8004-3


PUMP SPECIFICATIONSManufacturer................................................................................................................................................... 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 torquesPump 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 USEDo the following procedure any time you install a newor overhauled equipment pump:

1. Start and run the engine at half throttle for threeminutes.

2. With the engine running at half throttle, move thebucket control lever into roll back position. Holdthe bucket control lever in this position until thebucket stops moving.

3. Hold the bucket control lever in the roll backposition for five seconds. Then put the bucketcontrol lever in the NEUTRAL position for fiveseconds.

4. Repeat Step 3 for three minutes.

5. Increase the engine speed to full throttle andrepeat Steps 3 and 4.

6. Stop the engine and check for leaks.

7. Replace the hydraulic filter.

8004-4


EQUIPMENT PUMP

BC06F550

1. SNAP RING 11. TAPERED BEARING 21. PRESSURE PINS2. SEAL 12. BEARING RACE 22. BACKUP PLATE3. MAIN BODY 13. SHIM 23. SPRING4. O-RING 14. SPRING 24. SNAP RING5. PLUG 15. HALF BEARING 25. PORT PLATE6. CONTROL VALVE 16. SWASH PLATE 26. SHIM7. CAP SCREW 17. PISTONS 27. TAPERED BEARING8. PISTON ROD 18. RETAINING PLATE 28. BEARING RACE9. CONTROL PISTON 19. BALL 29. DOWEL PIN

10. SHAFT 20. CYLINDER 30. END COVER

7

6

5

43

21

8 9

4

5

1312

1415

16

15

1718

19

20

11

10

2122

2324

25

2627

28

29

30

8004-5


Disassembly

STEP 1Remove all dirt, oil, and grease from the exterior ofthe equipment pump.

STEP 2

BC06F551

Put alignment marks on the end cover and housing.

STEP 3

BC06F552

Remove the control valve.

STEP 4

BC06F553

Remove the four bolts.

8004-6


STEP 5

BC06F554

Remove the end cover.

NOTE: Watch for the flow plate, it can be stuck toeither the end cover or pump body.

STEP 6

BC06F555

Use a suitable bearing race puller and pull thebearing race from the end cover.

NOTE: Do not damage the sealing surfaces.

8004-7


STEP 7

BC06F556

Remove the bearing and shim.

STEP 8

BC06F557

Remove the rotary group from the housing in ahorizontal position.

STEP 9

BC06F558

Remove plug, pull control piston using a suitable toolas shown.

NOTE: Do not use a magnet to pull the piston.

STEP 10

BC06F559

Remove the piston rod and swash plate. Turn theswash plate slightly to break it free from the bearings.

8004-8


STEP 11

BC06F560

Remove the bearing and spring.

STEP 12

BC06F561

Remove the shaft and bearing.

STEP 13

BC06F562

Remove the retaining ring an seal.

STEP 14

BC06F563

Use a suitable bearing race puller and pull thebearing race from the housing.

STEP 15

BC06F564

Remove the shim and plug.

8004-9


Inspection

STEP 16Clean all parts in cleaning solvent. Be careful not toremove the a l ignment mar ks made dur ingdisassembly.

STEP 17

BC06F565

Check for wear on the splines, seal areas forgrooves, bearing areas for scaring, and key set.

STEP 18

BC06F566

Check the surface that the pistons contact forgrooves and scaring.

STEP 19

BC06F567

Check the bearing surface.

STEP 20

BC06F568

Check that the retaining plate is free of grooves andthat there is no sign of wear.

STEP 21

BC06F569

Check the sliding surface for scratches or metaldeposits, check the tightness of the cup on thepiston.

NOTE: If a piston needs to be replaced, all of thepistons must be replaced.

8004-10


STEP 22

BC06F570

Check the cylinder bores and splines for damage.

STEP 23

BC06F571

Check ball for grooves and wear.

STEP 24

BC06F572

Check cylinder surface for grooves, wear, embeddedparticles. Check flow plate for scratches or wear.

STEP 25

BC06F573

Check mounting surface for the flow plate fordamage.

8004-11


Assembly

STEP 26

BC06F574

Install the plug in the housing and tighten to 127 Nm(93.5 pound-feet). Install shim and press in thebearing race.

STEP 27

BC06F575

Put the shaft and bearing in the housing.

STEP 28

BC06F576

Press in a new race into the end cover.

8004-12


STEP 29

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 beobtained, add remove shims from bear ing asrequired.

STEP 31

BC06F579

Install the seal and retaining ring.

STEP 32

BC06F580

Put new bearings in the housing. Install the reactionspring.

8004-13


STEP 33

BC06F581

Install the swash plate into the housing, work theswash plate from side to side to seat it in thebearings and spring. Install the piston rod.

STEP 34

BC06F582

Install the piston into the housing with flat surfaceout. Lubricate the O-ring and install the plug, tightenthe plug to 90 Nm (66 pound-feet).

STEP 35

BC06F583

Use grease to hold the pressure pins into position,install the spacer, spring and snap ring.

8004-14


STEP 36

BC06F584

Use a suitable compressor, compress the spring andinstall the snap ring.

STEP 37

BC06F585

Place the ball onto the pressure pins, install thepistons into the retaining plate.

STEP 38

BC06F586

Lubricate the piston and retaining plate with clean oil,install the piston into the rotating housing.

STEP 39

BC06F587

Hold the pistons in the rotating housing using anO-ring, install the rotating group into the housing,remove the O-ring.

8004-15


STEP 40

BC06F588

Use the shim that was required for the bearing preload in step 30. Install the shim and bearing onto theshaft.

STEP 41

BC06F589

Install a new O-ring on the end cover, place the flowplate onto the rotating group with aligning notch up.Place the end cover onto the housing, make sure thatthe aligning pin in the end cover aligns with the slot inthe flow plate.

8004-16


STEP 42

BC06F590

Instal and tighten the four bolts to 165 Nm (121.5 pound-feet).

STEP 43

BC06F591

Use new O-rings, install and tighten the control valve.

Section8005

8005




LOADER CONTROL VALVE

8005-2


TABLE OF CONTENTS

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Spool Valve Housing Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Spool Valve Spool Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Spool Mounting Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Spool Mounting Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 and 4 Spool Valve Spool Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

DISSASEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Circuit Relief Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Circuit Relief Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

8005-3


SPECIFICATIONSManufacturer................................................................................................................................................... Rexroth

Special TorquesEnd 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 settingAuxiliary 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)

8005-4


BS03C033

2 SPOOL VALVE HOUSING CONFIGURATION

1. BOLT 7. LOAD SENSE SHUTTLE CHECK 13. FLOAT SOLENOID 18. LOAD CHECK

2. WASHER 8. ANTICAVITATION AND CIRCUIT

RELIEF 14. PLUG 19. FLOW LIMIT VALVE

3. LOCKING SCREWS 9. LOAD SENSE BLEED DOWN ORIFICE15. REGENERATION CHECK

VALVE20. PRESSURE RELIEF VALVE

4. PLATE 10. FLOW COMPENSATOR SPOOL 16. LOCKING SCREW 21. CONE5. REGENERATION

RELIEF VALVE11. HOUSING 17. SPRING 22. LOCKING SCREW

6. O-RINGS 12. PLUG

6

7

5

4

2

1

22

21

20

19

11

6

10

13

8

14

12 12

15

16

8

96 1718

3

6

6

8005-5


BC06F593

2 SPOOL VALVE SPOOL CONFIGURATION

6. O-RINGS 27. BOLT 32. BOLT23. SPRING RETAINER 28. PISTON 33. COVER24. SPRING 29. CAP NUT 34. ADJUSTING ROD25. SPRING 30. JAM NUT 35. SPOOL26. COVER 31. PISTON

25

24

6

34

6

27

33

23

35

2324

34 6

33

31

29

3230

31

32

6

3029

6

28

26

2423

8005-6


BS03C036

3 SPOOL MOUNTING CONFIGURATION

36. HOUSING 37. ANTICAVITATION AND CIRCUIT RELIEF

36

37

37

8005-7


BS03C035

4 SPOOL MOUNTING CONFIGURATION

38. NUT 39. STUD

39

38

8005-8


BS03C037

3 AND 4 SPOOL VALVE SPOOL CONFIGURATION

6. O-RINGS 31. PISTON23. SPRING RETAINER 32. BOLT24. SPRING 33. COVER29. CAP NUT 34. ADJUSTING ROD30. JAM NUT 35. SPOOL

2423

634

33

23

35

2324

346

33

31

29

3230

31

32

6

3029

6

8005-9


DISSASEMBLY

STEP 1Remove valve from machine, see section 8001.

STEP 2Remove bolts (27), cover (26), springs (24 and 25),and spring retainer (23).

STEP 3Remove bolts (32), covers (33), spring (24), andspring retainer (23).

STEP 4Use wooden dowel or brass drift and push spools(35) from housing (11).

IMPORTANT: Do not force spools from housing, ifspool binds work back and forth until spool comesout freely.

NOTE: Repeat steps 3 and 4 for a 3 and 4 spoolvalve configuration.

STEP 5Remove anticavitation valves (5, 8, 10, and 13).

NOTE: Repeat step for a 3 and 4 spool anticavitationvalves (37).

STEP 6Remove locking screw (22) and cone (21).

STEP 7Remove pressure relief valve (20).

STEP 8Remove flow limit valve (19).

STEP 9Remove locking screw (16), spring (17), and cone(18).

STEP 10Remove regeneration check valve (15).

STEP 11Remove locking screw (14).

STEP 12Remove load sense shuttle check valve (7).

STEP 13Remove locking screws (12).

STEP 14Remove pilot pressure reducing valve (9).

STEP 15Remove 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).

8005-10


STEP 16

BS03C025

Remove and discard O-rings and thrust rings frompilot pressure reducing valve (9).

STEP 17

BS03C026

Remove and discard O-rings and thrust rings fromflow limit valve (19).

STEP 18

BS03C027

Remove and discard O-rings and thrust ring fromlocking screw (14).

STEP 19

BS03C028

Remove and discard O-rings, thrust ring, and spoolseal from anticavitation valve (5).

1. O-RINGS 2. THRUST RINGS


11

2

2

2

11

1. O-RINGS 2. THRUST RING

1. O-RINGS 2. THRUST RING 3. SPOOL SEAL

21

1

2

1

1

1

3

8005-11


STEP 20

BS03C029

Remove and discard O-rings and thrust rings from pressure relief valve (20).

STEP 21

BS03C030

Remove and discard O-rings and thrust rings from anticavitation and pressure relief valves (10).


2

1

1

1

2

2


2

1

12

21

1

8005-12


STEP 22

BS03C031

Remove and discard O-rings and thrust rings from anticavitation valve (13).

1. O-RINGS 2. COIL

2

1

1

1

1

8005-13


STEP 23

BS03C032

Remove and discard O-rings and thrust rings from anticavitation and circuit relief valves (8 and 37).

1. O-RINGS 2. THRUST RING 3. SPOOL SEAL 4. LOCK NUT

1

2

1

1

34

8005-14


INSPECTION1. Discard all O-rings, thrust rings, and spool seals.

2. Clean all parts in cleaning solvent.

3. Check the spools and the spool bores fordamage and wear.

4. Check the parts of the pressure relief valve,anticavitation valves, and the anticavitation andcircuit relief valves. Use new parts as necessary.

Inspect the other parts of the control valve. If any ofthe parts are damaged, install new parts.

ASSEMBLY

STEP 1

BS03C032

Install new O-rings and thrust rings on anticavitation and circuit relief valves (8 and 37). Torque relief valve (A) intoanticavitation 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 indirection of arrow.

1. O-RINGS 2. THRUST RING 3. SPOOL SEAL 4. LOCK NUT

1

2

1

1

34

See Note

A

8005-15


STEP 2

BS03C031

Install new O-rings and thrust rings on anticavitation valve (13). Hand tighten coil nut (A).

STEP 3

BS03C030

Install new O-rings and thrust rings on anticavitation and pressure relief valves (10). Torque cap (A) to 100 Nm(73.7 pound feet).

1. O-RINGS 2. COIL

2

1

1

1

1

A


2

1

12

21

1

A

8005-16


STEP 4

BS03C029

Install new O-rings and thrust rings on pressure relief valve (20).


2

1

1

1

2

2

8005-17


STEP 5

BS03C025

Install new O-rings and thrust rings on pilot pressurereducing valve (9).

STEP 6

BS03C026

Install new O-rings and thrust rings on flow limit valve(19).

STEP 7

BS03C027

Install new O-rings and thrust ring on locking screw(14).

STEP 8

BS03C028

Install new O-rings, thrust ring, and spool seal onanticavitation valve (5).

STEP 9Install and torque regeneration check valve (15) to100 Nm (73.7 pound feet).

STEP 10Install and torque locking screw (14) to 100 Nm (73.7 pound feet).

STEP 11Install and tighten load sense shuttle check valve (7).

STEP 12Install and torque locking screws (12) to 240 Nm(177 pound feet).

STEP 13Install and torque pilot pressure reducing valve (9) to60 Nm (44 pound feet).

STEP 14Install new O-rings on housing (11). Install plate (4),bolts (1) and washers (2), onto housing (11). Torquebolts to 70 Nm (51.5 pound feet).

NOTE: For 4 spool configuration install new O-ringsbetween housings (36) and housing (11), install nuts(38) on studs (39). Torque nuts to 70 Nm (51.5 poundfeet).

STEP 15Install anticavitation valves (5, 10, and 13) and torqueto 100 Nm (73.7 pound feet).

NOTE: Repeat step for a 3 and 4 spool anticavitationvalves (37).



1. O-RINGS 2. THRUST RING

11

2

2

2

11

21

1

1. O-RINGS 2. THRUST RING 3. SPOOL SEAL

2

1

1

1

3

8005-18


STEP 16Install anticavitation valves (8) and torque to 200 Nm(147.5 pound feet).

STEP 17Install and torque flow limit valve (19) to 20 to 25 Nm(177 to 221 pound inches).

STEP 18Install cone (18), spring (17), locking screw (16).Torque locking screw to 100 Nm (73.7 pound feet).

STEP 19Install cone (21) and locking screw (22). Torquelocking screw to 40 Nm (30 pound feet).

STEP 20Lubricate spools with hydraulic oil and push spools(35) into housing (11).

IMPORTANT: Do not force spools into housing.

STEP 21Install spring retainers (23), springs (24), covers (33),and bolts (32). Torque bolts to 10.4 Nm (92 poundinches).

NOTE: Repeat steps 18 and 19 for a 3 and 4 spoolvalve configuration.

STEP 22Install spring retainers (23), spring (24 and 25), cover(26), and bolts (27). Torque bolts to 6 Nm (53 poundinches).

NOTE: Prior to installation in the machine, circuitreliefs can be tested.

STEP 23Install valve in machine, see section 8001.

STEP 24Check loader limit pressure, see section 8002.

Circuit Relief Pressure Test

STEP 1Connect the hand pump to the port for anticavitationand circuit relief valves (21).

NOTE: Repeat steps for machines that areconfigured with a 3 or 4 spool valve.

STEP 2Make sure that the hand pump is full of hydraulic oiland that the temperature of the oil is approximately21°C (70°F).

STEP 3Operate the handle of the hand pump and read thehighest pressure. Repeat this step several times tobe sure of the reading.

STEP 4Compare the reading to the specifications on Page 3.

STEP 5If the pressure is not correct, adjust the circuit reliefvalve.

Circuit Relief Adjustment

STEP 1Loosen the lock nut. Turn the adjustment screwc lockw ise to i nc rease the p ressure o rcounterclockwise to decrease the pressure.

NOTE: One turn of the adjusting screw will changethe pressure approximately 138 bar (2000 psi).

STEP 2Check the pressure again. Repeat the adjustment asnecessary.

Section8006

8006




CYLINDERS

8006-2


TABLE OF CONTENTS

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4


BUCKET CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

REPLACING THE BUSHINGS FOR THE LIFT CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

REPLACING BUSHINGS FOR THE BUCKET CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

8006-3


SPECIFICATIONSApproximate weight

Lift Cylinder...........................................................................................................................142.2 kg (313.5 pounds)

Bucket Cylinder........................................................................................................................199.2 kg (439 pounds)

SPECIAL TORQUESGland 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 TOOLSTorque Multiplier ......................................................................................................................................... CAS-1039

8006-4


LIFT CYLINDER

Disassembly1. Clean exterior of cylinder. If hoses were removed

with cylinder, remove hoses from cylinder.

2. Fasten tube (1) in an acceptable repair stand orother holding equipment. Do not damage tube(1).

3. Loosen and remove self-tapping screw (12).

4. Use a spanner wrench to loosen and removegland (4) from tube (1).

5. Pull piston rod (13) straight out of tube (1) toprevent damage to tube.

6. Fasten piston rod eye or yoke in a vise and put asupport under piston rod (13) near piston (15).Put a shop cloth between support and piston rodto prevent damage to piston rod.

7. Use a torque multiplier, CAS-1039, to loosen andremove bolt (14) that fastens piston (15) to pistonrod (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), andwear ring (18) from piston (15).

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).

Inspection1. Clean all parts in cleaning solvent. Use only lint

free cloths for cleaning and drying.

2. Check to be sure that piston rod (13) is straight.If piston rod is not straight, replace it with a newpiston rod.

3. Shine a light inside tube (1) and check for deepgrooves and other damage. If there is anydamage to tube, replace with a new tube.

4. Remove any small scratches on piston rod (13)or inside tube (1) with emery cloth of mediumgrit. Use emery cloth with a rotary motion.

5. Inspect bushings (2) in tube eye. Replace asrequired.

6. Inspect gland (4) for rust. Clean and remove rustas necessary.

7. Inspect gland end of tube (1) for sharp edgesthat may cut gland O-ring (11) and remove asnecessary.

8. Inspect piston (15) for damage and wear. Ifpiston is damaged or worn, replace with a newpiston.

8006-5


BC05J002

LIFT CYLINDER

1. TUBE 6. ROD SEAL 11. O-RING 16. SEAL2. BUSHING 7. BUFFER SEAL 12. SCREW 17. RING3. WIPER 8. BUSHING 13. ROD 18. WEAR RING4. GLAND 9. BACKUP RING 14. BOLT5. WIPER 10. O-RING 15. PISTON

135

15

1716

18

67

4

8

910

14

1

32

2

3

11

12

8006-6


AssemblyNOTE: If a new gland is being used, put part numberof cylinder on new gland.

1. Install bushing (8) in gland (4).

2. Install rod seal (6) in gland (4). Rod seal is to beinstalled 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 ofbuffer seal with groove must be toward bushing(8).

4. Install a new wiper (5) in gland (4). Lips of wipermust be toward outside end of gland (4).

5. Install a new O-ring (11) in groove on OD ofgland (4).

6. Install a new backup ring (9) in groove on OD ofgland (4). If both sides of backup ring are not flat,side that is not flat must be toward small end ofgland (4).

7. Install a new O-ring (10) next to backup ring (9)in groove on outside of gland (4). O-ring must betoward small end of gland.

8. Fasten piston rod (13) eye or yoke in vise.

9. Remove any marks and sharp edges on chamferat end of piston rod (13). Make sure that pistonrod 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 thepiston 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 Loctitecleaning solvent. Allow to dry. Apply Loctite 242to piston rod threads 6.3 mm (1/4 inch) fromopen 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.

15. Install bolt (14) into piston rod (13). Tighten boltto a torque of 2830 to 3220 Nm (2087 to 2374.9pound-feet). A torque multiplier can be used tohelp torque the bolt.

16. Install a new wear ring (18) in wide groove onoutside of piston (15).

17. Install a new ring (17) in the other groove on theoutside of the piston (15).

18. Install a new seal (16) on top of ring (17).

19. Fasten tube (1) in an acceptable repair stand orother holding equipment. Be careful to preventdamage 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) withclean oil.

24. Turn gland (4) into tube (1). Tighten gland to atorque 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 atorque of 2.3 Nm (20 inch-pounds).

C. If, after tightening gland, the self-tappingscrew (12) holes are not aligned, a new holefor self-tapping screw must be drilled. SeeStep 26.

26. If a new gland (4) or a new tube (1) are beingassembled:

A. Tighten gland (4) to 135 to 542 Nm (100 to400 pound-feet).

B. Use a No. 27 drill bit and drill a hole half ingland (4) and half in tube (1). Drill to a depth of11 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 atorque of 2.3 Nm (20 inch-pounds).

27. If hoses were removed with cylinder, install newO-rings, if equipped, on hose fittings. LubricateO-rings with clean oil. Install hoses.

8006-7


BUCKET CYLINDERS

Disassembly1. Clean the outside of the cylinder. If the hoses

were removed with the cylinder, remove thehoses from the cylinder.

2. Fasten the tube (1) in an acceptable repair standor other holding equipment. Do not damage thetube (1).

3. Loosen and remove the cap screws (2) andhardened washers (18) from the gland (3) andthe 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 andput a support under the piston rod (4) near thepiston (7). Put a shop cloth between the supportand the piston rod (4) to prevent damage to thepiston rod (4).

6. Remove the retaining ring (10) that fastens thepin (11) in the piston (7) and piston rod (4).

7. Remove the pin (11) from the piston (7) and thepiston rod (4).

8. Turn the piston (7) off the piston rod (4) andremove the piston (7).

9. Remove the gland (3) from the piston rod (4).

10. Remove the seal (6) from the OD of the piston(7).

11. Remove the wear ring (5) from the OD of thepiston (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), andbushing (17) from the gland (3).

Inspection1. Discard the parts that were removed from the

piston and the gland.

2. Clean all parts in cleaning solvent. Use only lintfree cloths for cleaning and drying.

3. Check to be sure that the piston rod is straight. Ifthe piston rod is not straight, replace it with anew piston rod.

4. Illuminate the inside of the tube for deep groovesand other damage. If there is any damage to thetube, replace it with a new tube.

5. Remove any small scratches on the piston rod orinside 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 oryoke and the tube. Replace as required.

7. Inspect the gland for rust and clean and removerust as necessary.

8. Inspect the gland end of the tube for sharp edgesthat will cut the gland O-ring and remove asnecessary.

9. Inspect the piston for damage and wear. If thepiston is damaged or worn, replace it with a newpiston.

8006-8


BC05M026

BUCKET CYLINDER

1. TUBE 7. PISTON 12. WIPER 17. BUSHING2. CAP SCREW 8. BACKUP RING 13. WIDE SEAL 18. HARDENED WASHER3. GLAND 9. O-RING 14. NARROW SEAL 19. SEAL4. PISTON ROD 10. RETAINING RING 15. BACKUP RING 20. BUSHING5. WEAR RING 11. PIN 16. O-RING6. SEAL

2

14

18

1312

3

1715

16

8

8

11

7

6

5

4

19

1

19

2019

10

9

19

20

8006-9


AssemblyNOTE: If a new gland is being used, put the partnumber of the cylinder on the new gland.

1. Install the bushing (17) in the gland (3), refer toillustration on page 8.

2. Install the wide seal (13) in the gland (3). Thewide seal (13) is to be installed so that the lips ofthe wide seal (13) are toward the bushing (17).The wide seal (13) can be difficult to install.

3. Install a new wiper (12) in the gland (3). The lipsof the wiper (12) must be toward the outside endof the gland (3).

4. Install the narrow seal (14) in the gland (3). Theside of the narrow seal (14) with the groove mustbe toward the bushing (17).

5. Install a new backup ring (15) in the groove onthe outside of the gland (3). If both sides of thebackup ring (15) are not flat, the side that is notflat 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). TheO-ring (16) must be toward the small end of thegland (3).

7. Remove any marks and sharp edges on thechamfer at the end of the piston rod (4). Makesure that the piston rod (4) is clean.

8. Lubricate the bore of the gland (3) and the pistonrod (4) with clean oil.

9. Push the gland (3) onto the piston rod (4). Ifnecessary, use a soft hammer to drive the gland(3) onto the piston rod (4).

10. Put a support below and near the end of thepiston rod (4). Use a shop cloth between thesupport and the piston rod (4) to prevent damageto the piston rod (4).

11. Install a new backup ring (8) in the groove in theID of the piston (7). If both sides of the backupring (8) are not flat, the side that is not flat mustbe toward the O-ring (9).

12. Install a new O-ring (9) in the groove in the ID ofthe piston (7) next to the backup ring (8).

13. Install the other new backup ring (8) in thegroove in the ID of the piston (7) next to theO-ring (9). If both sides of the backup ring (8) arenot flat, the side that is not flat must be towardthe O-ring (9).

14. Lubricate the ID of the piston (7) with clean oil.

15. Start the piston (7) onto the piston rod (4). Turnthe piston (7) onto the piston rod (4) until thepiston (7) is seated against the shoulder of thepiston rod (4).

16. If none of the holes in the piston (7) align with theholes in the piston rod (4), turn the piston (7)counterclockwise until one of the holes in thepiston (7) aligns with one of holes in the pistonrod (4). Do not turn the piston (7) more than 90degrees.

GS98J804

PISTON AND PISTON ROD HOLE ALIGNMENT

17. Install the pin (11) in the piston (7) and the pistonrod (4).

18. Install the retaining ring (10) in the pin (11).

7 11

10

4

8006-10


19. Install a new wear ring (5) in the wide groove onthe OD of the piston (7).

20. Install a new seal (6) in the groove on the OD ofthe piston (7).

21. Fasten the tube (1) in an acceptable repair standor other holding equipment. Be careful to preventdamage to the tube (1).

22. Lubricate the inside of the tube (1) and theoutside 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) withclean oil.

25. Push the gland into the tube (1) and align theholes in the tube (1).

26. Install the cap screws (2) and hardened washers(18).

27. Tighten the cap screws (2) in the sequenceshown. Torque to 420 to 500 Nm (310 to 368.8pound-feet).

BC05M027

TUBE AND GLAND HOLE ALIGNMENT

8006-11


REPLACING THE BUSHINGS FOR THE LIFT CYLINDERS

Removal1. Put piston tube (4) in a press.

2. Use an acceptable driver to press wipers (1) andbushings (2) out of piston tube (4) eye.

3. Clean bore for bushings (2) in tube (4) eye.

Installation1. Use an acceptable driver to press new bushings

(2) into tube (4) eye. Bushings shall be recessed8 mm (0.315 inch) in tube eye.

2. Use an acceptable driver to install wipers (1) untilflush with tube (4) eye. The lips of wipers mustbe toward outside of bore.

BS01C003

BUSHING AND WIPER REMOVAL AND REPLACEMENTLIFT CYLINDERS

1. WIPER 3. PISTON ROD YOKE2. BUSHING 4. TUBE

1

1

4

3

2

2

8006-12


REPLACING BUSHINGS FOR THE BUCKET CYLINDER

Removal1. Put piston rod eye (3) in a press.

2. Use an acceptable driver to press wipers (1) andbushing (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.

5. Clean bore for bushings (2) in piston rod eye (3)and tube (4) eye.

Installation1. 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) untilflush with piston rod eye (3). The lips of thewipers (1) must be towards outside of bore.

3. Use an acceptable driver to press new bushings(2) into tube (4) eye until recessed 8 mm (0.315inch).

4. Use an acceptable driver to install wipers (1) untilflush with tube (4) eye. The lips of wipers (1)must be towards outside of bore.

BS03B201

BUSHING AND WIPER REMOVAL AND REPLACEMENTBUCKET CYLINDERS

1. WIPER 3. PISTON ROD EYE2. BUSHING 4. TUBE

12

3

1

2

2

2

41

1

Section8007

8007




COUPLER SOLENOID LOCKING VALVE

8007-2


TABLE OF CONTENTS

coupler solenoid locking valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

8007-3


COUPLER SOLENOID LOCKING VALVE

Disassembly

STEP 1Clean exterior of valve.

STEP 2Remove nut (1) and solenoid (2) from valve cartridge(3).

STEP 3Remove valve cartridge (3) from valve housing (7).

STEP 4Remove and discard all O-rings (4 and 5) andback-up rings (6).

Cleaning and Inspection

STEP 5Immerse valve cartridge (3) and valve housing (7) incleaning solvent and agitate cleaning solvent. WEAREYE PROTECTION WHEN USING COMPRESSEDAIR. Use compressed air to remove foreign matterfrom interior of valve cartridge and housing and toensure that all passage ways and bores are clear.

STEP 6Check valve cartridge for (3) for cracks, breaks,chipping, or other damage. Replace if any of theseconditions are seen.

STEP 7Check bores in valve housing (7) for deep scratches,gouges, and other damage. Replace valve if any ofthese conditions are seen.

STEP 8Connect an ohmmeter across terminals of solenoid(2) connector. Replace solenoid (2) and valvecartridge (3) if ohmmeter indicates short or opencircuit.

Assembly

STEP 9Install new O-rings (4 and 5) and back-up rings (6) asshown.

STEP 10Lubricate O-rings (4 and 5) using clean oil then installvalve cartridge (3) in valve housing (7).

STEP 11Install solenoid (2) on valve cartridge (3).

STEP 12Install nut (1) to secure solenoid (2).

GS98J818

1. NUT 5. O-RING2. SOLENOID 6. BACKUP RING3. VALVE CARTRIDGE 7. VALVE HOUSING4. O-RING

3

4

5

6

6

5

6

6

6

5

6

7

2

1

8007-4


NOTES

Section8013

8013




RIDE CONTROL ACCUMULATOR

8013-2


TABLE OF CONTENTS

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3ACCUMULATOR SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5


CHARGING THE ACCUMULATOR WITH NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

8013-3


SPECIFICATIONSRide 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 TORQUESAccumulator 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 KITB786441M

CAS1456 GLAND WRENCH

8013-4


DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR

94L95

CAS10899 NITROGEN CHARGING KIT

1. Use the CAS-10899 Nitrogen Charging Kit tod ischarge the accumula tor, re fe r to theillustration above. The tool must be disconnectedfrom the nitrogen tank.

2. Close valves B, C and D.

3. Adjust the regulator A to the minimum pressuresetting by turning the knob counterclockwise.

4. Turn the T-handle on valve F fully out.

5. Remove the guard and valve assembly cap fromthe accumulator.

6. Connect valve F to the valve stem on theaccumulator.

7. Turn the T-handle inward on valve F to engagethe pin in the valve stem.

8. Open valve D and check the charge pressure ongauge E.

9. To discharge the accumulator, partially openvalve B. The accumulator charge will bleed downthrough the regulator.

10. Once the accumulator is fully discharged,disconnect valve F from the valve stem.

11. The accumulator can now be disassembled.

ABD

F

C E

8013-5


ACCUMULATOR

DisassemblyNOTE: Refer to Section 8001 for the properprocedure for the removal of the ride controlaccumulator.

1. Fasten the body (1) in a vise. Be careful not todamage the body (1), refer to the illustration onpage 6.

2. Remove the screws (9) and guard (11) from thebody (1).

3. Remove the pressure valve (12) from thebody (1).

4. Remove and discard the O-ring (10) from thepressure valve (12).

5. Loosen and remove the cap (8) from the body(1).

6. Loosen and remove the gland (3) from the body(1).

7. Remove the piston (4) from the body (1).

8. Remove and discard the wear ring (5), O-ring (7)and the backup ring (6) from the piston (4).

9. Remove the seals (2) from the gland (3).

Inspection1. Clean body (1), gland (3), cap (8) and piston (4)

in cleaning solvent, refer to the illustration onpage 6.

2. Inspect the piston (4) for cracks, burrs or otherdamage.

3. Inspect the bore of the body (1) for scratches orscoring using a light.

NOTE: Minor scratches or scoring in the bore of thebody (1) can be removed using crocus cloth.

4. Inspect the pressure valve (12) and replace asneeded.

Assembly1. Fasten the body (1) in a vise. Be careful not to

damage the body (1). Refer to the illustration onpage 6.

2. Install a new wear ring (5), O-ring (7) and backupring (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), roundsurface first. Then push the piston (4) farther intothe body (1).

NOTE: The piston (4) must be installed squarely andslowly into the body (1). Once the piston (4) is startedstraight into the bore of the body (1), use a hammerand wood block to gently tap the piston into thepolished area of the bore. Keep force on the piston(4) while tapping into the bore or damage may occurto the O-ring.

5. Install and tighten the cap (8) into the body (1).

6. Install new seals (2) on the gland (3).

7. Lubricate the seals (2) with clean oil and start thegland (3) into the body (1).

8. Tighten the gland (3).

9. Install a new O-ring (10) on the pressure valve(12).

10. Install the pressure valve (12) in the body (1).

11. Install the guard (11), screws (9) in the body (1).

12. Charge the accumulator with dry nitrogenaccording to instructions on page 7.

WARNING: DO NOT a t tempt todisassemble any accumulator until thenitrogen charge is properly discharged.

SM386

WARNING: Use on ly n i t rogen whencharging the accumulator. DO NOT use airor oxygen that will cause an explosion.

SM115A

8013-6


BS01B224

RIDE CONTROL ACCUMULATOR ILLUSTRATION

1. BODY 5. WEAR RING 9. SCREW2. SEALS (2) 6. BACKUP RING 10. O-RING3. GLAND 7. O-RING 11. GUARD4. PISTON 8. CAP 12. PRESSURE VALVE

1

11

9

9 12

4310

5 6 72 8

8013-7


CHARGING THE ACCUMULATOR WITH NITROGEN

GS98N801

NITROGEN CHARGING KIT CAS10899

M253A

M406

M407

IMPORTANT: The four valves must be in the positions noted in the procedure before connecting the NitrogenAccumulator 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 duringhigh pressure (10 bar/150 psi and above) applications.

1. VALVE C 4. VALVE B2. TO NITROGEN TANK 5. VALVE D3. VALVE A 6. TO ACCUMULATOR

WARNING: Use only nitrogen when charging the accumulator. Do not use air or oxygen that will cause anexplosion.

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 theaccumulator at a dangerous rate of speed.

WARNING: Do not expose the accumulator to temperatures above 49° C (120° F). A charged accumulatorcontains nitrogen compressed to 31 bar (450 psi). High heat will cause the safety plug to blow out of theaccumulator and the escaping nitrogen will propel the accumulator at a dangerous rate of speed.

2

3456

1

8013-8


1. Close the shutoff valve A by turning it all the wayto the left (counterclockwise), refer to theillustration on page 7.

2. Open valve B by turning it out all the way to theleft (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 wayto the right (clockwise).

5. Connect the charging hose to the nitrogen supplytank.

6. SLOWLY turn valve A clockwise while watchingthe high pressure gauge. Stop turning valve Awhen 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 thepressure setting again.

The charging kit is now ready to be installed on theaccumulator.

7. Remove the two cap screws (9) and theprotection bracket (11) from the body (1) on theaccumulator, 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 endo f the cha rg ing hose by tu r n ing i tcounterclockwise to the maximum amount. Thisprevents nitrogen from escaping from theaccumulator when the charging hose is attachedto the accumulator gas charging valve.

10. Install the charging hose fitting onto theaccumulator pressure valve (12).

11. Tighten the needle valve by turning it clockwise.Slowly open the gauge valve D and observe thereading on the gauge. This reading is thenitrogen pressure level inside the accumulator.

12. Open the shutoff valve A on the nitrogen supplytank. While observing the pressure on the gauge,s l i gh t l y open the need le va lve on theaccumulator charge hose. By regulating theneedle valve, fill the accumulator to pressureaccording to temperature chart below. Close theneedle valve. Close the shutoff valve A on thenitrogen supply tank.

TEMPERATURE/CHARGE PRESSURE RIDE CONTROL ACCUMULATOR

13. Close valve B by turning to the right (clockwise).After a few minutes, check the accumulator forleakage.

14. Back off the needle valve on the accumulator endo f the cha rg ing hose by tu r n ing i tcounterclockwise the maximum amount. This willprevent n i t rogen from escaping f rom theaccumulator as the hose is removed. Removethe charging hose from the accumulator pressurevalve (12).

15. Install the valve cap onto the pressure valve (12)on the accumulator.

16. Install the protection bracket (11) over thepressure valve (12) and secure it with cap screws(9).

17. Remove the charging hose from the nitrogensupply tank.

TEMPERATURE CHARGE PRESSURE10° C 50° F 1606 KPA 233 PSI13° C 55° F 1634 KPA 237 PSI16° C 60° F 1669 KPA 242 PSI18° C 65° F 1696 KPA 246 PSI21° C 70° F 1724 KPA 250 PSI24° C 75° F 1751 KPA 254 PSI27° C 80° F 1779 KPA 258 PSI29° C 85° F 1813 KPA 263 PSI32° C 90° F 1841 KPA 267 PSI35° C 95° F 1868 KPA 271 PSI38° C 100° F 1896 KPA 275 PSI

Section8014

8014




RIDE CONTROL VALVE

8014-2


TABLE OF CONTENTS

RIDE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Dissasembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

8014-3


RIDE CONTROL VALVE

BC05B015.

Dissasembly

STEP 1Remove ride control valve, refer to section 8001.

STEP 2Remove plugs (1), (8), (9), and (11).

STEP 3Remove the solenoid (12).

STEP 4Remove the spool (7) from the valve block (16).

STEP 5Remove cap screw (2), bushing (3), spring carrier(4), springs (5 & 6) from spool (7).

STEP 6Remove orifice (13), poppet (14), and orifice (15).

STEP 7Remove accumulator drain screw (10).

STEP 8Remove the pressure relief valve (17).

Inspection1. Discard all O-rings.

2. Clean all parts in cleaning solvent.

3. Check the spools and the spool bores fordamage and wear.

4. Check the parts of the pressure relief valve.

If any of the parts are damaged, install new parts.

1. PLUG 6. SPRING 10. ACCUMULATOR DRAIN SCREW 14. POPPET2. CAP SCREW 7. SPOOL 11. PLUG 15. ORFICE3. BUSHING 8. PLUG 12. SOLENOID 16. VALVE BLOCK4. SPRING CARRIER 9. PLUG 13. ORFICE 17. RELIEF VALVE 5. SPRING

910

15

12

8

16

14

13

11

7

65

43

12

17

8014-4


Assembly

STEP 1Install new O-rings.

STEP 2Install and torque pressure relief valve (17) to 50 Nm(37 lb-ft).

STEP 3Install and torque accumulator drain screw (10) to 3.5 Nm (31 lb-in). Install the plug for accumulatordrain screw and torque to 7 Nm (62 lb-in).

STEP 4Install 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 5Install and torque solenoid valve to 12 Nm (106 lb-in).

STEP 6Install 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 7Install spool (7) into valve block (16).

STEP 8Install and torque plug (1) to 270 Nm (199 lb-ft).

STEP 9Install plug (8) and torque to 140 Nm (103 lb-ft), plug(9) and torque to 30 Nm (22 lb-ft), and plug (11) andtorque to 90 Nm (66 lb-ft).

STEP 10Install the ride control valve in the machine, seesection 8001.

STEP 11Test the ride control system, see section 8002.




SECTION INDEX

MOUNTED EQUIPMENT

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


Section9002 90

02




AIR CONDITIONING TROUBLESHOOTING AND SYSTEM CHECKS FOR SYSTEMS WITH HFC-134A

REFRIGERANT

9002-2


TABLE OF CONTENTS

SAFETY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Problem: No Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6SYSTEM CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Mechanical Compressor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Blower and Compressor Clutch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Cab Temperature Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Visual and Leak Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Evaporator/Heater Core Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Evaporator/Heater Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

PRESSURE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Manifold Gauge Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Pressure Test Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

PRESSURE-TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14QUICK REFERENCE TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14A/C RECOVERY AND CHARGING STATION CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15PROBLEM: NO COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Indication of No Refrigerant or Low Refrigerant Charge: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Indication of Large Quantity of Air in System: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Condenser Malfunctioning - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Expansion Valve Malfunctioning - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Refrigerant Contamination: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18HFC-134a Stable Saturation Pressure/ Temperature Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

PROBLEM: NOT ENOUGH COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Air in the System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Not Enough Refrigerant - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20High Side Restriction - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Expansion Valve Not Operating - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Compressor Turning But Not Pumping Properly - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Expansion Valve Stuck Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Condenser Not Operating - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Air in the System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

PROBLEM: INTERMITTENT COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Moisture in the System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

PROBLEM: NOISE IN SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Too Much Refrigerant in System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

TUBE CONNECTIONS TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

9002-3


SAFETY PROCEDURES

ATTENTION: Only authorized technicians certifiedby an approved training and certification organizationmay service or repair motor vehicle or mobile airconditioning systems. It is mandatory that allrefrigerant must be RECOVERED and RECYCLEDwhen removed from a system during servicing.

Refrigerant HFC-134a is the most stable, and easiestto work with of the refrigerants now used in airconditioner systems. Refrigerant HFC-134a does notcontain any chlorofluorocarbons (CFC’s) which areharmful to the earth’s ozone layer.

Safety procedures must be followed when workingwith Refrigerant HFC-134a to prevent possiblepersonal injury.

1. Always wear safety goggles when doing anyservice work near an air conditioner system.Liquid refrigerant getting into the eyes can causeser ious injury. Do the fol lowing i f you getrefrigerant near or in your eyes:

A. Flush your eyes with water for 15 minutes.

B. See a physician immediately.

2. A drop of liquid refrigerant on your skin maycause frostbite. Open the fittings carefully andslowly when it is necessary to service the airconditioner system. Your skin must be treated forfrostbite or a physician must be seen if you getrefrigerant on your skin.

3. Keep refrigerant containers in the correct uprightposition. Always keep refrigerant containersaway from heat and sunlight. The pressure in acontainer will increase with heat.

4. Always reclaim refrigerant from the system, if youare going to weld or steam clean near the airconditioner system.

5. Always check the temperature and pressure ofthe air conditioner system before reclaimingrefrigerant and when you test the system.

6. Dangerous gas can form when refrigerant comesin contact with an open flame. Never permitfumes to be inhaled.

7. Never leak test with compressed air or flametesters. Tests have indicated that compressedmixtures of HFC-134a and air can form acombustible gas.

8. Always reclaim refrigerant from the systembefore removing any air conditioning component.

THIS SAFETY ALERT SYMBOL INDICATES IMPORTANTSAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEETHIS SYMBOL, CAREFULLY READ THE MESSAGE THATFOLLOWS AND BE ALERT TO THE POSSIBILITY OFPERSONAL INJURY OR DEATH. M171B

9002-4


299L7C

BELT TENSION TOOL CAS-10808

A22090

ELECTRONIC LEAK DETECTOR OEM-1437

A22094

REFRIGERANT RECOVERY, RECYCLING AND CHARGING STATION, OEM-1415

109L7

SAFETY GOGGLES CAS-10073-3

9002-5


OPERATIONThe refrigerant circuit of the air conditioning systemcontains f ive major components: compressor,condenser, receiver-drier, expansion valve andevaporator. These components are connected bytubes and hoses and operate as a closed system.The air conditioner system is charged with HFC-134arefrigerant.

The compressor receives the refrigerant as a lowpressure gas. The compressor then compresses therefrigerant and sends it in the form of a high pressuregas to the condenser. The air flow through thecondenser then removes the heat f rom therefrigerant. As the heat is removed the refrigerantchanges to a high pressure liquid.

The high pressure refrigerant liquid then flows fromthe condenser to the rece ive r -d r ie r. Thereceiver-drier is a container filled with moistureremoving material, which removes any moisture thatmay have entered the air conditioner system in orderto prevent corrosion of the internal components ofthe air conditioner system.

The refrigerant, still in a high pressure liquid form,then flows from the receiver-drier to the expansionvalve. The expansion valve then causes a restrictionin flow of refrigerant to the evaporator core. Theevaporator meters refr igerant f low based onevaporator heat load.

As the refrigerant flows through the evaporator core,the refrigerant is heated by the air around and flowingthrough the evaporator fins. The combination ofincreased heat and decreased pressure causes theair flow through the evaporator fins to become verycool and the liquid refrigerant to become a lowpressure gas. The cooled air then passes from theevaporator to the cab for the operator’s comfort.

The electrical circuit of the air conditioning systemconsists 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.

208L95

1. EXPANSION VALVE 3. COMPRESSOR 5. RECEIVER-DRIER2. EVAPORATOR 4. CONDENSER

1

2

3

45

9002-6


TROUBLESHOOTINGPerform a visual inspection of the machine. Checkthe following and correct as necessary:

1. - Obtain service history if possible.

2. - Is compressor drive belt in place and tensioned?

3. - Are grille screens, fan blades, condenser, air filter, andevaporator unobstructed?

4. - Are there any sharp bends or kinks in thehoses?

5. - Are there heavy accumulations of oil, or oilydust around the fittings, indicating refrigerantleakage?

6. - Are air ducts undamaged, sealed properly andin position?

7. - Condensate drain hoses and check valvespresent and unobstructed?

Problem: No Cooling

Compressor Runs No

Mechanical - See Mechanical Compressor Check Page 8Electrical - See Blower and Compressor Clutch Check Page 9

Yes

Internal System ProblemSee Pressure Testing, Page 13

9002-7


Problem:Not Enough Cooling

HEATER

Make sure the heater control is OFF and that there is no coolantflow through the heater core.

SEAL

Make sure the sealing material is correctly in place.

MECHANICAL

See Mechanical Compressor Check page 8. See EvaporatorHeater Core Check Page 12.

ELECTRICAL

See Blower and Compressor Clutch Check on Page 9.

REFRIGERANT

See Cab Temperature Check Page 10.

INTERNAL SYSTEM PROBLEM

See Pressure Testing, Page 13.

Problem:Erratic Cooling

MECHANICAL

See Mechanical Compressor Check Page 8.

ELECTRICAL

See Blower and Compressor Clutch Check - Blower MotorCheck, Blower Switch Check and Compressor Clutch Checkon Page 9.

INTERNAL SYSTEM PROBLEMS


Problem:System Makes Noise

MECHANICAL

See Mechanical Compressor Check Page 8.

See Blower Motor Check Page 9.

ELECTRICAL

See Compressor Clutch Check Page 9.

INTERNAL SYSTEM PROBLEM


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 muchslippage.

Compressor Mounting Brackets

1. Loose bracket mounting bolts - tighten thebolts to the correct torque.

2. Bracket has cracks or breaks - replace thebracket.

Compressor Clutch

1. The compressor belt will slip on thecompressor pulley if there is compressorseizure. Remove the compressor forservice or replacement.

2. Remove the dust cover and check the airgap on the compressor clutch. The gapbetween the f ront p late and pu l leyassembly must be 0.41 to 0.79 mm.

3. Use a socket wrench to slowly rotate thecompressor clockwise. Compressorrotation should be smooth and not requiremuch effort.

Pulley and Belt Alignment

1. The compressor pulley and thecompressor drive pulley must be alignedwithin 1.6 mm (1/16 inch) of each other.Use a straight edge to check pulleya l ignment . Ad jus t the compressormounting bracket if needed.

9002-9


Blower and Compressor Clutch Check

Compressor Clutch

NOTE: Check supply voltage withcompressor lead plugged in and engaged.Voltage drops will not be apparent withoutcurrent flow.

1. If there is electrical system voltage to theclutch, check for excessive voltage drop inthe ground circuit, then see Section 9004and 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 givefour different blower speeds: OFF, Low,High, and Purge.

2. Check for loose connections or brokenwires. Repair or replace as necessary.

3. Check resistor board.

Blower Motor

1. Check the wiring to the blower motor.Make repa i r s o r rep lace i tems asnecessary.

2. Check motor ground wire. Make suremotor ground wire is making good contactwith mounting bracket.

Temperature Control Switch

1. With key in ON position, turn switch tomaximum cold. Compressor clutch mustengage.

NOTE: Blower must be operating, sinceelectrical power to temperature control switchis received from blower switch.

2. Turn the blower off. Disconnect the wiresfrom the temperature control. Using anohmmeter, check the continuity betweenswitch terminals. If continuity is notpresent when switch is on maximum cold,replace switch.

9002-10


Cab Temperature Check

Air Louvers

1. Make sure louvers and recirculation vents are fully openfor most efficient air conditioning operation. Defrostlouvers must be closed.

2. Check blower; blower must be running.

Air Conditioning

ATTENTION: Use caution when feeling hoses. Hosesbecome very hot. Check temperature by slowly reaching forhose and touching briefly several times with finger tips,increasing the duration with each touch.

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 onrefrigerant, or compressor is not working correctly.

Duct Temperature

1. Put a thermometer in the air duct behind the seat andr un the compressor fo r f i ve m inu tes to maketemperature stable. Refer to page 12.

2. Duct temperature must be below 25° C (72° F) if thesystem is operating at maximum efficiency.

NOTE: Ambient temperature must be 27 to 43° C (80 to110° F).

3. If temperature is above 25° C (72° F), system is low onrefr igerant, there is a restr ict ion in the system,compressor is not working correctly, or air ducts are notsealed correctly.

Temperature Sensing Probe Check

1. Turn the engine OFF, key switch ON, blower switch ONand temperature control switch turned fully clockwise.

2. Remove the temperature sensing probe from theevaporator. Refer to Section 9004.

3. Put the end of the temperature sensing probe in acontainer with ice and water.

4. When the sensing tube has cooled to the temperature ofthe ice and water mixture, the temperature control switchshould interrupt the current flow to the compressor.Check for current at the control switch terminals as onprevious page. If current is not interrupted then replacethe control switch.

9002-11


Visual and Leak Check

Compressor Hoses

1. Make sure that all hose connections aretight.

2. Check hoses for bends or cracks. Replaceall hoses that have damage.

Leak Finding Check

1. Shut off the engine.

WARNING: When refrigerant comes incontact with an open flame, it can formdangerous gas. Never breathe these fumes.

2. Use electronic leak detector OEM -1437to inspec t a l l connec t ions. Useinstructions from manufacturer of leakfinding tool.

NOTE: When checking compressor seal for aleak, remove the dust cover and rotate theclutch shaft clockwise.

NOTE: To properly check the expansion valvefor leaks, remove the insulation tape.

3. Repair all leaks and recharge the system.See Section 9003.

Condenser

1. Make sure the condenser is clean and theseals are in place. Make sure condenserfans run when temperature control switchis ON.

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 theevaporator/heater core.

2. Inspect the fins on the evaporator/heatercore. All the fins that have bends ordamage must be made straight.

3. Inspect the evaporator/heater core forrest r ic t ions. I f the core is dr y, usecompressed air or a brush and vacuumcleaner. If the core is wet or filled withmud, flush the core with water using ahose without pressure. Make sure thewate r d ra ins f ree ly f rom theevaporator/heater core. DO NOT USESTEAM.

WARNING: Do not steam clean any airconditioning systems parts while the system ischarged. The heat will cause the refrigerant torise to a pressure that could cause the systemto explode.

Evaporator/Heater Core Sealing

1. See Section 9004 for access to theevaporator/heater core.

2. Make sure seals are in place so blowerw i l l pu l l a i r on ly th rough theevaporator/heater core and not around theevaporator/heater core.

Filters 1. Make sure the filters are clean.

9002-13


PRESSURE TESTING

Manifold Gauge SetNOTE: The gauge set is not accurate enough tooptimize an existing charge of HFC-134a. The bestuse of the gauge set is to determine whetherundercharge or overcharge exists, and thenevacuate, reclaim and recharge system with therecommended quantity (charge) of HFC-134a.

The manifold gauge set is the most important toolused to service the air conditioning system. Themanifold gauge set is used to measure the high andlow pressures of the system, as a tool to troubleshootfor correct refrigerant charge quantity, systemdiagnosis, and operating efficiency. The manifoldgauge set can read both the high (discharge) and low(suction) sides at the same time, since pressure mustbe compared in order to make a diagnosis of systemoperation.

LOW PRESSURE GAUGE - The low pressure gaugeis a compound gauge. It is best used to judgeevacuat ion effect iveness. A vacuum readingindicates a system malfunction. For this reason, it isnecessary to use a compound gauge that willindicate both pressure and vacuum.

During normal operation the low pressure gaugemust always indicate from 10 to 35 psi (0.7 to 2.4bar) after the system has run 10 to 15 minutes.

HIGH PRESSURE GAUGE - The high pressuregauge is used to indicate pressures in the high sideof the system. The gauge must indicate from 0 to 400psi (0 to 27.6 bar) minimum.

During normal operation, the high pressure gaugewill normally indicate from 120 to 310 psi (8.3 to 21.4bar). See pressure-temperature chart on page 14.

Pressure Test ConnectionConnect the manifold gauge set into the airconditioning system as shown. Make sure that bothvalves in the manifold gauge set are closed.

9002-14


PRESSURE-TEMPERATURE CHART

The pressure-temperature chart is based on thefollowing conditions:

NOTE: High humidity will cause higher air louvertemperatures and dramatic increase in suctionpressure. The table shown represents readings takenin low relative humidity. Adjust the chart according tolocal conditions.

1. Engine at 1500 RPM, no load, fan speed &temperature control at max setting, A/C switchON, all louvers and doors open

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.

QUICK REFERENCE TROUBLESHOOTING CHART

AMBIENT

TEMPERATURE

°F (°C)

NORMAL LOW

PRESSURE INDICATION

psi (bar)

NORMAL HIGH

PRESSURE INDICATION

psi (bar)

AIR LOUVER (BEHIND SEAT) MAXIMUM TEMP.

°F (°C)

80 (27) 9 to 12

(0.62 to 0.83)

145 to 165

(10 to 11.53)

55 (14)

90 (32) 11 to 15

(0.76 to 1.04)

190 to 210

(13.10 to 14.48)

61 (18)

95 (35) 16 to 18

(1.10 to 1.24)

210 to 230

(14.48 to 15.86)

63 (20)

100 (38) 17 to 19

(1.17 to 1.31)

235 to 255

(16.2 to 17.58)

66 (22)

105 (41) 20 to 21

(1.38 to 1.45)

260 to 280

(17.93 to 19.31)

68 (23)

110 (43) 22 to 24

(1.93 to 2.14)

290 to 310

(20 to 21.37)

72 (25)

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

9002-15


A/C RECOVERY AND CHARGING STATION CONNECTIONS

STEP 1Clean the external surfaces of the compressor andhoses. Remove the caps from the service ports onthe suction and pressure hoses.

STEP 2Connect the hoses from the test gauges to theservice ports by turning the knurled knobs on thedepressors.

STEP 3Connect the hose from the low pressure gauge to theport on the suction hose.

STEP 4Connect the hose from the high pressure gauge tothe port on the discharge hose.

STEP 5Make sure the charging station manifold gaugevalves are in the closed position.

STEP 6Start the engine and run at 1500 RPM maximumspeed. Operate the air condit ioner system atmaximum cooling setting and blower speed for 15minutes with the cab door open. Observe the testgauges and check the chart on page 13 against thegauge readings.

WARNING: Do not steam clean any airconditioning system parts while the system ischarged. The heat will cause the refrigerantto rise to a pressure that could cause thesystem to explode. SM104A

WARNING: Always wear safety goggleswhen working with liquid refrigerant. Liquidrefr igerant in your eyes could causeblindness. SM105A

9002-16


PROBLEM: NO COOLING

476L7SEE PRESSURE - TEMPERATURE CHART ON PAGE 14

Indication of No Refrigerant or Low Refrigerant Charge:

A. Discharge air from evaporator warm.

B. Compressor does not run, or cycles offrapidly after start-up. (A/C warning lightin cab should illuminate).

Yes

1. Leak test the system, see Page 11. It maybe necessary to add refrigerant. SeeSection 9003.

2. Evacuate and reclaim remainingrefrigerant from system. See Section9003.

3. Repair system leaks as needed. Followthe given repair procedure.

4. Check level of oil in compressor - possiblefor compressor to have an oil loss.

5. Remove air and moisture from thesystem. Replace Receiver-Drier. SeeSection 9004.

6. Charge system with new refrigerant. SeeSection 9003.

7. Continue performance test for otherpossible problems.

VERY LOW VERY LOW

9002-17



Indication of Large Quantity of Air in System:

Discharge air from evaporator warm Yes

1. Evacuate and reclaim refrigerant fromsystem. See Section 9003.

2. Replace receiver-drier.

3. Remove air and moisture from thesystem. See Section 9003.


Condenser Malfunctioning - Indications:

A. Liquid line (between evaporator andcondenser) is very hot.

B. Discharge air from evaporator warm.

1. Check for loose or worn compressor or engine fanbelt and proper condenser fan operation.

2. Check to see that condenser is clean andunobstructed and that the fins are straight.

3. Check system for too much refrigerant. Evacuate,reclaim and recharge refr igerant until gaugepressure is normal. See Section 9003.

4. Remove and check condenser for restrictionscaused by oil or reduced heat transfer.

A. Remove refrigerant from the system. SeeSection 9003.

B. Use compressed air to remove oil fromcondenser.

C. Replace receiver-drier.

D. Remove moisture and charge the system. Seesection 9003.

5. Continue the performance test for other possibleproblems.

HIGH HIGH

9002-18


HFC-134a Stable Saturation Pressure/ Temperature Chart

Expansion Valve Malfunctioning - Indications:

A. Discharge air from heater/evaporatorwarm.

B. Much condensation on suction hose atcompressor.

C. Much condensation on evaporatoroutlet.

See Section 9004 and replace the expansionvalve.

Refrigerant Contamination:

Refrigerant Contamination

1. See table below and check stable saturation pressures atgiven temperature to determine if contamination exists.

A. Measure pressure from gauge on reclamation unit.

B. Measure temperature from refrigerant in reclamationtank. If refrigerant has been in reclamation unit for sometime, use ambient temperature. The numbers in thetable represent the boiling point for HFC-134a.

C. Pressure readings below range given in chart indicatecontaminated refrigerant.

IMPORTANT: Do not use contaminated refrigerant or mixwith uncontaminated refrigerant. Dispose of in accordancewith all applicable laws and local procedure.

Temperature ° F (° C) Pressure PSIG (Bar)

50 (10) 45 (3.1)55 (13) 51 (3.5)60 (16) 57 (3.9)65 (18) 64 (4.4)70 (21) 71 (4.9)75 (24) 78 (5.4)80 (27) 88 (6.1)85 (29) 95 (6.6)90 (32) 104 (7.2)95 (35) 114 (7.9)100 (38) 124 (8.6)102 (39) 129 (8.9)104 (40) 133 (9.2)106 (41) 138 (9.5)108 (42) 142 (9.8)110 (43) 147 (10.1)112 (44) 152 (10.5)114 (46) 157 (10.8)116 (47) 162 (11.2)118 (48) 167 (11.5)120 (49) 172 (11.9)

9002-19


PROBLEM: NOT ENOUGH COOLING


Air in the System - Indications:

A. Suction line warm to your hand.

B. Discharge air from heater/evaporatoronly a little cool.

1. Test system for leaks. See page 11. Possibleleak has let air enter; check compressor sealcarefully.

2. Discharge system of refrigerant. See Section9003.

3. Repair system leak as necessary.


5. Check compressor oil level.

6. Remove air and moisture from the system.See Section 9003.


NORMAL TO SLIGHTLY HIGH NORMAL

9002-20



Not Enough Refrigerant - Indications:

A. Discharge air from evaporatorcool or warm - not cold.

1. Leak test system - system has a loss of refrigerant.

NOTE: Normally, the system will lose 1/2 to 1 ounce (14.7to 29.5 grams) of refrigerant between seasons.

A. If leak is found, go to Step 2.

B. If no leak is found, go to Step 6.

2. Discharge refrigerant from system. See Section 9003.

3. Repair system leaks as needed.

4. Check oil level in compressor - It is possible forcompressor to lose oil.

5. Remove air and moisture from the system. ReplaceReceiver-Drier. See Section 9004.

6. Charge system with new refrigerant. See Section9003.

High Side Restriction - Indications:

A. Discharge air from heater/evaporatoronly a little cool.

B. Condensation or frost onreceiver-drier.

C. Liquid line to receiver-drier cool, withfrost or condensation.

NOTE: The frost will form downstream fromor at the point of the restriction

1. Discharge refrigerant from system-restriction inreceiver-drier or liquid line must be removed.

2. Remove and replace part with restriction.

3. Remove air and moisture from the system. SeeSection 9003.

4. Charge system with new refrigerant. See Section9003.

LOW LOW

9002-21


Expansion Valve Not Operating - Indications:

A. Discharge air from evaporator warmor cool - not cold.

B. Condensation or frost on expansionvalve outlet.

C. Inlet end of expansion valve iswarm.

1. Expansion valve outlet with condensation or frost isan 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 noflow of refrigerant through the valve. Replaceexpansion valve. See Section 9004.

9002-22


476L7SEE THE PRESSURE - TEMPERATURE CHART ON PAGE 14

Compressor Turning But Not Pumping Properly - Indications:

A. System is fully charged.

B. Cool discharge air from evaporator.

1. Discharge refrigerant from system. See Section9003.

2. Remove the compressor from the machine. SeeSection 9004.

3. Remove and replace compressor because there isindication of internal leak in compressor.

4. Replace compressor.

5. Replace receiver-drier if:

A. System has been opened before.

B. Receiver-drier has been used two or moreyears. See Section 9004 for receiver-drierreplacement.

6. Charge the system with refrigerant. See Section9003.

Expansion Valve Stuck Open

Expansion Valve Stuck Open 1. Replace expansion valve. See Section 9004.

HIGH LOW

9002-23



Condenser Not Operating - Indications:

A. Liquid line very hot.

B. Discharge air from evaporator warm.

1. Check for loose or worn compressor belt andproper condenser fan operation.

2. Check to see that condenser is clean and thatthe fins are straight.

3. Check system for too much refrigerant.

A. Remove refrigerant from system until gaugepressure is below normal. See Section 9003.

B. Add refrigerant until gauge pressures arenormal. See Section 9003.

C. If there is still a problem, do step 4.

4. Remove and inspect condenser for restrictionscaused by oil or reduced heat transfer.

A. Discharge refrigerant from system. SeeSection 9003.

B. Use compressed air to remove oil fromcondenser.

C. Replace receiver-drier. See Section 9004.

Air in the System - Indications:

Warm discharge air from evaporator.

1. Discharge refrigerant from system. SeeSection 9003.




HIGH HIGH

9002-24


PROBLEM: INTERMITTENT COOLING


Moisture in the System - Indications:

Cooling is acceptable during cool part of daybut not acceptable during hot part of day.

1. Discharge system of refrigerant. If toomuch moisture enters the orifice of theexpansion valve, the freezing of thismoisture can stop refrigerant flow. SeeSection 9003.

2. Replace receiver-drier. The moistureremoving material could be full to capacitywith moisture. See Section 9004.


NOTE: The time needed to remove a largeamount of moisture will be two to three hoursminimum.


NORMAL NORMAL

9002-25


PROBLEM: NOISE IN SYSTEM


Too Much Refrigerant in System - Indications:

A. Cool discharge air from heater/evaporator.

B. Compressor makes noise.

1. Remove refrigerant from system until gaugereadings are below normal. See Section9003.

2. Add new refrigerant until gauge readings arenormal. See Section 9003.

NORMALTO HIGH HIGH

9002-26


TUBE CONNECTIONS TORQUE CHART

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 evaporatorsince these connections are easily distorted.

TUBING SIZE 3/8 inch 1/2 inch 5/8 inch

THREAD SIZE M10 -1.25 5/8-18 3/4-18OR

3/4-16

7/8-18OR

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

Section9003

9003




AIR CONDITIONER SYSTEM SERVICE

9003-2


TABLE OF CONTENTS

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3SAFETY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7PRESSURE - TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

9003-3


SPECIFICATIONSAir conditioning system refrigerant capacity ...................................................................................... 1.7 kg (3.75 lbs)

SPECIAL TOOLS

A22094

REFRIGERANT RECOVERY, RECYCLING AND RECHARGING STATION OEM-1415

109L7


9003-4


SAFETY PROCEDURES


Refrigerant HFC-134a is the most stable and easiestto work with of the refrigerants now used in airconditioning systems. Refrigerant HFC-134a doesnot contain chlorofluorocarbons (CFC’s) which areharmful to the Earth’s ozone layer.

Safety procedures must be followed when workingwith refr igerant HFC-134a to prevent possiblepersonal injury.






4. Always reclaim refrigerant from the system, if youare going to weld or steam clean near the airconditioner system.






9003-5


AIR CONDITIONER SYSTEM REFRIGERANT RECOVERYRecovered refr igerant passes through an oi lseparator and a filter-drier before entering therefrigerant tank. The moisture indicator will turngreen when dry refrigerant passes over it.

If possible, run the air conditioning system for tenminutes before starting the recovery process. Turnthe system off before proceeding.

STEP 1

BD03A213

Clean the external surfaces of the compressor andhoses. Remove the caps from the service ports onthe suction and pressure hoses.

STEP 2

BD03B001

With the charging station manifold gauge valves inthe closed position, connect the hoses from the testgauges to the service ports.

Connect the hose from the low pressure gauge to theport on the suction hose. Turn in valve depressor.

Connect the hose from the high pressure gauge tothe por t on the discharge hose. Turn in valvedepressor.

STEP 3

A22114

Open the high and low valves.

STEP 4

A22107

Make certain the refrigerant tank gas and liquidvalves are open.

9003-6


STEP 5

A22112

Connect the main power plug to a 115 volt AC outlet.Move the main power switch to the ON position anddepress the recovery start switch.

The compressor will shut OFF automatically whenrecovery is complete. Wait for 5 minutes and observethe manifold pressure gauges for a pressure rise. Ifpressure rises above 0 psi (0 bar), depress thehold/cont switch. Then wait for the compressor toautomatically shut OFF.

STEP 6

A22108

Drain the oil separator of the A/C system oil. Openthe air purge valve long enough to let some of thecompressor discharge pressure back into theseparator.

STEP 7

A22110

Slowly open the oil drain valve and drain the oil intothe reservoir. When the oil stops draining, close theoil drain valve completely.

STEP 8

A22111

Fill the A/C compressor with fresh SP-20 PAG oilequal to the amount in the reservoir.

STEP 9

BD03A213

Remove the hoses from the service ports and installthe caps.

9003-7


AIR CONDITIONER SYSTEM EVACUATION AND RECHARGINGIMPORTANT: Replace the receiver-drier if one ormore of the following conditions occurs before youremove the air and moisture from the system.

A. The system has been opened for servicebefore.

B. Receiver-drier has operated two or moreyears.

C. Disassembly of compressor shows smallparticles of moisture removing material (goldor brown particles).

D. Large system leak (broken hose, break inline).

E. Too much air or moisture in system.

F. Removal of compressor caused the system tobe open (uncapped) longer than 5 minutes.

STEP 10

BD03B001

With the charging station manifold gauge valves inthe closed position, connect the hoses from the testgauges to the service ports as follows:

1. Connect the hose from the low pressure gaugeto the port on the suction hose.

2. Connect the hose from the high pressure gaugeto the port on the discharge hose.

3. Turn in both thumbscrews to depress the servicevalves.

Removal of air and moisture from the system isnecessary after the refrigerant has been removedafter the system has been opened for maintenance.Air enters the system when the system is opened. Airhas moisture that must be removed to preventdamage to the system components.

NOTE: The pump on the reclamation unit will not pulla sufficient vacuum to remove air and moisture.

Air and moisture are removed from the system by avacuum pump. A vacuum pump is the on lyequipment made to lower the pressure enough tochange the moisture to vapor that can be removedfrom the system.

NOTE: Refer to the vacuum pump manufacturer’suser manual for additional information.

STEP 11

A22113

Connect the main power plug to a 115 volt AC outlet.Move the main power switch to the ON position. Ifprogram and vacuum do not appear at the top of thedisplay press the vacuum key. Program a minimum of45 minutes and press the Enter key. The display willflash once indicating the programmed data has beenaccepted.

STEP 12

A22115

Press the Charge key. “Program” and “Charge” willappear on the display.

9003-8


STEP 13

A22113

Program 3.5 lbs and press the enter key. The displaywill flash once indicating the programmed data hasbeen accepted.

STEP 14

A22114

Fully open the low and high pressure valves.

STEP 15

A22107

Open the red (vapor) and blue (liquid) valves on thetank.

STEP 16

A22123

Press the Vacuum key. “Automatic” will appear on thedisplay. Vacuum will appear on the display and aftera slight delay, the vacuum pump will star t. Thedisplay will show the amount of time programmedand begin a countdown to zero.

When the programmed t ime has elapsed, anautomatic hold occurs. Check the low pressuregauge to see that the A/C system maintains a 28 to29-1/2 inches of mercury (Hg). The low pressuregauge must not increase faster than one inch ofmercury (Hg) in 10 minutes. A previously charged,leak- f ree system wi l l leach ref r igerant f romcompressor oil and raise system pressure undervacuum. If the system will not hold vacuum, a leakexists that must be corrected before recharging canbegin. See Section 9002 in the manual for a leaktest.

STEP 17

A22113

Press the charge key to begin refrigerant charging.“Automatic” and “Charge” will appear on the display.The display shows the programmed amount andcounts down to zero as charging proceeds. Whencharging is completed, the display shows “CPL”.

9003-9


STEP 18

A22114

Completely close the high and low pressure manifoldvalves.

ATTENTION: Check the OEM equipment manualbefore performing Step 19 to avoid damaging therecovery unit. The pressure reading should beobtainable with valves closed. Damage may occur ifthe machine is started with the valves accidentlyopen or if either or both valves are opened while theA/C system is operating.

STEP 19Start the engine and run at 1500 RPM. Operate theair conditioner system at maximum cooling settingand blower speed with the doors and windows open.

NOTE: The compressor will not operate if thesystem pressure is too low or too high. The pressureindicator lamp will illuminate when the relay isactuated by a low or high pressure and thecompressor clutch will disengage. To restart thecompressor, the air conditioner control or blowerswitch must be turned to the OFF position and thento the ON position.

STEP 20

A22117

Observe the pressure gauge readings to determinethat the correct amount of refrigerant has entered thesystem. See chart on Page 9002-9 for temperatureand pressure variations.

STEP 21

BD03B001

Stop the engine, close any open valves and carefullyremove the manifold gauge hoses.

STEP 22

BD03B213

Install the caps on the service ports on the suctionand discharge hoses.

9003-10


PRESSURE - TEMPERATURE CHART

The pressure-temperature chart is based on thefollowing conditions:

1. Engine operating at 1500 RPM

2. No engine load

3. Fan speed control in maximum position and alllouvers open.

4. Cab temperature control set to maximumcooling.

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.

AMBIENTTEMPERATURE

°F (°C)

NORMAL LOWPRESSURE INDICATION

psi (bar)

NORMAL HIGH PRESSURE INDICATION

psi (bar)

AIR LOUVERMAXIMUM 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)

Section9004

9004




REMOVAL AND INSTALLATION OF AIR CONDITIONING AND HEATER COMPONENTS

9004-2


TABLE OF CONTENTS

SAFETY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5


EXPANSION VALVE, EVAPORATOR/HEATER CORE, HEATER VALVE, BLOWERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

CONDENSER AND RECIEVER DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

9004-3


SAFETY PROCEDURES


Refrigerant HFC-134a is the most stable, and easiestto work with of the refrigerants now used in airconditioner systems. Refrigerant HFC-134a does notcontain any chlorofluorocarbons (CFC’s) which areharmful to the earth’s ozone layer.

Safety procedures must be followed when workingwith Refrigerant HFC-134a to prevent possiblepersonal injury.






4. Always reclaim refrigerant from the system if youare going to weld or steam clean near the airconditioner system.






9004-4


SPECIAL TOOLS

A22094

REFRIGERANT RECOVERY, RECYCLING AND CHARGING STATION OEM-1415

BS03H012


9004-5


COMPRESSOR

Removal


STEP 2Discharge the air conditioning system according tothe instructions in Section 9003.

STEP 3

BD06F113

BD06F114

Loosen and remove the four bolts holding theprotective shield. Remove the shield.

STEP 4

BD06F116

Remove the fan belt.

STEP 5

BD06F117

Disconnect the low pressure line from the suctionport and the high pressure line from the dischargepor t on the compressor. Immediately instal lprotective caps on the open ports and lines.

9004-6


STEP 6

BD06F117

Disconnect the compressor clutch wire from theengine harness assembly.

STEP 7

BD06F117

Loosen and remove the three compressor mountingbolts.

STEP 8Remove the compressor from the machine.

Installation

STEP 9Place the compressor into position on the machine.

STEP 10

BD06F117

Install the three bolts to mount the compressor.

STEP 11

BD06F117

Connect the compressor clutch wire to the engineharness assembly.

9004-7


STEP 12

BD06F117

Slowly remove the protective cap, install a newO-ring, and connect the high pressure line to thedischarge port on the compressor.

IMPORTANT: Use caution when removing cap asnew compressors have internal pressure whenshipped.

STEP 13Carefully remove the protective cap, install a newO-ring, and connect the low pressure line to thesuction port on the compressor.

STEP 14Install the belt.

STEP 15Install the protective shield.

STEP 16Charge the air conditioning system according to theinstructions in Section 9003.

9004-8


EXPANSION VALVE, EVAPORATOR/HEATER CORE, HEATER VALVE, BLOWERS

BS06G118

1. EVAPORATOR 7. WASHER 13. LOWER BOX PPE2. UPPER BOX PPE 8. GROMMET 14. EXPANSION VALVE3. COVER PPE 9. HEATER CORE 15. BLOWER 4. SOLENOID DRIVER 10. HEATER VALVE 24V 16. RECIRCULATING VAIN5. UPPER BOX 11. THERMOSTAT 17. RECIRCULATING MOTOR6. BOLT 12. LOWER BOX 18. RESISTOR BLOWER MOTOR

1

2

3 6

4

57

8

10

9

1112

13

14

15

18

17

16

9004-9


Removal

STEP 17Park the machine on a level surface and lower thebucket to the floor.

STEP 18If changing any air condit ioning components,discharge the air conditioning system according tothe instructions in Section 9003.

STEP 19

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. Installcap after coolant has drained. Install radiator cap.

STEP 20Place the master disconnect in the OFF position.

STEP 21Disconnect the wiring harness from the operator’sseat (if equipped with air seat option).

STEP 22

BD06G202

Remove the four bolts that fasten the operator’s seatto the upper box, remove the seat from the machine.

STEP 23

BD06G212

Open the cover on the cooler.

STEP 24

BD06G213

Remove the four screws securing the air vent,remove the vent cover.

STEP 25

BD06G214

Remove the three screws securing the cooler to thecab, remove the cooler.

STEP 26Fold the rubber mat over to gain access to the upperbox mounting bolts.

9004-10


STEP 27

BD06G215

Remove the six bolts securing the upper box.

STEP 28

BD06G216

Remove two screws, one on each side of the upperbox, securing the upper box to the lower box.

STEP 29Place the air selector on the control panel to outsideair.

NOTE: In step 30 and 33 the upper box is shownremoved for clarity only, these steps must be doneprior to removing the upper box.

STEP 30

BD06G217

Going through the inside f i l ter area feel therecirculating vain to make sure is is in the outside air,“closed”, position.

STEP 31

BD06G218

The above photo shows that the recirculating vain isnot in the outside air “closed” position.

STEP 32

BD06G240

Use a screw driver and disconnect the linkage.

9004-11


STEP 33

BD06G219

Close the vain so the upper cover can be removed.

STEP 34Remove the upper box up and rest it against theconsole.

NOTE: The wiring harness for the HVAC systemgoes through the upper cover, by resting the coveragainst the console the wiring harness will not needto be removed.

STEP 35

BD06G220

Pull the wiring harness loose from the upper PPE.

STEP 36

BD06G203

Disconnect the solenoid driver.

STEP 37

BD06G236

Remove the upper PPE from the heater and airconditioning cores.

NOTE: If testing on the electrical components arerequired the solenoid driver can be reconnectedonce the upper PPE is removed.

9004-12


NOTE: If replacing the heater control valve, heatercore, air conditioning expansion valve, airconditioning evaporator core do steps 38 through 47,if replacing electrical components go to step 48.

STEP 38

BD06G204

Remove the right side cab skirt.

STEP 39

BD06G2051. TRANSMISSION FILTER2. AIR CONDITIONING HOSES3. HEATER HOSES

Fasten identification tags on the hoses. Disconnectthe hoses for the heater core and evaporator core,install plugs in the hoses and caps on the fittings.

STEP 40

BD06G206

Remove the thermostat probe and clamp from theevaporator core.

STEP 41

BD06G237

Disconnect the electr ical connectors from thethermostat control.

STEP 42

BD06G236

Disconnect the electrical connectors from the heatercontrol valve.

1

2 3

9004-13


STEP 43Pull the heater core and evaporator core from thelower box PPE.

STEP 44Remove the expansion valve from the evaporatorcore.

STEP 45Remove and discard the O-rings from the openingsin the expansion valve.

STEP 46Remove the screws from the heater core and removethe control valve.

STEP 47Remove and discard the O-rings from the heatercontrol valve.

STEP 48

BD06G2071. RESISTORS2. RESISTOR CONNECTOR3. BLOWER MOTOR CONNECTOR

Remove the fans from the lower PPE, disconnect theelectrical connectors. Remove the two mountingscrews for the resistor, remove the resistor.

STEP 49

BD06G208

Disconnect the e lec t r ica l connector for therecirculating vain motor, disconnect the linkage fromthe vain. Remove the mounting screws and removethe motor.

STEP 50

BD06G2091. FAN SPEED AND A/C SWITCH2. INSIDE/OUTSIDE AIR SELECTOR SWITCH3. THERMOSTAT

Remove the swi tch panel f rom the console.Disconnect the electrical connectors and removeswitches as required.

1

2

3

1 2 3

9004-14


Installation

STEP 51

BD06G2091. FAN SPEED SWITCH2. INSIDE/OUTSIDE AIR SELECTOR SWITCH3. THERMOSTAT

Replace switches and connect the electr icalconnectors as required. Install the switch panel in theconsole.

STEP 52

BD06G208

Install the motor and install the mounting screws andtighten. Connect the electrical connector for therecirculating vain motor, connect the linkage to thevain.

STEP 53

BD06G2071. RESISTORS2. RESISTOR CONNECTOR3. BLOWER MOTOR CONNECTOR

Install the resistor, install the two mounting screwsand tighten. Install the fans in the lower PPE, connectthe electrical connectors.

STEP 54Install new O-rings on the heater control valve.

STEP 55Install the control valve, install and tighten the screwsto the heater core.

STEP 56Install new O-rings on the openings of the expansionvalve.

STEP 57Install the heater core and evaporator core into thelower box PPE.

STEP 58

BD06G236

Connect the electrical connectors to the heatercontrol valve.

1 2 3

1

2

3

9004-15


STEP 59

BD06G237

Connect the electrical connectors to the thermostatcontrol.

STEP 60

BD06G206

Install the thermostat probe coil and clamp to theevaporator core “cold” tube.

STEP 61


Remove the plugs from the hoses and the caps fromthe fittings. Install new O-rings in the evaporatorfittings, connect the heater and evaporator hoses.Remove and discard identification tags that wereused during disassemble.

STEP 62

BD06G204

Install the right side cab skirt.

STEP 63

BD06G238

Insta l l the upper PPE on the heater and ai rconditioning cores.

1

2 3

9004-16


STEP 64

BD06G203

Connect the solenoid driver.

STEP 65

BD06G239

Push the wiring harness into the preformed notchesin the upper PPE.

STEP 66Place the air selector on the control panel to outsideair.

STEP 67

BD06G210.

Make sure that the recirculating vain is in the closedposition.

IMPORTANT: This photo shows it in the openposition and the upper box will not go back intoposition without damaging the recirculating vain.

STEP 68

BD06G241

Set the upper box into position on the heater andevaporator cores.

STEP 69

BD06G216

Install two screws, one on each side of the upper boxsecuring the upper box to the lower box.

9004-17


STEP 70

BD06G242

Install the insolation panel in the center of the upperbox.

STEP 71

BD06G215

Install and tighten the six bolts securing the upperbox.

STEP 72

BD06G243

Install the right rear floor mat into the cab, if machineis equipped with air ride seat make sure to pull thewiring up above the mat for the seat.

STEP 73Install the remainder of the floor mat.

STEP 74

BD06G214

Install and tighten the three screws securing thecooler to the cab.

STEP 75

BD06G213

Install the vent cover, install and tighten the fourscrews securing the air vent.

STEP 76

BD06G202

Install and torque the four bolts to 73 to 87 Nm (55 to65 pound-feet).

9004-18


STEP 77Connect the wiring connector to the operator’s seat(if equipped with air seat option).

STEP 78Fill engine coolant system with a solution of 50%Ethylene Glycol and 50% water. Install the radiatorcap. Fill the coolant reservoir up to the FULL mark onthe reservoir.


9004-19


CONDENSER AND RECIEVER DRIER

Removal

STEP 80Park the machine on a level surface and lower thebucket to the ground.


STEP 82Discharge the air conditioning system according tothe instructions in Section 9003.

STEP 83

BD01D142

Open the cover (1) to gain access to the condenser(2).

STEP 84

BD03A109

The condenser is connected to a bracket whichpivots on the cooling frame. Pivot the condenser togain access to the hoses.

STEP 85

BS03A107

Fasten ident i f icat ion tags on the hoses anddisconnect the hoses from the condenser.

STEP 86Install plugs in the hoses and caps on the fittings.

STEP 87

BS03A109

Loosen the bolts that fasten the condenser to thebracket, pivot the condenser and remove the boltsand condenser.

1. COVER 2. CONDENSER

2

1

9004-20


STEP 88

BD06G211

Fasten ident i f icat ion tags on the hoses anddisconnect the hoses from the receiver drier.

STEP 89Install plugs in the hoses and caps on the fittings.

STEP 90Disconnect the trinary switch, remove the mountingbolt, remove the receiver drier and bracket.

Installation

STEP 91Put the condenser in position on the bracket.

STEP 92

BS03A109

Install the bolts that fasten the condenser to thebracket, pivot the condenser down and tighten thebolts.

STEP 93

BS03A107

Pivot the condenser to gain access to the hoses.

STEP 94Remove the plugs from the hoses and the caps fromthe fittings. Install new O-rings and connect thehoses to the f i t t i ngs. Remove and d iscardiden t i f i ca t ion tags tha t were used dur ingdisassemble.

STEP 95Pivot the condenser down and close the cover.

STEP 96Mount the receiver drier and bracket, install andtighten the mounting bolt.

9004-21


STEP 97

BD06G211

Remove plugs from the hoses and caps from thefittings, install new O-rings and connect the hoses tothe fittings, connect the trinary switch. Remove anddiscard identification tags that were used duringdisassemble.



9004-22


NOTES

Section9006

9006




LOADER

9006-2


TABLE OF CONTENTS

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3BUCKET TEETH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Replacement of the Tooth Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Replacement of the Bucket Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Replacement of the Bucket Corner Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

RETURN TO DIG ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5REMOVING THE LOADER FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7INSTALLING THE LOADER FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

9006-3


SPECIFICATIONSSpecial Torques

Bolts for the Bucket Teeth........................................................................1315 to 1480 Nm (970 to 1090 pound-feet)

BUCKET TEETH

Replacement of the Tooth Points1. Use a hammer and punch to drive the retaining

pin (1) for the tooth point (2) out of the toothshank (3), refer to the illustration on this page.

2. Remove the tooth point (2).

3. Install a new tooth point (2) on the tooth shank(3).

4. Install the retaining pin (1) into the tooth point (2)and tooth shank (3). Make sure the shoulder onthe retaining pin is toward the cutting edge. Usea hammer to hit the retaining pin (1) until theretaining pin (1) is even with the outside of thetooth shank (3).

Replacement of the Bucket Teeth1. Loosen and remove the nuts (4), hardened

washers (5), and bolts (6) from the bucket teeth.

NOTE: If wear of the bolt or nut makes removaldifficult, the bolt or nut can be cut off.

2. Remove the tooth.

3. Install the new tooth on the bucket cutting edge(7).

4. Use new nuts (4), hardened washers (5), andbolts (6) for the tooth being installed.

5. Tighten the nuts (4) to 1315 to 1480 Nm (970 to1090 pound-feet).

Replacement of the Bucket Corner Teeth

1. Loosen and remove the nuts (9) and bolts (8)from the bucket corner teeth (10).

NOTE: If wear of the bolt or nut makes removaldifficult, the bolt or nut can be cut off.

2. Remove the corner tooth (10).

3. Install the new corner tooth (10) on the bucketcutting edge (7).

4. Use new nuts (9) and bolts (8) for the cornertooth being installed.

5. Tighten the nuts (9) to 1315 to 1480 Nm (970 to1090 pound-feet).

B0740A88J

BUCKET TEETH ILLUSTRATION

1. RETAINING RING 6. BOLT2. TOOTH POINT 7. CUTTING EDGE3. TOOTH SHANK 8. PLOW BOLT4. NUT 9. NUT5. HARDENED WASHER 10. CORNER TOOTH

45

6

2 1

3

7

12

3

7

8

9

10

9006-4


RETURN TO DIG ADJUSTMENT

BS01C083

RETURN TO DIG ADJUSTMENT ILLUSTRATION

IMPORTANT: Before adjusting the return-to-dig,make sure that the target bar on the bucket linkage isnot damaged. Slowly roll back and dump the bucketand make sure that the target bar stays the samedistance from the switch. The switch mountingbracket protects the switch. Make sure the target barcannot touch the switch when the bucket is dumped.

1. Park the machine on a level surface. Raise the liftarms until they are approximately horizontal anddump the bucket. Lower the bucket until thebucket edge is on the ground.

2. Apply the parking brake and stop the engine.

3. Loosen the bolts holding the target mountingbracket (1) to the tilt cylinder eye. Align the targetmounting bracket (1) parallel to the tilt cylinder(2). Tighten the bolts, refer to the illustration onthis page.

4. Loosen the bolts holding the proximity switchmounting bracket (4) to the tilt cylinder (2).Position the proximity switch (5) parallel to thetarget bar (3) and tighten the bolts.

5. Adjust the proximity switch (5) out towards thetarget bar (3), until an air gap of 3.2 to 5.0 mm(1/8 to 3/16 inch) is obtained. Torque the jam nutto 6 to 7.5 Nm (4.5 to 5.5 pound-feet).

NOTE: The proximity switch (5) must not protrudepast the proximity switch guard (6).

6. Start the engine, position the bucket to thecorrect digging angle and stop the engine.

7. Loosen the bolts holding the target bar (3) to thetarget mounting bracket (1). Slide the target bar(3) towards the proximity switch (5) until the faceof 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. DoNOT start the engine.

10. Place the bucket control lever in the ROLLBACKposition.

11. Loosen the bolts holding the target bar (3) to thetarget mounting bracket (1).

12. Slide the target bar (3) slowly away from theproximity switch (5), until the control lever returnsto the center position. Tighten the bolts holdingthe target bar (3).

13. Check to make sure that the 3.2 to 5.0 mm (1/8to 3/16 inch) gap is still maintained.


15. Place the detent switch in the ON position andplace the return to travel/float detent switch to theTRAVEL position.

16. Raise the lift arms approximately horizontal, andput the bucket in the fully dumped position.

17. Place the loader control lever in the ROLLBACKposition, and verify that the electromagnet holdsit 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 atthe correct digging angle.

1. TARGET MOUNTING BRACKET 3. TARGET BAR 5. PROXIMITY SWITCH2. BUCKET CYLINDER 4. PROXIMITY SWITCH MOUNTING BRACKET 6. PROXIMITY SWITCH GUARD

1

2

34

5

6

9006-5


HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT

BS01C081

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 onthe ground.

4. Stop the engine.

NOTE: To avoid damage to the proximity switch (3),it must be adjusted back to clear everything on the liftarm as it passes. Refer to the illustration on thispage.

5. Position the return to travel target (5) oppositethe proximity switch (3) and tighten it to the targetmounting plate (1).

6. Adjust the proximity switch (3) out towards thereturn to travel target (5) until an air gap of 3.2 to5.0 mm (1/8 to 3/16 inch) is obtained.

7. Lock the proximity switch (3) in this position withthe jam nut. Torque the jam nut to 6 to 7.5 Nm(4.5 to 5.5 pound-feet).

1. TARGET MOUNTING PLATE 3. PROXIMITY SWITCH 5. RETURN TO TRAVEL TARGET2. HEIGHT CONTROL TARGET 4. LIFT ARM 6. FRONT CHASSIS (TOP LEFT HAND SIDE)

12

3

4

56

WARNING: Raised equipment on the machinewithout an operator can cause injury or death.Before you leave the operators compar tment,a l w a y s s u p p o r t o r l o w e r t h e e q u i p m e n t(backhoe, blade, boom, bucket , e tc . ) to theground and stop the engine.

CSM105

9006-6


BS01C082

HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT ILLUSTRATION

8. Refer to the table and the illustration on thispage. Position the height control target (1) on thetarget mounting plate (3) using the table above.

NOTE: The higher the height control target (1) ispositioned 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 thetable above.

NOTE: The higher the return to travel target (2) ispositioned 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) andall of the mounting bolts are tight. Refer to theillustration on page 5.


13. Place the detent switch in the ON position, andset the return to travel/float detent switch to thereturn to travel position.

14. Place the loader control lever in the raise positionand verify that the electromagnet holds it in thatposition until the height control target (2) passesin front of the proximity switch (3). Refer to theillustration on page 5.

15. With the lift arms still raised, place the loadercontrol lever in the lower position and verify thatthe electromagnet holds it in that position untilthe return to travel target (5) passes in front ofthe proximity switch (3). Refer to the illustrationon page 5.

16. Repeat steps 8 through 15 until the desiredheights are reached.

17. Lower the bucket to the ground and stop theengine.

1. HEIGHT CONTROL TARGET 2. RETURN TO TRAVEL TARGET 3. TARGET MOUNTING PLATE

MACHINE A

APPROXIMATE RESULTING RETURN TO

TRAVEL HINGE PIN HEIGHT

B

APPROXIMATE RESULTING HEIGHT CONTROL HINGE PIN

HEIGHT

821E 56 mm (2.2 inches) 414 mm (16.3 inches) 42 mm (1.6 inches) 3302 mm (130 inches)

1

2

3

A

B

9006-7


REMOVING THE LOADER FRAME1. Park the machine on a level surface and apply

the parking brake. Roll the bucket all the wayforward and lower the bucket to the floor. Stopthe engine.

2. Loosen the filler plug in the reservoir to releasethe air in the reservoir.

3. Fasten a chain hoist to the cross member (1) ofthe loader frame (2), refer to the illustration onpage 8.

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 liftcylinder (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 lowerthe bucket so that the bucket is flat on the floorand fasten the chain hoist to a lift cylinder (4 or6).

8. Raise the lift cylinder (4 or 6) slightly and removethe driver.

9. Repeat steps 7 and 8 for the other lift cylinder (4or 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) tothe bell crank (11).

12. Use an acceptable driver and drive the pivot pin(7) out of the piston rod eye of the bucket cylinder(8).

13. Raise the bucket cylinder (8) and use a chain orother acceptable holding equipment to hold thebucket cylinder (8) in place.

14. If the machine is equipped with auxiliaryhydraulics, disconnect the two hoses from thetubes at the bracket on the right side of theloader frame (2). Install caps on the hoses andplugs in the tube fittings.

15. If the machine is equipped with front lamps,loosen and remove the cap screws and lockwashers that fasten the lamp brackets to the frontframe. Put the lamp brackets on the fenders.

16. Connect the chain hoist to the loader frame (2).

17. Loosen and remove the bolt (19), flat washer(20) and spacer (21) that fasten the pivot pin (9or 10) to the front frame.

18. Raise the loader frame slightly. Use anacceptable 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 andthe loader frame (2).

BD01G009

19. Remove the proximity switch cover. Left-handside of the machine only.

BD01G010

20. Disconnect the electrical connector (1), removethe lock nut from the proximity switch (2) andremove the proximity switch (2) from themachine. Left-hand side of the machine only.

21. Repeat Steps 17 and 18 for the other pivot pin (9or 10).

22. Raise the loader frame (2) out of the front frame.Carefully move the machine out of the loaderframe (2).

1. ELECTRICAL CONNECTION 2. PROXIMITY SWITCH

1

2

9006-8


BS01G022

LOADER FRAME ILLUSTRATION

1. CROSS MEMBER 7. PIVOT PIN 13. WASHER 19. BOLT2. LOADER FRAME 8. BUCKET CYLINDER 14. SPACER 20. WASHER3. PIVOT PIN 9. PIVOT PIN 15. BOLT 21. SPACER4. LIFT CYLINDER 10. PIVOT PIN 16. WASHER 22. WIPER5. PIVOT PIN 11. BELL CRANK 17. SPACER 23. DUMP LINK6. LIFT CYLINDER 12. BOLT 18. WASHER

12

3

45

5

5

6 7

8

9

10

11

12

13

14

1516

17

1818

19

20

21

22

23

9006-9


INSTALLING THE LOADER FRAME1. 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 loaderframe (2).

3. Lower the loader frame (2) into alignment withthe front frame.

4. Apply antiseize compound to the pivot pins (9and 10) that fasten the loader frame (2) to thefront frame.

5. Start the pivot pins (9 and 10) into the frontframe. Install the washers (18) and new wipers(22) between the loader frame (2) and the frontframe.

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 thebolt.

8. Install the proximity switch and cover. Left-handside of the machine only.

9. Disconnect the chain hoist from the loader frame(2).

10. If the machine is equipped with front lamps, holdthe front lamps in place and install the capscrews and lock washers that fasten the frontlamps to the front frame. Tighten the cap screws.

11. If the machine is equipped with auxiliaryhydraulics, remove the plugs from the tubefittings and the caps from the hoses. Connect thehoses to the tubes.

12. Connect the chain hoist to the bucket cylinder (8)and lower the bucket cylinder (8).


14. Have another person help you at this time. Movethe bucket control lever as required to align thepiston rod eye of the bucket cylinder (8) with thebell crank (11). Stop the engine.

15. Install the pivot pin (7) in the bell crank (11) andthe 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.

17. Disconnect the chain hoist from the bucketcylinder (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 or6) so the piston rod yoke is aligned with theloader frame (2).

20. Install a driver in the piston rod yoke and theloader frame (2).

21. Repeat Steps 18, 19, and 20 for the other liftcylinder (4 or 6).

22. Disconnect the chain hoist from the lift cylinder (4or 6).

23. Start the engine. Raise the loader frame and rollthe bucket all the way forward. Lower the bucketto the floor. Stop the engine.

24. Fasten the chain hoist to the cross member (1) ofthe loader frame (2).


26. Have another person help you at this time. Movethe lift control lever as required to align the pistonrod yoke of one of the lift cylinders (4 or 6) withthe loader frame (2).

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 liftcylinder (4 or 6). Stop the engine.

30. Lubricate the pivot pins with molydisulfidegrease.

31. Disconnect the chain hoist from the crossmember (1) of the loader frame (2).

32. Tighten the filler plug in the reservoir.

33. If the machine is equipped with auxiliaryhydraulics, start the engine and run the engine atlow idle.

34. Slowly extend and retract the clam cylinders fourtimes to remove air from the auxiliary circuit.

35. Stop the engine, check the level of the oil in thereservoir, and check for leaks. Add oil to thereservoir as required.

IMPORTANT: D o no t u s e yo u r f i ng e r s t oc h e c k t h e a l i g n m e n t o f t h e c y l i n d e r r o d .Personal injury can be the result.

48-88

IMPORTANT: D o n o t u s e yo u r f i ng e r s t oc h e ck t h e a l i g n m e n t o f t h e c y l i n d e r r o d .Personal injury can be the result.

48-88

9006-10


NOTES

Section9007

9007




ROLLOVER PROTECTIVE STRUCTURE (ROPS)CAB STRUCTURAL FRAME (CSF)

9007-2


TABLE OF CONTENTS

ROLLOVER PROTECTIVE STRUCTURE (ROPS)CAB STRUCTURAL FRAME (CSF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3MAINTENANCE AND INSPECTION OF THE (CSF) CAB OR (ROPS) CANOPY . . . . . . . . . . . . . . . . . . . . . . . . 3CSF CAB AND ROPS CANOPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4


9007-3


ROLLOVER PROTECTIVE STRUCTURE (ROPS)CAB STRUCTURAL FRAME (CSF)

The Rollover Protective Structure (ROPS) or CabSt ruc tura l Frame (CSF) is a spec ia l sa fe tycomponent of your machine.

DO NOT attach any device to the ROPS or CSF forpulling purposes.

The ROPS or CSF is a certified structural supportand any damage, fire, corrosion or modification willweaken the structure and reduce your protection. Ifthis occurs, the ROPS or CSF MUST be replaced sothat it will provide the same protection as a newROPS or CSF.

After an accident, fire or rollover, the following MUSTbe performed before returning the machine to field orjob site operation:

● The ROPS or CSF structure MUST be replaced.

● The ROPS or CSF mounting or suspension,operator seat and suspension, seat belts andmounting components and wiring within theoperator’s protective system MUST be carefullyinspected for damage.

● All damaged parts MUST be replaced.

DO NOT WELD, ATTEMPT TO STRAIGHTEN ORREPAIR THE ROPS OR CAB STRUCTURALFRAME.

MAINTENANCE AND INSPECTION OF THE (CSF) CAB OR (ROPS) CANOPYAfter every 500 hours of operation or every sixmonths, whichever comes first, do the following:

1. Check the torque on the CSF cab or ROPScanopy mounting bolts; torque should be 773 to854 Nm (570 to 630 lb-ft). If necessary, tightenthe bolts to the correct torque.

2. Check that seat belt mounting hardware is tightand seat belt is not cut or frayed. Check thetorque on operators seat mounting bolts; torqueshould be 73 to 87 Nm (54 to 64 lb-ft) . I fnecessary, tighten the bolts to the correct torque.Replace parts that are worn or damaged.

Attention

WARNING: Grade 8 hardware is used tomount and anchor the ROPS. Parts used forreplacement must be those shown in theparts catalog. 47-27A

WARNING: Do not install attachments thatwill make the total weight of the machinemore than the weight shown in the maximumgross vehicle weight section of the ROPSserial number plate. 47-26

WARNING: Do not change the ROPS in anyway. Changes made to the ROPS which arenot authorized, such as welding, drilling orcutting will make the ROPS weaker anddecrease your protection. Replace theROPS if it becomes damaged in any way.DO NOT TRY TO MAKE REPAIRS TO THEROPS. 47-25

9007-4


CSF CAB AND ROPS CANOPY

RemovalNOTE: Procedures and photos in following stepscover in detail removal and installation of CSFstructure. Removal and installation of ROPS issimilar to removal and installation of CSF structure.

STEP 1Park machine on a level surface and lower bucket tofloor. Stop engine. Actuate brake pedal several timesto discharge brake accumulators. Put key switch inON position and move loader control lever back andforth at least 30 times to release any pressure fromhydraulic circuit. Put key switch in OFF position.

STEP 2

BD01F143


STEP 3Put battery disconnect switch in OFF position.

STEP 4

BD01F184

If machine is equipped with a heater, put a 40 liters(10 Gallons) container below radiator drain. Removecap and drain coolant into container. Install cap aftercoolant has drained.

STEP 5

BD06G191

Remove skirting under each side and front of cab.

STEP 6

BD06G186

Remove the ducts from the machine.

STEP 7

BD06G189

At RH rear, bottom of cab, disconnect ground strapfrom rear chassis.

9007-5


STEP 8

BD06G194

If machine is equipped with windshield washers,identify, tag, and disconnect front and rear windshieldwasher nozzle hoses from supply hoses.

STEP 9


If machine is equipped with a heater disconnectheater hoses (3), if machine is equipped with airconditioning discharge the air conditioning system,see section 9003, and disconnect the air conditioninghoses (2), cap and plug lines and fittings.

STEP 10

BD06G193

Disconnect throttle connector and the air duct.

STEP 11

BD06G192

Identify, tag, and disconnect hoses from steeringcontrol valve. Plug hoses and cap steering controlvalve fittings to prevent entry of foreign matter intohydraulic system.

STEP 12

BD06F207

Unlatch and open the window on the right hand side.

STEP 13

BD06F208

Open and remove the access panel.

1

2 3

9007-6


STEP 14

BD06F209

Remove the front access panel.

STEP 15

BD06F210

Disconnect the electrical connectors for the remotecontrol valve.


STEP 17Put identification tags on each hose and disconnectone at a time from the remote control valve. Installplugs in the hoses and caps on the fittings to prevententry of foreign matter into hydraulic system.

STEP 18Push the hoses out of the bottom of the cab with therubber gromment.

STEP 19

BD06G187

Disconnect the e lect r ica l connectors, pushconnectors out of the bottom of the cab with therubber gromment

STEP 20

BD06G188

Raise floor mat up and away from brake pedal to gainaccess to mounting hardware.

STEP 21

BD06G185

Remove hardware securing brake valve to cab floor.Let brake valve rest on the frame.

9007-7


STEP 22

BD06G184

Install lifting eyes in threaded holes at top of the cab.

STEP 23Connect lifting equipment to cab at lifting eyes. Takeup all slack in lifting equipment.

STEP 24Remove nuts, bolts, and washers securing cab torear chassis.

STEP 25Slowly raise cab from rear chassis. Check that all tiestraps and clamps have been removed and all hoses,tubes, and wires are disconnected and free. Checkthat brake valve with hoses attached are free andclear of cab. Remove the ROPS or CSF from themachine. Lower ROPS or CSF onto wooden blocksto prevent damaging cab or canopy.

9007-8


BC06G031

1. NUT 4. RUBBER MOUNT2. WASHER 5. WASHER3. RUBBER MOUNT 6. BOLT

6

4

3

5

1

2 1

2

6

4

3

5

9007-9


Installation

STEP 26Check rubber mounts (3 an 4) for deterioration, tears,deformation, or other damage; replace rubbermounts as necessary.

STEP 27

BD01D388

Position cab over rear chassis then put wood blocksunder brake valve. Slowly lower cab onto rearchassis making sure that brake valve is positioned sothat brake pedal enters into cab. Remove woodblocks as cab is lowered onto brake valve.

STEP 28Install washers, bolts, and nuts to secure cab to rearchassis. Tighten bolts to a torque of 773 to 854 Nm(570 to 630 pound feet)

STEP 29Disconnect lifting equipment from cab.

STEP 30Remove lifting eyes.

STEP 31

BD06G185

Align mounting holes in brake valve with associatedholes in cab or canopy floor. Install hardware tosecure brake valve to floor.

STEP 32

BD06G188

Position floor mat.

STEP 33

BD06G192

Remove plugs from hoses and caps from fittings.Connect hoses to steering control valve followingtags installed during removal. Remove and discardtags.

STEP 34

BD06G193

Connect throttle connector and mount air duct.

9007-10


STEP 35

BD06G186

Install the ducts on the machine.

STEP 36

BD06G189

At RH rear, bottom of cab, connect ground strap torear chassis.

STEP 37

BD06G194

If machine is equipped with windshield washers,connect front and rear windshield washer nozzlehoses following tags installed during removal.Remove and discard tags.

STEP 38


If machine is equipped with a heater, remove plugsfrom hoses and caps from fittings, connect heaterhoses (3 ) , i f mach ine i s equ ipped w i th a i rconditioning, remove plugs from hoses and capsfrom fittings, connect air conditioning hoses (2),charge the air conditioning system, see section 9003.

STEP 39Remove plugs from hoses and caps from fittings.Connect hoses to joystick and two-lever controllerand install in hose mounting grommet halves asshown on pages 11, 12, and 13.

1

2 3

9007-11


BC05M092

JOYSTICK AND 2 LEVER HOSE COLOR CODING

1. PILOT TANK HOSE 4. ORANGE BLACK GREEN 7. GREEN WHITE GREEN2. PILOT PRESSURE HOSE 5. GREEN BLACK GREEN 8. RED WHITE GREEN3. YELLOW BLACK GREEN 6. RED BLACK GREEN

1 2

2

1

3

4

8

6

87

57

8

5

4

6

3

7

9007-12


BC05M091

3 LEVER HOSE COLOR CODING JOYSTICK AND 1 LEVER HOSE COLOR CODING

7 77

71

23

6

54

12

36

54

21

5

6

4

3

7

3

1

26

5

4

7



9007-13


BC05M090

2 LEVER HOSE COLOR CODING JOYSTICK HOSE COLOR CODING

12

36

54

3

1

2

6

54

2

1

5

64

3

12

36

54



9007-14


STEP 40

BD06F210

Connect the electrical connectors for the remotecontrol valve.

STEP 41

BD06F209

Place the access panel into position, install andtighten the screw.

STEP 42

BD06G187

Connect wiring harness connectors.

STEP 43

BD06F208

Install and close the access panel.

STEP 44

BD06F207

Close the right hand window.

STEP 45

BD06G191

Install skirting under each side and front of cab.

9007-15


STEP 46

BD01F184

If machine is equipped with a heater and coolant wasdrained, check that coolant drain cap is tight.

STEP 47Fill engine coolant system with a solution of 50%Ethylene Glycol and 50% water. Cooling systemcapacity is 36.9 liters (9.75 U.S. Gallons). Installradiator cap. Fill coolant reservoir up to FULL markon reservoir.

STEP 48Put battery disconnect switch in ON position.

STEP 49Start engine and run engine at low idle. Run engineat operating temperature for approximately fiveminutes to completely mix Ethylene Glycol andwater. When coolant is at operating temperature,stop engine. When engine has cooled, check coolantlevel at reservoir.

WARNING: Hot coolant can spray out if radiator capis removed. To remove radiator cap: let system cool,turn to first notch, then wait until all pressure isreleased. Scalding can result from fast removal ofradiator cap.


9007-16


NOTES

Section9010

9010




CAB GLASS INSTALLATION

9010-2


TABLE OF CONTENTS

PREPARATION FOR GLASS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3GLASS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3SILICONE SEALANT APPLICATION - FRONT WINDOWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

9010-3


PREPARATION FOR GLASS REPLACEMENT1. 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 oiland dust. Clean the frame with rubbing alcoholwith a clean rag. Do not reuse the rag.

4. Apply a 25 mm (1 inch) wide band of metalprimer (349-108) to the window recesses.

5. Clean the new glass section. Apply a 25 mm (1inch) wide band of glass primer (349-110) to theblack ceramic painted edges of the window.

6. When replacing a front window section, asilicone forming tool is needed, refer to Figure 2.Use the template and instructions provided tomake the tool.

GLASS INSTALLATIONNOTE: Once the adhesive is applied, the glass mustbe installed within 5 minutes. If the glass is notinstalled within the 5 minute period, the adhesivemust be removed and applied again.

1. Apply a 10 mm (3/8 inch) diameter bead ofadhesive (345-135) to the pr imed surfaceapproximately 12 mm (1/2 inch) from edge.

2. The adhesive may be applied either to theprimed glass or to the primed metal frame. DONOT apply the adhesive to both the glass andthe frame.

NOTE: When replacing two or more sections of thefront glass apply extra adhesive in corners, refer toFigure 3.

3. For front glass installations install a glass spacer12 mm (1/2 inch) from each corner on bottomedge of each glass section, refer to Figure 3.

4. Install the glass. The glass edges must notcontact the metal frame at any point.

5. For front glass installations position the glass tomaintain a uniform 3 mm (1/8 inch) gap betweenfront and front side glass sections.

SILICONE SEALANT APPLICATION - FRONT WINDOWS1. Clean the edges of the front center and front side

windows. Use glass cleaning primer.

2. Apply masking tape to the inside edge of eachglass section next to the gap.

3. Apply the polyester tape on top of the maskingtape across the inside side gap. Do not push thetape into the gap.

4. Apply masking tape to the outside edge of eachglass section. Align the edge of the tape withedge of glass on both sections.

5. The tape must be smooth to get the best resultwhen using the silicone forming tool.

6. Fill the joint with the clear silicone sealant(114328A1), refer to Figure 1. The silicone mustcompletely penetrate and fill the gap between theglass sections. The sealant must extend at least1.5 mm (1/16 inch) above the outside surface ofthe glass section for the length of the gap. Besure the sealant fills against the adhesive at eachend of the joint.

7. Remove the polyester tape from the inside joint.

8. Remove the extra silicone from the outside jointby carefully sliding the forming tool down thelength of the joint. The tool must remain incontact with the glass sections during thisprocess. Refer to Figure 2 for forming tooltemplate.

9010-4


498L93

FIGURE 1. SILICONE APPLICATION

NOTE: Make the forming tool from 10 mm (3/8 inch)plexiglass, or wood. Sand all radius and edgessmooth.

9. Remove all the silicone from the forming toolimmediately after use.

10. Remove the outside tape from the glasssections.

11. Remove the extra silicone sealant from the insidejoint by carefully sliding the forming tool down thelength of the joint.

12. Remove all the silicone from the forming toolimmediately after use.

13. Remove the inside joint masking tape.

14. If two or more glass sections are being replaced,use the procedure on the second joint.

15. Apply the gray silicone sealant above the frontcenter, front side or rear windows for additionalleak protection.

16. Apply the gray silicone sealant (345-174) downapproximately 50 mm (2 inches) from the top oneach front side window replaced, refer to Figure3.

17. Apply the gray silicone sealant (345-174) downapproximately 50 mm (2 inches) from the topedge of the rear glass, if replaced.

496L93FIGURE 2. SILICONE FORMING TOOL TEMPLATE

1. FRONT RH SIDE GLASS 3. SILICONE BEFORE SMOOTHING

2. FRONT CENTER GLASS 4. SILICONE AFTER SMOOTHING

1 2

3

4

(1/2 INCH) R6 MM

120°

4 MM(3/16 INCH) R

120°

9010-5


497L93

FIGURE 3 SILICONE APPLICATION

NOTE: After completting the installation, DO NOT slam the cab door. The increased air pressure may break theseal on newly installed glass. DO NOT operate the machine for a period of 12 hours, allowing the adhesive andsilicone to properly set.

1. SIDE GLASS ADHESIVE 4. RIGHT HAND SIDE GLASS SPACER LOCATIONS2. CENTER GLASS ADHESIVE 5. APPLY GRAY SILICONE SEALANT DOWN 50 MM (2 INCHES)

FROM TOP OF FRONT SIDE GLASS3. APPLY EXTRA ADHESIVE HERE WHEN REPLACING BOTH

CENTER AND SIDE PANELS6. APPLY GRAY SILICONE SEALANT ALONG BOTTOM EDGE OF

CENTER GLASS

2

3

1

21

5

6

4

9010-6


NOTES

Vended Schematic5-3310

case 821e service manual

Documents

torque values

thick nuts

engine oil

cnh america llc

cnh ameica llc

metric conversion chart

state streetracine

fasteners withboth unc