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521D Loader
Service Manual
6-40742
Table of Contents
Description Section No. Form No.
General Tab 1
Section Index - General 6-42730
Standard Torque Specifications 1001 8-71602
Fluids and Lubricants 1002 6-40762
Metric Conversion Chart 1003 7-52950
Loctite Product Chart 8-98902
Engines Tab 2
Section Index - Engines 6-42281
Engine and Radiator Removal and Installation 2000 6-42290
Engine and Radiator Removal and Installation P.I.N. JEE0135501 and Above 2000 6-48920
Stall Tests 2002 6-40770
For Engine Repair, See the Engine Service Manual
Electrical Tab 4
Section Index - Electrical 6-42311
Removal and Installation of Starter and Alternator 4001 6-42321
Electrical Specifications and Troubleshooting 4002 6-40782
Electrical Specifications and Troubleshooting P.I.N. JEE0135501 and Above 4002 6-48930
Batteries 4003 6-42330
Information and Diagnostic Center 4005 6-42351
Alternator - 65 Ampere 4007 7-12260
Alternator - 45 Ampere 4008 6-42360
Steering Tab 5
Section Index - Steering 6-42370
Removal and Installation of Steering Components 5001 6-42380
Steering Specifications, Pressure Checks, and Troubleshooting 5002 6-40790
Steering Control Valve 5003 6-42390
Steering Priority Valve 5004 6-42400
Steering Cylinders 5005 6-42410
Center Pivot 5006 6-42420
Auxiliary Steering Motor and Pump 5008 6-42430
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
521D Loader
Service Manual
6-40742
Table of Contents
Description Section No. Form No.
Brakes Tab 7
Section Index - Brakes 6-42510
Removal and Installation of Brake Components 7001 6-42521
Hydraulic Brake Troubleshooting 7002 6-40811
Brake Accumulators 7004 6-42531
Parking Brake 7008 6-42540
NOTE: For parking brake and brake pedal adjustments, see Section 9001.
Hydraulics Tab 8
Section Index - Hydraulics 6-42550
Removal and Installation of Hydraulic Components 8001 6-42560
Hydraulic Specifications, Troubleshooting, and Pressure Checks 8002 6-40820
Cleaning the Hydraulic System 8003 7-49640
Cylinders 8006 6-42590
Coupler Solenoid Locking Valve 8007 6-42600
Pilot Pressure Accumulator and Ride Control Accumulator 8013 6-42621
521D Loader
Service Manual
6-40742
Table of Contents
Description Section No. Form No.
Electrical Schematic Foldouts and Hydraulic Schematic Foldout In Rear Pocket 6-40841
Electrical Schematic Foldouts and Hydraulic Schematic Foldout P.I.N
In Rear Pocket 6-49280
JEE0135501 and Above
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
SECTION INDEX
GENERAL
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright 2001 Case Corporation
3350 South Service Road Printed in U.S.A.
Hamilton, ON L7N 3M6 CANADA Bur 6-42730 August, 2001
Copyright
Copyright
1001
Section
1001
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
TABLE OF CONTENTS
TORQUE SPECIFICATIONS - DECIMAL HARDWARE ......................................................................................... 3
M14 106 to 127 144 to 172 M36 2580 to 3090 3500 to 4200
Pound- Newton
Size Feet metres
1/2-13 55 to 65 74 to 88
5/8-11 140 to 150 190 to 203
1002
Section
1002
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright 2002 Case Corporation
3350 South Service Road Printed in U.S.A.
Burlington, ON L7N 3M6 CANADA Bur 6-40762 March, 2001 (Revised June, 2002)
Copyright
1002-2
TABLE OF CONTENTS
CAPACITIES AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CONVERSION FORMULAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ENGINE OIL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DIESEL FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fuel Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Specifications for Acceptable No. 2 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Model 521D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Model 521D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CONVERSION FORMULAS
Imperial quart = litres x 0.879877
Imperial gallons = litres x 0.219969
BS99M162
MAINTENANCE SCHEDULE
Model 521D
Instructions
AS REQUIRED
22 SERVICE THE AIR CLEANER IF THE AIR CLEANER WARNING LAMP ILLUMINATES................................... SEE OPERATORS MANUAL
30 REPLACE THE TRANSMISSION FILTER
IF THE TRANSMISSION FILTER RESTRICTION WARNING LAMP ILLUMINATES ......................................................... USE CASE FILTER
19 CHECK THE RADIATOR COOLANT LEVEL IF THE WARNING LAMP ILLUMINATES ...................................... SEE OPERATORS MANUAL
6.REPLACE THE HYDRAULIC FILTER IF THE HYDRAULIC FILTER WARNING LAMP ILLUMINATES............................... USE CASE FILTER
CHECK THE AIR CONDITIONING DRIVE TENSION (IF EQUIPPED) NOT SHOWN ...............................................ADJUST AS REQUIRED
MAINTENANCE SCHEDULE
Model 521D
12
19
14 1
3 40
16
34
6 39
33 23 36
36
28
30
8
22 38
21 8
2
34
31 26 29 31 4
39 38
7 18
24
BS01B021
If you operate the machine in severe conditions, See your Operators manual for maintenance of
lubricate and service the machine more frequently. It safety related items and for detailed information of
is recommended that you see your Case dealer for the service items on this chart. Operators and
in fo rmatio n o n the Syste m G u ard L ub ricatio n service manuals are available for this machine from
Analysis System. your Case dealer.
Section
1003
1003
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
TABLE OF CONTENTS
CONVERSION FACTORS ............................................................................................................................................. 3
Metric to U.S. .......................................................................................................................................................... 3
U.S. to Metric ......................................................................................................................................................... 4
CONVERSION FACTORS
Metric to U.S.
MULTIPLY BY TO OBTAIN
U.S. to Metric
MULTIPLY BY TO OBTAIN
* = exact
515 Purple 0.010 750 psi -65 to +300 1 hr/24 hrs 764 Gasket Eliminator 515
Rac 8-98902 * Products 404-496 (except for #445) are all instant adhesives (super glues) they differ mostly in viscosity Printed in U.S.A.
LOCTITE PRODUCT CHART
Working Fixture/Full Cure
Similar Gap Strength Temperature (Steel/Steel) Time
Product Color Products (In Inches) (Steel/Steel) Range-Farenheit Primer Description
518 Red 515 0.030 500psi -65 to +300 1hr/24 hrs 764 Gasket Eliminator 518 for Aluminum
542 Brown 569 N/A 132/92 in lbs -65 to +300 2 hr/24 hrs 747 Hydraulic Sealant
Low Strength Pneumatic/Hydraulic
545 Purple N/A 25/20 in lbs -65 to +300 4 hr/24 hrs 747
Sealant
549 Orange 504 0.020 2500 psi -65 to +300 2 hr/24 hrs 747 Instant Seal Plastic Gasket
554 Red 277 0.015 240/240 in lbs -65 to +300 2 to 4 hrs/24 hrs 764 Refrigerant Sealant
567 White 592 N/A 500 psi -65 to +400 4 hrs/24 hrs 764 Pipe Sealant for Stainless Steel
568 Orange 277 0.015 2500 psi -65 to +300 12 hrs/24 hrs 764 Plastic Gasket
569 Brown 545 0.010 40/25 in lbs -65 to +300 1 hr/24 hrs 764 Hydraulic Sealant
570 Brown 592 N/A 25/40 in lbs -65 to +300 6 hrs/72 hrs 764 Steam Sealant
571 Brown 592 0.015 40/20 in lbs -65 to +300 2 to 4 hrs/24 hrs 764 Pipe Sealant
572 White 578.575 N/A 80/27 in lbs -65 to +300 24 hrs/72 hrs None Gasketing
592 White 0.020 500 psi -65 to +400 4 hrs/72 hrs 736 Pipe Sealant with Teflon
593 Black 0.250 400 psi -95 to +400 30 min/24 hrs N/A RTV Silicone
601 Green 609 0.005 3000 psi -65 to +300 10 min/24 hrs 764 Current PIN #609
609 Green 0.005 3000 psi -65 to +300 10 min/24 hrs 764 General Purpose Retaining Compound
High Temperature Retaining
620 Green 640 0.015 3000 psi -65 to +450 30 min/24 hrs 747
Compound
635 Green 680 0.010 4000 psi -65 to +300 1 hr/24 hrs 747 High Strength Retaining Compound
638 Green 680 0.015 4100 psi -65 to +300 10 min/24 hrs 747 High Strength Retaining Compound
640 Green 620 0.007 3000 psi -65 to +400 1 hr/24 hrs 747 High Temperature Retaining Compound
660 Silver 0.020 3000 psi -65 to +300 20 min/24 hrs 764 Quick Metal
675 Green 609 0.005 3000 psi -65 to +300 20 min/24 hrs 747 General Purpose Retaining Compound
680 Green 635 0.015 4000 psi -65 to +300 10 min/24 hrs 747 High Strength Retaining Compound
706 Clear 755 N/A N/A N/A N/A N/A Cleaning Solvent
707 Amber N/A N/A N/A N/A N/A Activaltor for Structural Adhesives
736 Amber N/A N/A N/A N/A N/A Primer NF
738 Amber N/A N/A N/A N/A N/A Depend Activator
747 Yellow N/A N/A N/A N/A N/A N/A Primer T
751 Clear N/A N/A N/A N/A N/A Activator for Structural Adhesives
755 Clear N/A N/A N/A N/A N/A Cleaning Solvent
764 Green N/A N/A N/A N/A N/A Primer N
767 Silver N/A N/A -65 to +1600 N/A N/A Anti-Seize Lubricant
Copyright
Printed in U.S.A.
Copyright
SECTION INDEX
ENGINES
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright 2003 Case Corporation
3350 South Service Road Printed in U.S.A.
Hamilton, ON L7N 3M6 CANADA Bur 6-42281 August, 2001 (Revised February, 2003)
Copyright
Copyright
Section
2000
2000
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright 2001 Case Corporation
3350 South Service Road Printed in U.S.A.
Burlington, ON L7N 3M6 CANADA Bur 6-42290 August,2001
Copyright
2000-2
TABLE OF CONTENTS
ENGINE . . . . ....... ...... ....... ...... ....... ...... ...... ....... ...... ................... 3
Removal . ....... ...... ....... ...... ....... ...... ...... ....... ...... ................... 3
Installation ....... ...... ....... ...... ....... ...... ...... ....... ...... .................. 15
RADIATOR . ....... ...... ....... ...... ....... ...... ...... ....... ...... .................. 27
Removal . ....... ...... ....... ...... ....... ...... ...... ....... ...... .................. 27
Installation ....... ...... ....... ...... ....... ...... ...... ....... ...... .................. 29
SPECIFICATIONS
Cooling System Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.1 Liters (9 Gallons)
Engine Oil
Capacity with Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 Liters (11 Quarts)
Type of Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Case No. 1 Engine Oil (SAE 15W-40
Hydraulic Reservoir
Refill Capacity with Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.5 Liters (18 Gallons)
Type of Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MS-1209 Hy-Tran Ultra
SPECIAL TORQUES
Engine Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244 to 298 Nm (180 to 220 lb-ft)
Engine Drive Shaft Mounting Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 to 62 Nm (39 to 46 lb-ft)
Radiator Hose Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 to 11.3 Nm (90 to 100 lb-inch)
Counterweight Mounting Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 693 to 780 Nm (510 to 575 lb-ft)
Counterweight Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 955 to 1075 Nm (704 to 793 lb-ft)
Charge Air Tube Hose Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 to 11.3 Nm (90 to 100 lb-inch)
Muffler Front Mounting Bracket Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 to 133 Nm (87 to 98 lb-ft)
Muffler Rear Mounting Bracket Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 to 39 Nm (25 to 28 lb-ft)
Turbocharger Elbow Clamp at Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 to 25 Nm (15 to 18 lb-ft)
Turbocharger Elbow Clamp at Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8 to 5.2 Nm (42.5 to 46 lb-inch)
Air Cleaner Hose Clamp at Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 to 11.3 Nm (90 to 100 lb-inch)
Air Cleaner Inlet Hose Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6 to 4.5 Nm (32.9 to 39.6 lb-inch)
Hood Mounting Bolts at Cooling Frame Pivot Points . . . . . . . . . . . . . . . . . . . . . . . . . 36 to 45 Nm (26.5 to 32.5 lb-ft)
Screen Hinge Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 to 33 Nm (19.8 to 24.4 lb-ft)
Coupler to Flywheel Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 to 62 Nm (39 to 46 lb-ft)
ENGINE
Removal STEP 5
STEP 1
Park machine on a level surface and lower bucket to
floor. Stop engine. Actuate brake pedal several times
to discharge brake accumulators. Put key switch in 2
ON position and move loader control lever back and 3 1
forth at least 30 times to release any pressure from
hydraulic circuit. Put key switch in OFF position.
STEP 2
BD01D141
STEP 6
BD00M030
STEP 3
Slowly loosen the filler cap for hydraulic reservoir to
release air pressure in hydraulic reservoir.
STEP 4
BD01D142
Open screen.
STEP 7
BD01D139
BD01D143
6
4 7
BD01D144 BD01D145
Remove four bolts (4) securing hinges of screen to Remove lock nut (6) securing LH spring (7) to hood.
hood. Disconnect prop bar (5) from screen and Repeat to remove lock nut securing RH spring to
remove screen. hood. Disconnect springs from hood; it may be
necessary to raise hood to disconnect springs from
STEP 9 hood.
STEP 12
BD01D255
STEP 13
Lower hood.
BD01D256
BD01D149 BD01D254
Install two lifting eyes and connect lifting strap to Carefully raise and remove hood from loader. Lower
eyes. hood onto suitable platform and disconnect lifting
equipment.
STEP 15
STEP 18
BD01D254
STEP 19
BD01D147
Re mo ve tw o nu ts an d bo lts a nd fo ur w ashe rs
securing hood. BD01D152
BD01D154 BD01D158
Loosen clamp on turbocharger intake hose and Disconnect battery cable from LH battery negative
disconnect hose from turbocharger. post. Put a plastic cap over the negative post.
STEP 21 STEP 24
BD01D155 BD01D161
Remove bolt and washer securing front of battery Disconnect battery cable from RH battery positive
cover. post. Put a plastic cap over the positive post.
STEP 22 STEP 25
8
9
BD01D156 BD01D162
Loosen bolt. Slide battery cover forward and remove. Support air cleaner assembly (9) and remove two
Repeat Steps 21 and 22 to remove RH battery cover. lock nuts, washers, bolts (8), and washers. Remove
air cleaner and support as an assembly.
11
10
BD01D165 BD01D167
Remove four bolts (10) and washers securing drive Support muffler and brackets and remove three bolts
belt guard (11) to master disconnect switch mounting and washers at rear of engine. Remove muffler and
bracket and belt guard bracket. brackets as an assembly from engine.
STEP 27 STEP 30
BD01D168 BD01D169
Remove clamp securing elbow to muffler. Loosen clamp and remove tube from turbocharger.
STEP 28 STEP 31
13
12
12
BD01D166 BD01D170
At fron t o f en gin e, re move two b olts (12 ) an d Loosen two clamps. Remove tube and hose as an
washers securing wiring harness clamps and muffler assembly.
mounting bracket (13).
14 14
15
16
15
BD01D172 BD01D178
Loosen two clamps. Remove tube and hose as an Remove two nuts (14) and washers and two bolts
assembly. (15), washers, and nuts. Remove counterweight (16)
from loader and place on pallet.
STEP 33
STEP 36
BD01D177
combination lamp wire. Identify, tag, and disconnect Identify, tag, and disconnect the four connectors.
r e a r c h a s s i s w i r in g h a r n e s s c o n n e c t o r f r o m
combination lamp connector. Repeat this step for RH STEP 37
rear combination lamp.
STEP 34
18
17
BD01D173
BD01D250 BD01D175
Identify and tag wire connected to starter solenoid Remove nut and washer from engine ground stud.
terminal. Pull the plastic cap from starter solenoid Disconnect the five ground wires of the rear chassis
termin al. U sin g a Ph illips scre wdriver, lo ose n wiring harness from the stud.
terminal screw and disconnect wire from terminal.
STEP 41
STEP 39
21
20
22
19
BD01D176
BD01D174
BD01D257
23
25
26
23
24
BD00M031 BD01D188
Put a 37.8 liter (10 gallon) container below radiator At top of cooling system frame, loosen two hose
drain. Remove cap and drain coolant into container. clamps (23). Remove hose (24). Remove two nuts
Install cap after coolant has drained. (25) securing U-bolt (26). Remove U-bolt, clamp, and
spacer.
STEP 43
STEP 46
BD01D184
STEP 47
BD01D185
BD01D189
27
28
29
BD01D180 BD00M031
If loader is equipped with air conditioning, identify, Put a 18.9 liter (5 gallon) container below engine oil
tag, and disconnect the engine wiring harness d r a in . R e m o ve c a p a n d d r a in e n g in e o il in t o
connectors from air compressor clutch connector container. Install cap after oil has drained.
(27) an d high pressure switch connector (28).
Disconnect engine wiring harness connector from STEP 52
disconnect switch wiring harness connector (29).
STEP 49
BD01D194
STEP 50 31 30
BD01D200
33
37
38
34
BD01D208 BD01D210
Disconnect engine wiring harness connector (32) Cut, remove, and discard tie strap (35) securing
f r o m t r a n s m i s s i o n w i r in g h a r n e s s b u l k h e a d ether start tube (36). Move ether start tube away
connector. Remove clamp (33) securing fuel supply from engine. Loosen clamp (37). Tag and disconnect
hose to engin e flywhee l housing. Remove two fuel supply hose (38) from primer pump. Plug hose
clamps (34) securing fuel return hose to engine. and cap fitting to prevent intrusion of foreign matter
into fuel system.
STEP 55
STEP 57
40
39
41
42
BD01D209
44
45 43
BD01D215 BD01D217
Connect a vacuum pump to hydraulic reservoir. If a Remove nut (43), washer, and bolt securing clamp
vacuum pump is not available, drain the hydraulic oil (44) and engine oil pressure sender (45) to rear
(hydraulic reservoir holds 68.5 liters (18 gallons) of chassis. Remove these parts as an assembly and
oil). Turn o n va cu um pump (if a va ilable). Tag, secure to engine using suitable means.
disconnect, and plug hoses connected to brake
pump. Plug hoses securely and cap fittings. Turn off STEP 61
vacuum pump. Remove clamp securing fuel return
hose to engine.
STEP 59
BD01D219
STEP 62
BD01D216
BD01D203
If e q u ip p e d , d is c o n n e ct e t h e r s t a r t s o l e n o i d
connector from engine wiring harness connector.
BD01D220 BD01D181
Connect lifting equipment to engine lifting brackets. At rear of rear chassis, between fuel tank mounting
Take up all slack in lifting equipment. plate and rear chassis, remove bolt and washer
securing rear of engine to rear chassis.
STEP 64
STEP 66
Slowly raise engine from rear chassis. Be sure all
harness c onnect ions and hoses hav e been
disconnected and out of the way. Remove engine
from machine.
BD01D206
Installation STEP 68
STEP 67 A
56 48
B
55
47
51
52 46
49
A
50
53
BC01D129
54
46. RUBBER ISOLATOR 50. BOLT
B 47. SPACER A. ENGINE
48. RUBBER ISOLATOR B. REAR CHASSIS
49. WASHER
58 57 If engine rear rubber isolators require replacement,
remove and discard isolators (46 and 48) and spacer
BC01D128
(47). Install new rubber isolators (46 and 48) and
51. RUBBER ISOLATOR 56. BOLT spacer (47) in rear chassis.
52. WASHER 57. WASHER
53. RUBBER ISOLATOR 58. NUT
54. WASHER A. ENGINE
STEP 69
55. WASHER B. REAR CHASSIS Slowly raise engine and move into position over rear
chassis. Be sure all harness connections and hoses
If engine front rubber isolators require replacement,
are out of the way then lower engine. Put washer
remove and discard isolators (51 and 53). Install new
(54) between front rubber isolator (53) and rear
rubber isolator (53), washer (52), then rubber isolator
chassis. Install washer (55), bolt (56), washer (57),
(51).
and nut (58) in engine front isolators. Lower engine
into position. Install washer (49) and bolt (50) in rear
isolator.
STEP 70
56
BD01D206
50
BD01D181 BD01D219
At rear of rear chassis, between fuel tank mounting Position belt guard bracket on rear chassis and
plate and rear chassis, tighten bolt (50) to a torque of secure using two nuts.
244 to 298 Nm (180 to 220 lb-ft).
STEP 75
STEP 72
44
45 43
BD01D217
BD01D203
start solenoid connector to engine wiring harness Remove plug from hose and cap from fuel injection
connector if equipped. pump fitting. Connect fuel return hose to fuel injection
pump following tag installed during removal. Position
and tighten clamp. Remove and discard tag.
BD01D215 BD01D209
Install clamp to secure fuel return hose to engine. If equipped, connect ether start nozzle to intake
Turn on vacuum pump conne cted to hydraulic manifold.
reservoir. Remove caps from fittings and plugs from
hoses. Connect hoses to brake pump following tags STEP 80
installed during removal. Remove and discard tags.
Turn off and disconnect vacuum pump from hydraulic 35
reservoir.
36
STEP 78
40 37
38
39
41
BD01D210
42
Re mo ve c ap fr om fittin g a nd p lug fr om h os e.
Connect fuel supply hose (38) to primer pump
following tag installed during removal. Position and
tighten clamp (37). Remove and discard tag. Install a
BD01D212 new tie strap (35) to secure ether start tube (36).
Position throttle bracket with throttle cable and ball
joint attached on engine. Install two washers and STEP 81
socket head bolts (41) to secure throttle bracket (42)
to engine. Connect ball joint (39) to throttle lever (40) 32
and secure with nut and washer.
33
34
BD01D208
31 30
27
28
29
BD01D200 BD01D180
STEP 86
BD01D194
Remove plug from oil drain hose and cap from fitting
installed in engine oil pan. Connect and tighten hose
to fitting. BD01D189
BD01D193
BD01D192 BD01D184
Insert top coolant pipe in cooling system frame. Install bottom hose. Position and tighten hose
Install spacer, clamp, and U-bolt then install two nuts. clamps.
Do not tighten nuts at this time.
STEP 91
STEP 88
23
25
26
23
24 BD01D257
BD01D188
STEP 89
BD01D176
BD01D185
BD01D175 BD01D250
Connect the five ground wires of the rear chassis Connect wire to starter solenoid terminal following
wiring harness to the stud. Install washer and nut to tag in sta lled du ring re mova l. Using a P hillips
secure ground wires to engine ground stud. screwdriver, tighten terminal screw. Install plastic cap
in terminal screw recess. Remove and discard tag.
STEP 93
STEP 95
21
20 18
22
19
BD01D174 17
Install bolt (20), lock washer, and washer to secure BD01D173
harness clamps to engine. Top harness (21) is rear Connect wires to starter B+ terminal (18) following
chassis wiring harness; bottom harness (22) is tags installed during removal. Install flat washer, lock
engine wiring harness. Connect ground cables to washer, and nut to secure wires. Position rubber boot
engine ground stud. Install washer and nut (19) to (17) over starter B+ terminal. Remove and discard
secure ground cables. tags from wires.
STEP 96
BD01D164
BD01D179 BD01D172
STEP 100
15
16
15
BD01D178
STEP 101
BD01D177
BD01D167 BD01D168
Install and support muffler and brackets on engine Position clamp securing elbow to muffler. Tighten
while connecting muffler to tube installed in Step 101. clamp to a torque of 20 to 25 Nm (15 to 18 lb-ft).
Install three washers and bolts at rear of engine Tighten clamp securing opposite end of elbow to
finger tight. turbocharger to a torque of 4.8 to 5.2 Nm (42.5 to 46
lb-inch).
STEP 103
STEP 105
13 11
12
10
12
BD01D166
muffler mounting bracket (13). Secure clamps and Position drive belt guard (11) and secure using four
muffler mounting bracket using two washers and washers and bolts (10) to master disconnect switch
bolts (12). Tighten bolts to a torque of 118 to 133 Nm mounting bracket and belt guard bracket.
(87 to 98 lb-ft). Tighten the three rear bolts installed
in Step 102 to a torque of 34 to 39 Nm (25 to 28 lb-ft). STEP 106
8
9
BD01D162
BD01D161 BD01D155
Remove plastic cap installed over the positive post Install bolt and washer to secure front of battery
during removal. Connect battery cable to RH battery cover.
positive post.
STEP 111
STEP 108
BD01D154
BD01D158 C o n n e c t h o s e f r o m a ir c l e a n e r a s s e m b ly t o
Remove plastic cap installed over the negative post turbocharger. Position clamp and tighten to a torque
during removal. Connect battery cable to LH battery of 10.1 to 11.3 Nm (90 to 100 in-inch).
negative post.
STEP 112
STEP 109
BD01D152
BD01D150 BD01D147
Connect engine wiring harness connector to air filter Install two bolts, four washers, and two nuts to
restriction switch following tag installed during secure hood. Tighten bolts to a torque of 36 to 44 Nm
removal. Remove and discard tag. (26.5 to 32.5 lb-ft).
BD01D242 BD01D254
STEP 115
BD01D149
BD01D256 BD01D255
Take up all slack in strap connected to hood handle. Disconnect lifting strap from hood handle.
6
7 4
BD01D145 BD01D144
Connect springs (7) to hood; it may be necessary to Position screen on hood. Install four bolts (4) to
raise hood to connect springs. Install lock nuts (6) to secure hinges of screen to hood. Tighten bolts to a
secure LH and RH springs to hood. torque of 27 to 33 Nm (19.8 to 24.4 lb-ft). Connect
prop bar (5) to screen.
STEP 120
STEP 124
BD01D258
harness connector to rear chassis wiring harness Install three washers and cotter pin.
connector following tag installed during removal.
Remove and discard tag.
STEP 121
Lower hood.
STEP 130
Fill engine coolant system with a solution of 50%
Ethylene Glycol and 50% water. Cooling system
capacity is 34.1 liters (9 gallons). Install the radiator
cap. Fill the coolant reservoir up to the FULL mark on
the reservoir.
STEP 131
BD01D142
STEP 126
2
3 1
BD01D140
STEP 133
Lower and close hood.
STEP 134
Put articulation lock in OPERATING position.
BD00M031
STEP 128
Install a new oil filter on engine. Fill engine with 10.5
liters (11 quarts) of Case No. 1 Engine Oil (SAE
15W-40).
RADIATOR
STEP 135
Park loader on level surface and lower bucket to
ground. Apply parking brake and shut down engine.
STEP 136
BD01D155
STEP 141
BD00M030
STEP 137
Open and raise hood.
STEP 138
BD00M031
STEP 142
BD01D139 1 3
Put master disconnect switch in OFF position.
STEP 139
Remove the hood (Steps 5 through 17).
5 2 4
BD01D221
9 10
5
11
12
6
BD01D222 BD01D223
Support fuel cooler (5); remove two bolts (6) and Remove radiator cap (9) and disconnect overflow
washers. Remove fuel cooler. h o se ( 1 0 ) fr o m r a d ia to r. I n st a ll r a d ia to r ca p .
Disconnect connector from coolant level sender (11).
STEP 144 Remove screw (12) and install lifting eye.
STEP 147
7 13
14
7
8
BD01D188
STEP 148
BD01D229
15
BD01D225 BD01D227
Remove four bolts (15) and lock washers securing Disconnect lifting equipment from lifting eyes.
radiator to cooling frame. Carefully and slowly raise
radiator from cooling frame and remove from loader. STEP 153
Installation
13
STEP 150
Move radiator into position above cooling frame.
Carefully lower radiator while guiding it into position
in cooling frame. 14
STEP 151
BD01D226
STEP 154
9 10
BD01D225
11
12
BD01D223
1 3
5 2 4
BD01D229 BD01D221
At bottom of radiator, install bottom radiator hose. Remove plugs from hoses (3 and 4) and caps from
Position and tighten two hose clamps to a torque of fuel cooler ports. Connect hoses to fuel cooler.
10.1 to 11.3 Nm (90 to 100 lb-inch). Position two hose clamps (1 and 2) and tighten.
7
8
BD01D188 BD01D155
At top of cooling system frame, install hose (8). Install LH fender. Install two bolts and washers to
Position hose clamps and tighten to a torque of 10.1 secure LH fender.
to 11.3 Nm (90 to 100 lb-inch).
STEP 160
STEP 157 Install the hood (Steps 114 through 126).
STEP 161
5
BD01D222
STEP 165
Lower and close hood.
STEP 166
Put articulation lock in OPERATING position.
BD01D140
Section
2000
2000
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright 2003 Case Corporation
3350 South Service Road Printed in U.S.A.
Burlington, ON L7N 3M6 CANADA Bur 6-48920 February, 2003
Copyright
2000-2
TABLE OF CONTENTS
ENGINE . . . . ....... ...... ....... ...... ....... ...... ...... ....... ...... ................... 3
Removal . ....... ...... ....... ...... ....... ...... ...... ....... ...... ................... 3
Installation ....... ...... ....... ...... ....... ...... ...... ....... ...... .................. 17
RADIATOR . ....... ...... ....... ...... ....... ...... ...... ....... ...... .................. 31
Removal . ....... ...... ....... ...... ....... ...... ...... ....... ...... .................. 31
Installation ....... ...... ....... ...... ....... ...... ...... ....... ...... .................. 33
SPECIFICATIONS
Cooling System Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.1 Liters (9 Gallons)
Engine Oil
Capacity with Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 Liters (11 Quarts)
Type of Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Case No. 1 Engine Oil (SAE 15W-40
Hydraulic Reservoir
Refill Capacity with Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.5 Liters (18 Gallons)
Type of Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MS-1209 Hy-Tran Ultra
SPECIAL TORQUES
Engine Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244 to 298 Nm (180 to 220 lb-ft)
Engine Drive Shaft Mounting Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 to 62 Nm (39 to 46 lb-ft)
Radiator Hose Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 to 11.3 Nm (90 to 100 lb-inch)
Counterweight Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 955 to 1075 Nm (704 to 793 lb-ft)
Charge Air Tube Hose Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 to 11.3 Nm (90 to 100 lb-inch)
Muffler Front Mounting Bracket to Engine Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . 118 to 133 Nm (87 to 98 lb-ft)
Muffler Rear Mounting Bracket to Engine Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . 68 to 77 Nm (50 to 56.5 lb-ft)
Muffler Mounting Brackets to Muffler Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 to 44 Nm (29 to 32 lb-ft)
Turbocharger Elbow Clamp at Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 to 25 Nm (15 to 18 lb-ft)
Turbocharger Elbow Clamp at Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8 to 5.2 Nm (42.5 to 46 lb-inch)
Air Cleaner Hose Clamps at Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 to 11.3 Nm (90 to 100 lb-inch)
Air Cleaner Inlet and Outlet Hose Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6 to 4.5 Nm (32.9 to 39.6 lb-inch)
Hood Mounting Bolts at Cooling Frame Pivot Points . . . . . . . . . . . . . . . . . . . . . . . . . 36 to 44 Nm (26.5 to 32.5 lb-ft)
Screen Hinge Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 to 33 Nm (19.8 to 24.4 lb-ft)
Coupler to Flywheel Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 to 62 Nm (39 to 46 lb-ft)
Air Conditioning Compressor Mounting Bracket Mounting Bolts
M8 Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 to 44 Nm (25 to 32.5 lb-ft)
M10 Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 to 87 Nm (49.4 to 64 lb-ft)
ENGINE
Removal STEP 5
STEP 1
Park machine on a level surface and lower bucket to
floor. Stop engine. Actuate brake pedal several times
to discharge brake accumulators. Put key switch in 2
ON position and move loader control lever back and 3 1
forth at least 30 times to release any pressure from
hydraulic circuit. Put key switch in OFF position.
STEP 2
BD01D141
1. CLIP
2. HOOD PROP
3. STUD
Using a flat blade screwdriver or other suitable tool,
disengage bottom clip (1) from hood prop (2) and pull
bottom of prop from stud (3). Repeat to remove top of
prop from hood; remove prop then close hood.
STEP 6
BD00M030
STEP 3
Slowly loosen the filler cap for hydraulic reservoir to
release air pressure in hydraulic reservoir.
STEP 4
BD01D142
Open screen.
STEP 7
BD01D139
BD01D143
6
4 7
BD01D144 BD01D145
STEP 12
BD01D255
STEP 13
Lower hood.
BD01D256
BD01D149 BD01D254
Install two lifting eyes and connect lifting strap to Carefully raise and remove hood from loader. Lower
eyes. hood onto suitable platform and disconnect lifting
equipment.
STEP 15
STEP 18
BD01D254
BD01D147
Re mo ve tw o nu ts an d bo lts a nd fo ur w ashe rs
securing hood.
8 9
13
14
10 8
15
11 BD01D161
10 Disconnect battery cable from RH battery positive
11 12
11 post. Put a plastic cap over the positive post.
11 12
STEP 23
BS02J037
STEP 21
18 23
24
25
25
26
BD01D158 BS02J036
Disconnect battery cable from LH battery negative 16. CLAMP 22. TUBE
post. Put a plastic cap over the negative post. 17. INTAKE HOSE 23. HOSE
18. CLAMP 24. LOCK NUT
19. HOSE 25. WASHER
20. CLAMP 26. BOLT
21. HOSE 27. AIR CLEANER
Loosen clamp (16) on air cleaner intake hose (17)
and remove intake hose.
STEP 26
38
32 33
28
29
30 37
34
35
29
28
BS02J046
STEP 29
Support muffler (38) and brackets (36 and 37) and
remove two bolts (34) and washers (35) at rear of
e n g in e . R e m o v e m u ff le r a n d b r a c k e t s a s a n
assembly from engine.
STEP 30
Loosen clamp (39) and remove exhaust tube elbow
(40) from turbocharger.
45
41
42
44 46 BD01D179
BD01D177
60 STEP 40
66
BS02J055
STEP 37
Remove bolt (59) and washer securing cable clamp
(60) to engine.
STEP 38
65
BS02J054
67. CONNECTOR
63
62 61
BS02J056
79 80
71 80 78
81
72
69
73 68
75 74
83
BS02J059 76 77
68. CONNECTOR 72. CONNECTOR BS02J058
69. CONNECTOR 73. BOLT
76. BOLT 80. WASHER
70. BOOT 74. NUT
77. WASHER 81. CLAMP
71. WIRE 75. STUD
78. NUT 82. FLYWHEEL HOUSING COVER
Id e nt ify, ta g , a n d d isc o n ne c t e n g ine h ar n es s 79. BOLT 83. CONNECTOR
connector (68) from disconnect harness connector Remove bolt (76) and washer (77) securing clamps
(69). of engine harness and rear chassis harness to
engine block. Top harness is rear chassis harness;
STEP 43 bottom harness is engine harness.
Pull boot (70) away from alternator stud. Identify, tag,
and disconnect engine harness wire (71) from stud. STEP 48
Remove two nuts (78) and bolts (79 ) and four
STEP 44 washers (80) securing two clamps (81) to flywheel
Identify, tag, and disconnect two connectors (72). housing cover (82).
STEP 45 STEP 49
Remove bolt (73) and washer securing engine Route engine harness and rear chassis harness to
harness clamp to engine. front of engine and away from flywheel housing
cover. Remove any hardware securing harness
STEP 46 clamps to engine as necessary.
Remove nut (74) and washer securing five ground
wires of rear chassis harness and three ground wires STEP 50
of engine harness to stud (75). Identify, tag, and Identify, tag, and disconnect four connectors (83).
disconnect ground wires from stud.
89 C
B
85 91
92
84
90
A
87
86
88
BS02J060
STEP 51 STEP 56
Identify, tag, and disconnect connector (84) from Identify, tag, and disconnect connector (90) from fuel
engine coolant temperature sender. filter heater.
STEP 52 STEP 57
Remove bolt (85) and washer securing engine Identify, tag, and disconnect connector (91) from fuel
harness clamp. filter temperature switch.
STEP 53 STEP 58
If wheel loader is equipped with air conditioning, Identify and tag wire (92). Locate connector on end
identify, tag, and disconnect connector (86) from air of wire (92) and disconnect from fuel injection pump
conditioner compressor clutch. Identify. tag, and fuel solenoid.
disconnect connector (87) from air conditioning high
pressure switch. STEP 59
Ro u te en gin e ha rn e ss a w ay fro m e n gin e a n d
STEP 54 towards front of engine compartment.
Identify, tag, and disconnect wire (88) from engine oil
pressure switch.
STEP 55
If equipped, identify, tag, and disconnect wire (89)
from grid heater.
STEP 63
99
98
96 95
97
94
93
BS02J066
STEP 61
102 105
104
101
106
105
BS02J069
103
105.CLAMP
BS02J067 106.HOSE
107
109 117
112 114
STEP 69
BS02J068
107.CLAMP 111.HOSE
108.BLEED LINE HOSE 112.PIPE
109.CLAMP 113.TIE STRAP
110.CLAMP 114.HOSE
Loosen two clamps (107) securing bleed line hose 121
(108). Disconnect bleed line hose (108) from fittings. 127
STEP 66
Loosen clamps (109 and 110). Disconnect and 120
remove hose (111) from engine and pipe (112). 124
Disconnect and remove pipe (112) with bleed line 126 125 119
hose (108) attached from hose (114). If necessary,
cut, remove, and discard tie straps (113) to separate 118
bleed line hose (108) from pipe (112). 123
STEP 67 122
BS02J070
118.NUT 123.WASHER
119.WASHER 124.U-BOLT
120.BALL JOINT 125.CLAMP
121.THROTTLE LEVER 126.THROTTLE CABLE
122.NUT 127.SUPPORT BRACKET
Remove nut (118) and washer (119) securing ball
joint (120) to throttle lever (121).
STEP 70
Remove two nuts (122) and washers (123), U-bolt
(124), and clamp (125) securing throttle cable (126)
BD00M031
to support bracket (127). Position throttle cable away
Put a 18.9 liter (5 gallon) container below engine oil
from engine.
d r a in . R e m o ve c a p a n d d r a in e n g in e o il in t o
container. Install cap after oil has drained.
Bur 6-48920 Issued 2-03 Printed in U.S.A.
Copyright
2000-14
STEP 71 STEP 72
139
131
130 138
137
128
137
129 136
136
BS02J072
135
134
128.BOLT 130.FUEL SUPPLY HOSE
129.CLAMP 131.FUEL RETURN HOSE
Remove bolt (128) and washer securing clamp (129)
135
132
holding in-line fuel filter to engine block. Tag and
133
disconnect fuel supply hose (130) from priming
BS02J071
pump. Plug hose and cap fitting. Tag and disconnect
fuel return hose (131) from fuel injection pump. Plug 132.BOLT 136.WASHER
133.WASHER 137.WASHER
hose and cap fitting.
134.CLAMP 138.HOSE BRACKET
135.BOLT 139.FLYWHEEL HOUSING COVER
Remove bolt (132) and washer (133) securing fuel
return hose clamp (134) to flywheel housing cover
(139). Remove two bolts (135), washers (136 and
137) holding hose bracket (138) to flywheel housing
cover. (Throttle cable and associated clamp and (if
used) air conditioning hoses and associated clamp
are also secured to hose bracket.)
STEP 73
Connect a vacuum pump to hydraulic reservoir. If a
vacuum pump is not available, drain the hydraulic oil
(hydraulic reservoir holds 68.5 liters (18 gallons) of
oil). Turn on vacuum pump (if available). At RH side,
front of engine, tag, disconnect, and plug hoses
connected to brake pump. Plug hoses securely and
cap fittings. Turn off vacuum pump.
140
141
BD01D200
BD01D181
140.BOLT 141.DRIVE SHAFT
At front of engine, remove six bolts (140) securing
drive shaft (141) to engine coupling. Use a pry bar to 156
move drive shaft away from engine coupling.
STEP 75
Connect lifting equipment to engine lifting brackets.
Take up all slack in lifting equipment.
155
STEP 76
154
144
145
147 153
150
149 153
153
152
147
151
148
146 BS02J064
151.BOLT 154.BOLT
152.WASHER 155.WASHER
153.ENGINE MOUNT 156.ENGINE SUPPORT
Installation STEP 83
STEP 82 144
145
156 147
150
149
155
154
147
148
153 146
153
143
153 142
152 BS02J073
STEP 85
At front of engine, tighten two bolts (144) to a torque
of 244 to 298 Nm (180 to 220 lb-ft).
139
151
138
137
137
136
BD01D181
151.BOLT 136
At rear of rear chassis, between fuel tank mounting
135
plate and rear chassis, tighten bolt (151) to a torque
of 244 to 298 Nm (180 to 220 lb-ft).
134
STEP 87 135
132
Disconnect lifting equipment from engine lifting 133
brackets.
BS02J071
132.BOLT 136.WASHER
STEP 88 133.WASHER 137.WASHER
134.CLAMP 138.HOSE BRACKET
135.BOLT 139.FLYWHEEL HOUSING COVER
140 141
Position and support hose bracket (138) with throttle
ca b le a n d a sso c iat ed cla mp a n d , if u se d , a ir
conditioning hoses and associated clamp on flywheel
housing cover (139). Install four washers (137 and
136) and two bolts (135) to secure hose bracket.
Positio n fue l re tu rn h ose with cla mp (13 4) o n
flywheel housing cover and secure using washer
(133) and bolt (132).
BD01D200
STEP 89
Turn on vacuum pump conne cted to hydraulic
reservoir. Remove caps from brake pump fittings and
plugs from brake pump hoses. Connect hoses to
brake pump following tags installed during removal.
Remove and discard tags. Turn off and disconnect
vacuum pump from hydraulic reservoir.
STEP 94
131
130
117
128
129
115 116
BS02J072
Remove plug from fuel return hose (131) and cap 115.HOSE
from fuel injection pump fitting. Connect fuel return 116.ELBOW
hose to fuel injection pump. Remove plug from fuel 117.ENGINE OIL PAN
supply hose (130) and cap from priming pump fitting. Remove plug from oil drain hose (115) and cap from
Connect fuel supply hose to priming pump. Position fitting (116) installed in engine oil pan (117). Connect
clamp (129) holding in-line fuel filter and secure to hose to fitting and tighten.
engine block using washer and bolt (128).
STEP 92
121
127
120
124
126 125 119
118
123
122
BS02J070
118.NUT 123.WASHER
119.WASHER 124.U-BOLT
120.BALL JOINT 125.CLAMP
121.THROTTLE LEVER 126.THROTTLE CABLE
122.NUT 127.SUPPORT BRACKET
Route throttle cable (126) up and over towards fuel
injection pump. Put clamp (125), throttle cable (126),
and U-bolt (124) on support bracket (127) and secure
using two washers (123) and nuts (122).
107
109
112 114
105
113 113
106
111 108
110 110 105
107
BS02J069
105.CLAMP
106.HOSE
Put clamps (105) on hose (106). Connect hose (106)
BS02J068
between bottom pipe and engine coolant inlet.
107.CLAMP 111.HOSE Position clamps and tighten to a torque of 10.1 to
108.BLEED LINE HOSE 112.PIPE 11.3 Nm (90 to 100 lb-inch).
109.CLAMP 113.TIE STRAP
110.CLAMP 114.HOSE
STEP 98
Put clamp (109) on hose (114). Connect pipe (112) to
hose (114). Position clamp (109) and tighten to a
torque of 10.1 to 11.3 Nm (90 to 100 lb-inch). Put
clamps (110) on hose (111). Connect hose (111) to 102 104
pipe (112) and engine coolant outlet. Position clamps 101
(110) and tighten to a torque of 10.1 to 11.3 Nm (90
to 100 lb-inch).
STEP 96
Put hose clamps (107) on bleed line hose (108) and
connect hose to fittings. Position clamps (107) and
tighten to a torque of 10.1 to 11.3 Nm (90 to 100
lb-inch). Install three tie straps (113) to secure bleed
line hose (108) to pipe (112).
103
BS02J067
101.BOLT 103.BOLT
102.DRIVE BELT 104.AC COMPRESSOR
Position and support air conditioning compressor
(104) on mounting bracket. Secure using bolt (103),
three washers, and nut. Install bo lt (101), two
washers, spacer, and nut.
STEP 105
99 If equipped, connect wire (89) to grid heater following
tag installed during removal. Remove and discard
tag.
98
96 STEP 106
95
Connect wire (88) to engine oil pressure switch
following tag installed during removal. Remove and
discard tag.
97
94 STEP 107
93
BS02J066 If wheel loader is equipped with air conditioning,
93. BOLT 97. BRACKET
connect con necto r (86) to a ir co nditioni ng
94. WASHER 98. CLAMP compressor clutch following tag installed during
95. BOLT 99. HOSE removal. Connect connector (87) to air conditioning
96. WASHER 100.HOSE high pressure switch following tag installed during
removal. Remove and discard tags.
Position and support bracket (97) with clamp (98)
and hoses (99 and 100) on engine block. Secure
bracket (97) using two bolts (93 and 95) and washers STEP 108
(94 and 96). Position engine harness clamp on engine and secure
using bolt (85) and washer.
STEP 101
R o u t e e n g in e h a rn e s s b r a n c h c o n t a in i n g a ir STEP 109
conditioning compressor connectors and engine Connect connector (84) to engine coolant
coolant temperature sender connector from front of temperature sender following tag installed during
engine compartment to RH side of engine towards removal. Remove and discard tag.
rear of engine compartment.
STEP 102
Locate connector on end of wire (92) and connect to
fuel injection pump fuel solenoid followin g tag
installed during removal. Remove and discard tag.
89 C
B
85 91
92
84
90
A
87
86
88
BS02J060
STEP 112
Route engine harness and rear chassis harness to
rear of engine.
STEP 113
P o s i t io n c la m p s o f e n g in e a n d r e a r c h a s s i s
83 harnesses on engine block. Top harness is rear
76 77
chassis harness; bottom harness is engine harness.
BS02J058
Install bolt (76) and washer (77) to secure clamps.
76. BOLT 80. WASHER
77. WASHER 81. CLAMP
78. NUT 82. FLYWHEEL HOUSING COVER
79. BOLT 83. CONNECTOR
Connect four connectors (83) following tags installed
during removal. Remove and discard tags.
71
72
69
73 68
75 74
BS02J054
67. CONNECTOR
BS02J059
Connect rear chassis harness connector (67) to grid
68. CONNECTOR 72. CONNECTOR
heater temperature switch following tag installed
69. CONNECTOR 73. BOLT
during removal. Remove and discard tag.
70. BOOT 74. NUT
71. WIRE 75. STUD
STEP 120
Connect five ground wires of rear chassis harness
and three ground wires of engine harness to stud
(75) following tags installed during removal. Install
nut (74) and washer to secure ground wires. Remove
and discard tags.
STEP 115 66
Position engine harness clamp on engine block.
Secure using bolt (73) and washer.
STEP 116
Connect two connectors (72) following tags installed BS02J055
during removal. Remove and discard tags.
66. STARTER SOLENOID WIRE
STEP 118
Connect engine harness connector (68) to
disconnect harness connector (69) following tags
installed during removal. Remove and discard tags.
STEP 125
64
63 55
62 61
BS02J056
56 57 58
BS02J057
38
40
31
36
39
BD01D177
45
41
BS02J046
27 20 21 20
29
28 22
18 23
BS02J049
28. BOLT
29. WASHER 24
30. DRIVE BELT GUARD 25
Position drive belt guard (30) and secure using four
washers (29) and bolts (28) to master disconnect
switch mounting bracket and belt guard bracket. 25
26
BS02J036
STEP 135
Connect turbocharger intake hose (23) attached to
tube (22) to turbocharger and crankcase hose (21) to
breather pipe. Position clamps (18 and 20) and
tighten. Tighten clamps (18) to a torque of 10.1 to
11.3 Nm (90 to 100 lb-inch).
STEP 136
Connect a ir clea ner intake hose (17) betwe en
cooling frame and air cleaner inlet. Position clamp
(16) and tighten to a torque of 3.6 to 4.5 Nm (32.4 to
39.6 lb-inch).
8 9
13
14
10 8
15
BD01D161
11
Remove plastic cap installed over the positive post 10
11 12
during removal. Connect battery cable to RH battery 11
positive post. 11 12
STEP 138 BS02J037
STEP 140
BD01D158
BD01D150
BD01D242 BD01D254
STEP 142
BD01D149
Raise and move hood into position above loader. STEP 145
Slowly and carefully lower hood into position while
guiding hood pivot points into position with pivot
points on top of cooling frame.
STEP 143
BD01D256
BD01D147
6
7
BD01D145 BD01D255
BD01D144
STEP 148
Lower hood.
BD01D143
STEP 156
If hydraulic reservoir was drained, fill reservoir with
68.5 liters (18 gallons) of MS-1209 Hy-Tran Ultra
fluid.
STEP 157
Fill engine coolant system with a solution of 50%
Ethylene Glycol and 50% water. Cooling system
BD01D142
capacity is 34.1 liters (9 gallons). Install the radiator
Close screen and open hood. cap. Fill the coolant reservoir up to the FULL mark on
the reservoir.
STEP 153
STEP 158
2
3 1
BD01D141
1. CLIP BD01D140
2. HOOD PROP Put master disconnect switch in ON position.
3. STUD
WARNING: Hot coolant can spray out if radiator cap
Using a flat blade screwdriver or other suitable tool,
is removed. To remove radiator cap: Let system cool,
disengage bottom clip (1) from hood prop (2) and
turn to first notch, then wait until all pressure is
push bottom of prop onto stud (3). Repeat to install
released. Scalding can result from fast removal of
top of prop to hood.
radiator cap.
STEP 160
Lower and close hood.
STEP 161
BD00M031
Put articulation lock in OPERATING position.
Check and make sure that drain caps are tight.
RADIATOR
STEP 162
Park loader on level surface and lower bucket to
ground. Apply parking brake and shut down engine.
STEP 163
BD01D155
STEP 168
BD00M030
STEP 164
Open and raise hood.
STEP 165
BD00M031
STEP 169
BD01D139
1
2
BD01D188
BD01D229 BD01D227
Loosen two clamps securing radiator bottom hose. Connect lifting equipment to lifting eyes. Take up all
Remove bottom hose. slack in lifting equipment.
3 4
5
6
BD01D223 BD01D225
STEP 172
BD01D226
7. BOLTS 8. SCREW
Remove two bolts (7) and lock washers on sides of
radiator. Remove screw (8) and install lifting eye.
STEP 175
Move radiator into position above cooling frame. 7
Carefully lower radiator while guiding it into position
in cooling frame.
STEP 176 8
9 BD01D226
7. BOLT 8. SCREW
Remove lifting eye and install screw (8). Install two
lock washers and bolts (7) to secure radiator on both
sides.
STEP 179
BD01D225
9. BOLTS
3 4
Install four lock washers and bolts (9) to secure
radiator to cooling frame.
STEP 177
5
6
BD01D223
BD01D229 BD00M031
At bottom of radiator, install bottom radiator hose. Check that coolant drain cap is tight.
Position and tighten two hose clamps to a torque of
10.1 to 11.3 Nm (90 to 100 lb-inch). STEP 185
Fill engine coolant system with a solution of 50%
STEP 181 Ethylene Glycol and 50% water. Cooling system
capacity is 34.1 liters (9 gallons). Install the radiator
cap. Fill the coolant reservoir up to the FULL mark on
the reservoir.
1 STEP 186
1
2
BD01D188
STEP 187
Start engine and run the engine at low idle. Run the
engine at operating temperature for approximately
five minutes to completely mix the Ethylene Glycol
a n d w a te r. W h e n th e c o o la n t is a t o p e r a ti n g
temperature, stop the engine. When engine has
cooled, check the coolant level at the reservoir.
WARNING: Hot coolant can spray out if radiator cap
is removed. To remove radiator cap: Let system cool,
turn to first notch, then wait until all pressure is
released. Scalding can result from fast removal of
BD01D155 radiator cap.
Install LH fender. Install two bolts and washers to
secure LH fender. STEP 188
Lower a nd close hood. Put articulation lock in
STEP 183 OPERATING position.
Install the hood (Steps 141 through 153).
Bur 6-48920 Issued 2-03 Printed in U.S.A.
Copyright
2002
Section
2002
STALL TESTS
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright 2001 Case Corporation
3350 South Service Road Printed in U.S.A.
Burlington, ON L7N 3M6 CANADA Bur 6-40770 March, 2001
Copyright
2002-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Stall Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
STALL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Procedure to Heat the Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Test No. 1 - Torque Converter and Hydraulic Stall Together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Understanding the Results of Test No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Test No. 2 - Torque Converter Stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Understanding the Results of Test No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Test No. 3 - Hydraulic Stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Understanding the Results of Test No. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SPECIFICATIONS
Low idle ..........................................................................................................................................1020 to 1080 rpm
Full throttle (no load)........................................................................................................................2220 to 2280 rpm
Temperature of the torque converter oil.......................................................................82 to 104 C (180 to 220 F)
Temperature of the hydraulic oil....................................................................................... 51 to 79C (125 to 175F)
Stall Speeds
Torque converter..............................................................................................................................1930 to 2090 rpm
Hydraulic system .............................................................................................................................1945 to 2255 rpm
Torque converter and hydraulic system together.............................................................................1395 to 1705 rpm
STALL TESTS
During these tests the engine runs at full throttle and works against the torque converter, the hydraulic system, or
both the torque converter and the hydraulic system. The results of these tests will show if the cause of poor
performance is one or more of the following: (1) engine, (2) torque converter or transmission, and (3) hydraulic
system.
8. Increase the engine speed to full throttle and run 4. Make sure the parking brake is released (OFF).
the engine at this speed until the instrument 5. Run engine at low idle. Push the clutch cutout
cluster shows a temperature of 115C (239F). switch to OFF. Put the transmission in manual
9. Decrease the engine speed to low idle and move mode. Push down and hold the brake pedal for
the transmission control lever to the Neutral the remainder of this procedure.
position. 6. Make sure that the transmission is in Forward
10. Wait and allow the converter temperature to cool and turn the transmission control lever to third
to 90C (194F). gear.
11. Repeat steps 4 through 9 (approximately three 7. Increase the engine speed to full throttle.
times) until the temperature of the torque 8. Hold the bucket control lever in the ROLLBACK
converter oil is 82 to 104C (180 to 220F). position.
NOTE: The engine speed must be checked while the 2. If the engine speed was more than specified, the
bucket is rolled back and the lift arms are moving. problem can be in the torque converter or the
t r a n s m i s s i o n . S e e S e c t i o n 6 0 0 2 fo r
11. Release the bucket control lever. troubleshooting information.
12. Decrease the engine speed to low idle. 3. If the engine speed was less than specified, do
13. Stop the engine. Test No. 3.
1. If the engine speed was as specified, the engine, 2. Increase the engine speed to full throttle.
torque converter, transmission and hydraulic 3. Hold the bucket control lever in the ROLLBACK
system are probably good. position.
2. If the engine speed was not as specified, do Test 4. Repeatedly raise and lower the lift arms.
No. 2 and 3.
5. Check the engine speed by pressing the program
Test No. 2 - Torque Converter Stall switch, left side of the program/reset switch.
Press the up count switch until the display reads
1. Sit in the seat. 01. Return the program switch to the center
(OFF) position.
2. Start the engine and run the engine at low idle.
NOTE: The engine speed must be checked while the
3. Press the brake pedal, and shift into Forward.
bucket is rolled back and the lift arms are moving.
4. Make sure the parking brake is released (OFF).
6. Release the bucket control lever.
5. Run the engine at low idle.
7. Decrease the engine speed to low idle.
6. Push down and hold the brake pedal for the
8. Stop the engine.
remainder of this test.
7. Make sure that the transmission is in Forward Understanding the Results of Test
and turn the transmission control lever to third
gear.
No. 3
8. Increase the engine speed to full throttle. 1. If the engine speed was as specified, the engine
and hydraulic system are good.
9. Check the engine speed by pressing the program
switch, left side of the program/reset switch. 2. If the engine speed was more than specified, a
Press the up count switch until the display reads component in the hydraulic system is probably
01. Return the program switch to the center the cause. See Section 8002 for troubleshooting
(OFF) position. information.
10. Decrease the engine speed to low idle. 3. If the engine speed was less than specified in all
tests, the engine is probably the cause.
11. Stop the engine.
SECTION INDEX
FUEL SYSTEM
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright 2001 Case Corporation
3350 South Service Road Printed in U.S.A.
Hamilton, ON L7N 3M6 CANADA Bur 6-42300 August, 2001
Copyright
Copyright
SECTION INDEX
ELECTRICAL
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright 2003 Case Corporation
3350 South Service Road Printed in U.S.A.
Hamilton, ON L7N 3M6 CANADA Bur 6-42311 August, 2001 (Revised February, 2003)
Copyright
Copyright
4001
Section
4001
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright 2003 Case Corporation
3350 South Service Road Printed in U.S.A.
Burlington, ON L7N 3M6 CANADA Bur 6-42321 August, 2001 (Revised February, 2003)
Copyright
4001-2
TABLE OF CONTENTS
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
P.I.N. JEE0135500 AND BELOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
P.I.N. JEE0135501 AND ABOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
P.I.N. JEE0135500 AND BELOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
P.I.N. JEE0135501 AND ABOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
STARTER
P.I.N. JEE0135500 AND BELOW
Removal Installation
NOTE: The starter is located on the left side of the
STEP 8
engine, mounted on the engine flywheel housing.
Position and support starter (3) on engine. Install
STEP 1 washers (7) and bolts (6) to secure starter. Tighten
Put master disconnect switch in OFF position. bolts (6) to a torque of 41 to 74 Nm (30 to 54 lb-ft).
STEP 2 STEP 9
Remove air cleaner and air cleaner bracket. Connect positive cables to starter following tags
installed during removal. Install nut (2) and tighten to
STEP 3 a torque of 22.5 to 29.4 Nm (17 to 22 lb-ft). Push boot
Move boo t to ga in a ccess to nu t (2 ). Refe r to over nut.
illustration below.
STEP 10
STEP 4 Conn ect so leno id wire to starter followin g ta g
Remove nut (2) and tag and disconnect all positive installed during removal. Secure using screw (4).
cables from starter (3). Tighten screw to a torque of 2.6 to 4.6 Nm (2 to 3.4
lb-ft).
STEP 5
Move cover to gain access to screw (4). STEP 11
Push cover over screw (4).
STEP 6
Remove screw (4) and tag and disconnect solenoid STEP 12
wire from starter (3). Install air cleaner bracket and air cleaner.
STEP 7 STEP 13
Remove bolts (6) and washers (7). Remove starter
Put master disconnect switch in ON position.
(3).
6
2
6 4 5
BS01C137
STARTER
P.I.N. JEE0135501 AND ABOVE
Removal STEP 17
NOTE: The starter is located on the left side of the Remove nut and washer securing cables to starter
engine, mounted on the engine flywheel housing. B+ stud (5). Identify, tag, and disconnect the two
cables from B+ stud.
STEP 14
STEP 18
Put master disconnect switch in OFF position.
STEP 15
Remove air cleaner and air cleaner bracket.
6
STEP 16
4 BS02J055
3 STEP 19
2 Support starter and remove bolts and washers
1 securing starter to engine. Remove starter.
BS02J056
STEP 21 STEP 25
Put master disconnect switch in ON position.
BS02J055
STEP 22
3
2
1
BS02J056
ALTERNATOR
P.I.N. JEE0135500 AND BELOW
Removal Installation
STEP 26 STEP 33
Put master disconnect switch in OFF position and Install alternator (4), shield (3), washer (19) and bolt
remove drive belt guard. (18) on machine. Tighten bolt (18) to a torque of 60 to
104 Nm (42.5 to 76 lb-ft). Refer to illustration on
STEP 27 following page.
Use a wrench to move belt tensioner (2) and loosen
tension on belt (1). Refer to illustration on following STEP 34
page. Install washer (16), nut (14) and bolt (13). Tighten
bolt (13) to a torque of 60 to 104 Nm (42.5 to 76 lb-ft).
STEP 28
Remove belt (1). STEP 35
Use a wrench to move belt tensioner (2) until belt (1)
STEP 29 can be installed.
Remove boots (5 and 8), nuts (6 and 9), and lock
washers (7 and 10). Tag and disconnect wires (11 STEP 36
and 12) from alternator (4). Install belt (1).
STEP 30 STEP 37
Remove bolt (13), nut (14), and washer (16) from Install wire (12), lock washer (7) and nut (6) on
support bracket (17) and alternator (4). alternator D+ terminal. Tighten nut (6) to a torque of
3.5 to 3.9 Nm (2.6 to 2.9 lb-ft).
STEP 31
Loosen and remove bolt (18) and washer (19). STEP 38
Install boot (5).
STEP 32
Remove alternator (4) and shield (3) from machine. STEP 39
Install wire (11), lock washer (10) and nut (9) on
alternator B+ terminal. Tighten nut (9) to a torque of
15 to 27 Nm (11 to 20 lb-ft).
STEP 40
Install boot (8).
STEP 41
Install drive belt guard and put master disconnect
switch in ON position.
7 10
6 9
5 8
12
11
17
14
16
2
4
13
18
19
20
15 21
BS01C136
BS01E102
ALTERNATOR WITH AIR CONDITIONING DRIVE BELT INSTALLATION - P.I.N. JEE0135500 AND BELOW
ALTERNATOR
P.I.N. JEE0135501 AND ABOVE
Removal STEP 45
STEP 42
Put master disconnect switch in OFF position. 5
STEP 43 6
1
2
7
3
BS02J059
5. BOOT 7. CONNECTOR
6. WIRE
STEP 46
Identify, tag, and disconnect two connectors (7).
STEP 47
BS02J049
1. BOLT 9
2. WASHER 8
3. DRIVE BELT GUARD
Remove four bolts (1) and washers (2) securing drive
belt guard to master disconnect switch mounting
bracket and belt guard bracket.
STEP 44
10
4 BS02K146
11
A
10
BS02K147
Put a 12.7 mm (1/2 inch) drive breaker bar or ratchet 8. BOLT 10. BOLT
(A) in bracket for automatic belt tensioner. Push 9. BRACE 11. ALTERNATOR
down on breaker bar or ratchet to release drive belt Remove bolt (8 ) securing bra ce (9) to engine.
tension and remove drive belt (4) from alternator Loosen bolt (10) and move alternator then remove
pulley. b o lt ( 1 0 ) a n d a s s o c ia te d h a r d w a r e . R e m o v e
alternator.
Bur 6-42321 Revised 2-03 Printed in U.S.A.
Copyright
4001-10
Installation STEP 50
Connect engine harness wire (6) to alternator stud
STEP 48 following tag installed during removal. Push boot (5)
over alternator terminal. Remove and discard tag.
11 STEP 51
4
10
A
BS02K145
9
8
BS02K147
STEP 49
2
1
5
BS02J049
1. BOLT
7 2. WASHER
BS02J059 3. DRIVE BELT GUARD
4002
Section
4002
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright 2002 Case Corporation
3350 South Service Road Printed in U.S.A.
Burlington, ON L7N 3M6 CANADA Bur 6-40782 March, 2001 (Revised June, 2002)
Copyright
NOTES
Copyright
4002-3
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ELECTRICAL WIRE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
UNDERSTANDING THE TROUBLESHOOTING TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
LOCATING COMPONENTS ON THE SCHEMATIC POSTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
TROUBLESHOOTING BATTERIES, FUEL SHUTOFF, CHARGING, STARTING, ALTERNATOR, ETHER START,
IGNITION SWITCH AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Master Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Fuel Shutoff Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Starter Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Fuel Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Ether Start Temperature Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Ether Start Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Ether Start Relay No. 6 (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Ether Start Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Neutral Start Relay No. 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Ignition Relay No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
TROUBLESHOOTING IGNITION RELAY, ACCESSORY RELAY, VOLTMETER RELAY, AND TIME DELAY
MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Ignition Relay No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Accessory Relay No. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Voltmeter Relay No. 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Time Delay Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
TROUBLESHOOTING TRANSMISSION SOLENOIDS, SENSORS AND SWITCHES, CONTROL MODULE,
SHIFTER, DIAGNOSTIC CONNECTOR, AND BACK-UP ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Output Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Engine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Intermediate Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Turbine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Filter Maintenance Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Torque Converter Output Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Transmission Solenoid Valve and Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Transmission Electronic Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Transmission Shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Diagnostic Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Transmission Kick-down Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Transmission Auto Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Declutch Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Brake Declutch Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Transmission Enable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
FNR Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Back-up Alarm Relay No. 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Back-up Alarm Disable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Back-up Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
TROUBLESHOOTING INDICATOR SWITCHES AND SENDERS, PROGRAM/RESET SWITCH, PARK BRAKE
SWITCH, INSTRUMENT CLUSTER, PILOT CONTROL SWITCH, AND UP/DOWN COUNT SWITCH . . . 46
Brake Warning Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Coolant Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
SPECIFICATIONS
Electrical System ............................................................ Two 12 volt batteries connected in series, negative ground
System Voltage............................................................................................................................................... 24 volts
Batteries
Specifications are the same for production battery and replacement battery.
Production Battery Case P/N ................................................................................................................... A176482
Replacement Battery Case P/N ............................................................................................................... A180406
Group Size .......................................................................................................................................................... 31
Reserve Capacity ................................................................................................................................ 170 minutes
Cold Cranking Capacity At -17C (0F) for 60 Seconds At 6.0 Volts .................................................700 amperes
Load of Capacity (Load) Test .............................................................................................................400 amperes
Plates per Cell ..................................................................................................................................................... 17
Approximate weight with electrolyte ..................................................................................... 25.9 kg (57.1 pounds)
Nonspill caps ............................................................................................................................................ Standard
Alternator ..................................................................................................................................... 24 volt, 45 amperes
Voltage Regulator ............................................................................................................. Solid State, Not Adjustable
Starter................................................................................................................................ 24 volt, Solenoid Actuated
Bucket Control Valve (Joystick) Detent Electromagnets Resistance at 20C (68F) (Nominal) ................ 68.2 ohms
Bucket Control Valve (Single Axis) Detent Electromagnets Resistance at 20C (68F) (Nominal) ............ 305 ohms
Fuel Level Sender .............................................................................................................................. 33 to 240 ohms
Coolant, Torque Converter, and Hydraulic Temperature Sender 20C (68F) .......................................... 3521 ohms
Coolant and Hydraulic Temperature Sender (Yellow Line) 105C (221F) ................................................. 154 ohms
Coolant and Hydraulic Temperature Sender (Red Line) 110 C (230F) .................................................. 133.9 ohms
Transmission Filter Restriction Switch with 510 ohms Internal Resistor (Normally Open)
Closing Setpoint ............................................................................................................................. 2.8 Bar (40 psi)
Hydraulic Filter Restriction Switch (Normally Open) Closing Setpoint ............................................... 2.8 Bar (40 psi)
Air Filter Restriction Switch (Normally Open) Closing Setpoint .................................. -6.4 kPa (Gauge) (-0.928 psig)
Brake Warning Pressure Switch (Normally Closed) Opening Setpoint ...................................... 117.2 Bar (1700 psi)
A/C High Pressure Switch (Normally Open) Closing Setpoint..................... 27.6 Bar (400 psi) (increasing pressure)
A/C Low Pressure Switch (Normally Closed) Opening Setpoint .................... 1.4 Bar (20 psi) (decreasing pressure)
Thermostat Switch
Contacts 2 to 3 close at initial turn of the switch. Contacts 1 to 2 close with thermal setting.
Engine Oil Pressure Switch (Normally Closed) Opening Setpoint ................................................... 0.69 Bar (10 psi)
Fuel Solenoid Resistance (pull in) At 20C (68F) (Nominal) ..................................................................... 1.1 ohms
Fuel Solenoid Resistance (hold in) At 20C (68F) (Nominal) ................................................................... 41.5 ohms
Brake Declutch Pressure Switch (Normally Closed) Opening Setpoint............................................. 24 Bar (350 psi)
Redundant Brake Pressure Switches (Normally Open) Closing Setpoint ......................................... 62 Bar (900 psi)
Brake Lamp Pressure Switch (Normally Open) Closing Setpoint....................................................... 4.1 Bar (60 psi)
Float Pressure Switch (Normally Open) Closing Setpoint ................................................................. 19 Bar (275 psi)
Secondary Steering Pressure Switch (Form C) Closing Setpoint ...................................................... 2.4 Bar (35 psi)
Ether Start Temperature Switch
Opens.................................................................................................................................. 13 3C (55.4 5.4F)
Closes ............................................................................................................................. 1.5 4.5C (34.7 8.1F)
Ether Start Solenoid DC Resistance At 25 C (77F) (Nominal)................................................................... 2.2 ohms
Parking Brake Solenoid DC Resistance At 20C (68F) (Nominal) ........................................................... 40.3 ohms
Pilot Pressure Solenoid (Joystick) DC Resistance At 20C (68F) (Nominal) ........................................... 29.9 ohms
Pilot Pressure Solenoid (Single Axis) DC Resistance At 20C (68F) (Nominal) ...................................... 27.4 ohms
52 Fan Reverse Sol W-1.0-SXL 158 Fan Rev Sol Opt A 21M Rear Cab 27
57 Pin Engage Sol Pwr W-1.0-SXL 1 Cab-Frnt Chas U 107M Pin Engage Opt A
58 Ride Cntrl Sol Pwr W-1.0-SXL 1 Cab-Frnt Chas V SPL_A7 Ride Cntrl Sol Pwr SPL_A7
64 Horn Or-1.0-SXL 1 Cab-Frnt Chas N 147 Horn Pwr 1
0_A Ground Bk-1.0-SXL 125 LH Rear Comb Lt 5 SPL_E4 SPL_E4 1
0_AA Height-RTT Grnd Bk-1.0-SXL 10 Height Cntrl-RTT B SPL_A2 Splice A2 SPL_A2
0_AB Pin Engage Grnd Bk-1.0-SXL 107M Pin Engage Opt B SPL_A1 Splice A1 SPL_A1
0_AC Ride Cntrl Grnd Bk-1.0-SXL 5F Ride Control Opt 2 SPL_A1 Splice A1 SPL_A1
0_AD Horn Grnd Bk-1.0-SXL 146 Horn Grnd 1 SPL_A1 Splice A1 SPL_A1
0_AF RTD Grnd Bk-1.0-SXL 12F RTD B SPL_A2 Splice A2 SPL_A2
0_DA AC Brk Lt Time Del Horn Grnd Bk-0.8-SXL 204F Relay Brake Lights 85 220F Ground Cab 1
0_DAB Signal Ground Bk-0.8-SXL 22F Cab Transmission 15 13F Cab-Pedestal 38
0_DAC Relay Grnd Bk-0.8-SXL 13F Cab Pedestal 53 222F Ground Cab 1
0-DAD Relay Grnd Bk-1.0-SXL 222F Ground Cab 1 SPL_D13 Ground 1
0_DAE Ground Bk-1.0-SXL 199F Trans Enable Sw 7 SPL_D13 Ground 1
0_DAF Switch Grnd Bk-1.0-SXL 210F Fan Reverser Sw 7 40F Pin Engage Sw 9
0_DAG Switch Grnd Bk-1.0-SXL 39F Return To Travel Sw 7 SPL_D13 Ground 1
0_DAH Switch Grnd Bk-1.0-SXL 39F Return To Travel Sw 1 39F Return To Travel Sw 7
0_DAJ Switch Grnd Bk-1.0-SXL 36F Detent Switch 7 39F Return To Travel Sw 1
0_DAK Switch Grnd Bk-1.0-SXL 36F Detent Switch 7 38F Declutch Switch 7
0_DAL Switch Grnd Bk-1.0-SXL 40F Pin Engage Sw 9 44F Ride Control Sw 7
0_DAM Switch Grnd Bk-1.0-SXL 44F Ride Control Sw 7 41F Trans Auto Sw 7
0_DAN Flasher Module Grnd Bk-0.8-SXL 62M Flasher Module 3 SPL_D14 Module Grnds 1
0_DAP Ground Bk-1.0-SXL 199F Trans Enable Sw 7 42F Beacon Sw 7
0_DAQ Flasher Module Grnd Bk-0.8-SXL 62M Flasher Module 4 SPL_D14 Module Grnds 1
0_DAR Blwr Wiper Seat Grnd Bk-1.0-SXL 35F Wiper and Washer Sw 1 218F Ground Cab 1
0_DAS Time Delay Mod Grnd Bk-0.8-SXL 63M Time Delay Module 3 SPL_D14 Module Grnds 1
0_DAT Brk Lt Time Del Horn Grnd Bk-0.8-SXL 220F Ground Cab 1 SPL_D14 Module Grnds 1
Bur 6-40782 Revised 6-02 Printed in U.S.A.
Copyright
4002-11
0_DJ Relay Grnd Bk-0.8-SXL 54F Neutral Start Relay 85 222F Ground Cab 1
0_DK AC Brk Lt Time Del Horn Grnd Bk-0.8-SXL 203F Relay AC 85 204F Relay Brake Lights 85
0_DL Signal Ground Bk-0.8-SXL 22F Cab-Transmission 23 13F Cab-Pedestal 39
0_DM Speed Sensor Grounds Bk-0.8-SXL 19F TECM 3 22F Cab Transmission 11
0_DN Out Speed Sensor Grnd Bk-0.8-SXL 19F TECM 4 22F Cab Transmission 28
0_DP Diag TECM Grnd Bk-0.8-SXL 19F TECM 1 221F Ground Cab 1
0_DQ Diag TECM Grnd Bk-0.8-SXL 19F TECM 2 221F Ground Cab 1
0_DR Dome Court Work Lt Grnd Bk-1.0-SXL 24M Cab Roof E 223F Ground Cab 1
0_DS Dome Court Work Lt Grnd Bk-1.0-SXL 24M Cab Roof G 223F Ground Cab 1
0_DT Dome Court Work Lt Grnd Bk-1.0-SXL 23F Cab Roof B 223F Ground Cab 1
0_DU Beacon Wiper Diode Grnd Bk-1.0-SXL 23F Cab Roof C 206F Cab Floor Weld Stud 1
0_DV Beacon Wiper Diode Grnd Bk-0.8-SXL 206F Cab Floor Weld Stud 1 13F Cab-Pedestal 61
0_DW Ground Bk-0.8-SXL 45F Rear Wiper Sw 7 118F Back-up Alarm Dis Sw 7
0_DX Horn Ground Bk-0.8-SXL 13F Cab-Pedestal 41 220F Ground Cab 1
0_DY Blwr Wiper Seat Grnd Bk-1.0-SXL 28M Seat Comp Motor B 218F Ground Cab 1
0_DZ Blwr Wiper Seat Grnd Bk-2.0-SXL 29M Blower Motor 4 218F Ground Cab 1
0_E Fuel Redundant Br Cool Grnd Bk-1.0-SXL 160 Engine Grounds 1 171 Fuel Sender Grnd 1
0_F Frt Rear Wash Hot Grnd Bk-1.0-SXL 162 Engine Ground 1 3 Rear Washer 2
Bur 6-40782 Revised 6-02 Printed in U.S.A.
Copyright
4002-12
0_KL Pilot Light Grnd Bk-0.8-SXL 75 Program Reset Switch 7 74 Up Down Count Switch 7
0_KM Pilot Light Grnd Bk-0.8-SXL 13M Pedestal-Cab 53 75 Program Reset Switch 7
0_KN Front Wiper Grnd Bk-0.8-SXL 13M Pedestal-Cab 61 60 Front-Wiper Motor 1
0_KP Analog Grnd Bk-0.8-SXL 76 Instrument Cluster 8 13M Pedestal-Cab 8
0_KQ Signal Grnd Bk-0.8-SXL 76 Instrument Cluster 37 SPL_K1 SPL_K1 1
0_KR Signal Grnd Bk-0.8-SXL 13M Pedestal-Cab 38 SPL_K1 SPL_K1 1
0_L Ground Bk-1.0-SXL 157 Redundant Brake Sw B SPL_E9 SPL_E9 1
Bur 6-40782 Revised 6-02 Printed in U.S.A.
Copyright
4002-13
0_MM Dome Lt Grnd Bk-0.8-SXL 84F Dome Light B 84F Dome Light C
0_MN Dome Courtesy Lt Grnd Bk-0.8-SXL 24F Roof-Cab E SPL_M5 Dome Courtesy Lt Grnd 1
0_N Brk Warn Pr Sw Bk-1.0-SXL 88 Brk Warn Pr Sw B SPL_E9 SPL_E9 1
0_NA Chas Grnd Blck Grnd Bk-62.0-SGR 232F Chas Grnd Blck Grnd 1 233F Chas Grnd Blck Grnd 1
0_NB Discon-Blck Grnd Bk-62.0-SGR 235F Discon-Blck Grnd 1 234F Discon-Blck Grnd 1
0_NC Disconect Battery Bk-62.0-SGR 237F Disconect Battery 1 236F Disconect Battery 1
0_ND Chas Grnd-Sec Strg Mtr Bk-62.0-SGT 242F Chas Grnd-Sec Strg Mtr 1 243F Chas Grnd-Sec Strg Mtr 1
0_P Fuel Redundant Br Cool Grnd Bk-1.0-SXL 160 Engine Grounds 1 SPL_E9 SPL_E9 1
0_PA Left Spkr Ground Bk-0.8-SXL 114F 2 112M B
0_PB Right Spkr Ground Bk-0.8-SXL 114F 4 111M B
0_PC Radio Ground Bk-0.8-SXL 114F 3 110F 24/12V Converter B
0_PD Radio Ground Bk-1.0-SXL 247F Radio Ground 1 109M 24/12V Converter B
0_Q Park Str Fuel Relay Grnd Bk-1.0-SXL 87 Parking Brk Sol 2 165 Engine Ground 1
0_QA Left Spkr Ground Bk-0.8-SXL 114M 2 113 Radio 4
0_QB Right Spkr Ground Bk-0.8-SXL 114M 4 113 Radio 2
0_QC Radio Ground Bk-0.8-SXL 114M 3 113 Radio 5
0_RA Converter Ground Bk-5.0-SXL 251F Converter Ground 1 254F Converter Ground 1
0_RB Outlet Ground Bk-3.0-SXL 252F Outlet Ground 1 253F Power Outlet B
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Copyright
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12V_A 12V Pwr To Outlet R-3.0-SXL 257F 12V Pwr To Outlet 1 253F Power Outlet A
12V_B 12V Pwr To Fuse Blck R-5.0-SXL 258F 12V Pwr To Fuse Blck 1 18F Fuse Block 6
13C Fuel Sol Or-1.0-SXL 94M Engine Trans 1 139F Disc Harness A
13C_A Fuel Sol Or-1.0-SXL 94F Eng-Trans 1 22M Cab-Transmission 1
13C_B Fuel Sol Pwr Or-0.8-SXL 57F Engine Shutdown Relay 87 217M Engine Shutdown Jumper A
13C_C Fuel Sol Pwr Or-0.8-SXL 57F Engine Shutdown Relay 87 140M Diode Module D
13C_D Fuel Sol Pwr Or-0.8-SXL 22F Cab-Transmission 1 57F Engine Shutdown Relay 87
13C_E Fuel Sol Pwr Or-1.0-SXL 139M Disconnect-Engine A 231F Fuel Sol Disconnect 1
13D Delay Pwr (2 Way) Or-1.0-SXL 63M Time Delay Module 1 18F Fuse Block S1
13K Ignition Switch Pwr Or-0.8-SXL 13M Pedestal-Cab 56 69 Ignition Switch 3
13K_A Ignition Switch Pwr Or-1.0-SXL 48F Ignition Relay #2 86 47F Ignition Relay #1 86
13K_B Ignition Switch Pwr Or-1.0-SXL 48F Ignition Relay #2 86 57F Engine Shutdown Relay 30
13K_C Ignition Switch Pwr Or-1.0-SXL 58F Volt Meter Relay 86 57F Engine Shutdown Relay 30
13K_D Ignition Switch Pwr Or-0.8-SXL 57F Engine Shutdown Relay 30 217F Engine Shutdown Jumper A
13K_E Ignition Switch Pwr Or-0.8-SXL 58F Volt Meter Relay 86 SPL_D22 Ignition Switch 1
13K_F Ignition Switch Pwr Or-0.8-SXL 63M Time Delay Module 5 SPL_D22 Ignition Switch 1
13K_G Ignition Switch Pwr Or-0.8-SXL 13F Cab-Pedestal 56 SPL_D22 Ignition Switch 1
13M Fuel Sol Hold In Or-1.0-SXL 139F Disc Harness B 134 Fuel Solenoid A
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Copyright
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18C_A High Beam Fused Pwr Or-0.8-SXL 1F Cab-Frnt Chas Q 18F Fuse Block C2
18C_B High Beam Fused Pwr Or-0.8-SXL 13F Cab-Pedestal 15 18F Fuse Block C2
18C_C High Beam Telltale Or-0.8-SXL 76 Instrument Cluster 15 13M Pedestal-Cab 15
18D Low Beam LH Or-1.0-SXL 1 Cab-Frnt Chas O 6 Lights LH 2
18D_A Low Beam LH Or-0.8-SXL 1F Cab-Frnt Chas O 18F Fuse Block D2
18E Low Beam RH Or-1.0-SXL 1 Cab-Frnt Chas P 8 Lights RH 2
18E_A Low Beam RH Or-0.8-SXL 1F Cab-Frnt Chas P 18F Fuse Block E2
18F Position LH Or-1.0-SXL 1 Cab-Frnt Chas F 6 Lights LH 4
18F_A Left Tail Or-1.0-SXL 125 LH Rear Comb Lt 3 21M Rear-Cab 5
18F_D Left Tail Pos Or-0.8-SXL 21F Cab-Rear 5 18F Fuse Block F2
18F_E Left Tail Pos Or-0.8-SXL 1F Cab-Frnt Chas F 18F Fuse Block F2
19C_A Pilot Ride Cntrl Fused Pwr Or-1.0-SXL 18F Fuse Block C2 SPL_D24 Ride Cntrl Fuse Pwr 1
19C_B Ride Ctrl Fused Pwr Or-1.0-SXL 44F Ride Control Sw 2 SPL_D24 Ride Cntrl Fuse Pwr 1
19C_C Ride Ctrl Fused Pwr Or-0.8-SXL 13F Cab-Pedestal 68 SPL_D24 Ride Cntrl Fuse Pwr 1
19C_D Pilot Ride Cntrl Fused Pwr Or-1.0-SXL 56F Pilot Control Relay 30 18F Fuse Block C2
19C_E Pilot Ride Cntrl Fused Pwr Or-1.0-SXL 56F Pilot Control Relay 30 56F Pilot Control Relay 86
19D_A Parking Brake Rel Fused Pwr Or-1.0-SXL 55F Brake Lights Relay 30 18F Fuse Block D2
19D_B Parking Brake Rel Fused Pwr Or-1.0-SXL 55F Brake Lights Relay 30 55F Brake Lights Relay 86
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Copyright
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19L Access To Fuse L (3 Way) Or-1.0-SXL 18F Fuse Block L2 18F Fuse Block 5
19L_A Radio Power Or-1.0-SXL 246M Radio Power A 109M 24/12V Converter A
19L_B Converter Pwr Ign Or-1.0-SXL 249M Converter Pwr Ign A 256F Converter Pwr Ign 1
19M_A Sec Str Accessory Or-0.8-SXL 1F Cab-Frnt Chas H 18F Fuse Block M2
19M_B Sec Str Accessory Or-1.0-SXL 180F Sec Str Mod Opt 1 1 Cab-Frnt Chas H
19M_C Sec Str Accessory Or-1.0-SXL 90M Sec Str Mod 7 180M Sec Str Mod-Frnt Harn 1
19N_A Access Seat Fused Pwr (3 Way) Or-1.0-SXL 28M Seat Comp Motor A 18F Fuse Block N2
19N_B Access Seat Fused Pwr (3 Way) Or-1.0-SXL 18F Fuse Block N2 18F Fuse Block 1
19P_A Fan Rev Pin Eng Fused Pwr Or-1.0-SXL 40F Pin Engage Sw 2 18F Fuse Block P2
19P_B Fan Rev Pin Eng Fused Pwr Or-1.0-SXL 210F Fan Reverser Sw 2 40F Pin Engage Sw 2
19R_A Sec Str Ignition Or-0.8-SXL 1F Cab-Frnt Chas J SPL_D25 SPL_D25 Splice
19R_B Sec Str Ignition Or-1.0-SXL 180F Sec Str Mod Opt 2 1 Cab-Frnt Chas J
19R_C Sec Str Ignition Or-1.0-SXL 90M Sec Str Mod 1 180M Sec Str Mod-Frnt Harn 2
19R_D Sec Strg Ignition Or-0.8-SXL SPL_D25 SPL_D25 Splice 262F Diode Module C
19R_E Cab Switched Pwr Or-0.8-SXL 216F Alternator Resistor 1 SPL_D25 SPL_D25 Splice
19R_F Sec Strg Ignition Or-0.8-SXL 262F Diode Module A 18F Fuse Block R2
19S Instr Cluster Fused Del Pwr Or-0.8-SXL 13F Cab-Pedestal 2 18F Fuse Block S2
19S_A Instr Cluster Fused Del Pwr Or-0.8-SXL 74 Up Down Count Switch 2 13M Pedestal-Cab 2
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19Z Frnt Flood Illum Fused Pwr Or-1.0-SXL 34F Light Switch C 18F Fuse Block Z2
1A_A Ign Prog Reset Sw Pwr R-0.8-SXL 13M Pedestal-Cab 62 69 Ignition Switch 1
1A_B Ign Prog Reset Sw Pwr R-0.8-SXL 75 Program Reset Switch 2 69 Ignition Switch 1
1A_C Ignition Switch Power R-0.8-SXL 13F Cab-Pedestal 62 SPL_D21 CB A Load 1
1A_D CB A Load R-0.8-SXL 214F Ign Sw Cir Brkr 1 SPL_D21 CB A Load 1
1A_E Time Delay Pwr R-0.8-SXL 63M Time Delay Module 2 SPL_D21 CB A Load 1
1B Hazard Switch Pwr R-0.8-SXL 13M Pedestal-Cab 65 71 Hazard Switch 2
1B_A Brake Lt Sw Pwr R-1.0-SXL 159 Brake Lt Pres Sw 1 21M Rear-Cab 28
1B_B Flasher Module Pwr R-0.8-SXL 62M Flasher Module 1 SPL_D19 CB B Load 1
1B_C Hazard Switch Power R-0.8-SXL 13F Cab-Pedestal 65 SPL_D19 CB B Load 1
1B_D CB B Load R-0.8-SXL 212F Flasher Cir Brkr 1 21F Cab-Rear 28
1B_E Brake Lt Relay Pwr R-0.8-SXL 204F Relay Brake Lights 30 SPL_D19 CB B Load 1
1B_F CB B Load R-0.8-SXL 212F Flasher Cir Brkr 1 SPL_D19 CB B Load 1
1_A B+ R-1.0-SXL 21M Rear-Cab 21 156 Fuel Str Rel B+ 1
1_B B+ R-13.0-SXL 156 Fuel Str Rel B+ 1 155 Cab Power B+ 1
1_C Starter Fuel Relay Pwr R-8.0-SXL 190 Jblock Relay 1 191 Jblock-Relay 1
1_D Starter Fuel Relay Pwr R-2.0-SXL 190 Jblock Relay 1 192 Jblock-Relay 1
1_E Power R-19.0-SGT 195 Jblock Pwr 1 196 Jblock Pwr 1
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1_Q Dome Lt Horn Pwr R-1.0-SXL 18F Fuse Block U1 SPL_D16 B+ Power 1
1_R Cigar Lighter Pwr R-3.0-SXL 18F Fuse Block W1 227F Power Cab 1
1_S Ign Relay #1 Pwr R-3.0-SXL 47F Ignition Relay #1 30 SPL_D17 B+ Power 1
1_T Ign Relay #2 Pwr R-3.0-SXL 48F Ignition Relay #2 30 SPL_D17 B+ Power 1
1_U B+ Power (4 Way) R-3.0-SXL 18F Fuse Block Z1 225F Power Cab 1
1_V Converter 24V Pwr R-5.0-SXL 250F Converter 24V Pwr 1 255F Converter 24V Pwr 1
1_W Sec Strg Mtr B+ R-1.0-SXL 263F Sec Str Mtr 1 90M Sec Str Mod 3
1_X Radio Memory Power R-1.0-SXL 270F Radio Memory Power 1 269 Radio Fuse Holder 1
21C_A Fuel Relay Signal W-1.0-SXL 172 Fuel Relay 1 SPL_G2 Splice G2 1
21C_B Starter Relay Signal W-1.0-SXL 135 Starter Relay 1 SPL_G2 Splice G2 1
21C_C Starter Fuel Relay Signal W-1.0-SXL 93M Relay Box A SPL_G2 Splice G2 1
21C_D Starter Fuel Relay Signal W-1.0-SXL 93F Rear-Fuel Str Rel A 21M Rear-Cab 11
21C_E Starter Fuel Relay Signal W-0.8-SXL 54F Neutral Start Relay 87 21F Cab-Rear 11
21C_F Starter Fuel Relay Signal W-0.8-SXL 54F Neutral Start Relay 87 140M Diode Module E
21K Ign Sw Start Signal W-0.8-SXL 13M Pedestal-Cab 64 69 Ignition Switch 2
21K_A Ign Sw Start Signal W-0.8-SXL 54F Neutral Start Relay 30 13F Cab-Pedestal 64
23C Engine Shutdown Signal W-0.8-SXL 76 Instrument Cluster 23 13M Pedestal-Cab 23
23C_A Engine Shutdown Signal W-0.8-SXL 57F Engine Shutdown Relay 85 13F Cab-Pedestal 23
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25Y_A Trans Kickdown Signal LU-0.8-SXL 13F Cab-Pedestal 50 SPL_D11 Trans Kick Down Signal 1
25Y_B Trans Kickdown Sig LU-0.8-SXL 19F TECM 22 SPL_D11 Trans Kick Down Signal 1
25Y_C Trans Kickdown Signal LU-0.8-SXL 20M Trans Kick-Down 2 SPL_D11 Trans Kick Down Signal 1
25Z 1st And 4th Gear Signal LU-0.8-SXL 13M Pedestal-Cab 49 183 Transmission Shifter C
25Z_A 1st And 4th Gear Signal LU-0.8-SXL 19F TECM 63 13F Cab-Pedestal 49
26E Trans Enable Signal LU-0.8-SXL 19F TECM 31 199F Trans Enable Sw 3
26F_A FNR Forward Signal LU-0.8-SXL 198 FNR Switch 6 197M FNR-Main Cab 2
26F_B FNR Forward Signal LU-0.8-SXL 19F TECM 20 197F Main Cab FNR 2
26J FNR Switch Jumper LU-0.8-SXL 198 FNR Switch 2 198 FNR Switch 4
26N_A FNR Neutral Signal LU-0.8-SXL 198 FNR Switch 3 197M FNR-Main Cab 3
26N_B FNR Neutral Signal LU-0.8-SXL 19F TECM 44 197F Main Cab FNR 3
26R_A FNR Reverse Signal LU-0.8-SXL 198 FNR Switch 1 197M FNR-Main Cab 4
26R_B FNR Reverse Signal LU-0.8-SXL 19F TECM 30 197F Main Cab FNR 4
28C Ether Start Control W-0.8-SXL 13M Pedestal-Cab 52 182 Ether Switch 1
28C_A Ether Start Control W-0.8-SXL 52F Ether Start Relay 86 13F Cab-Pedestal 52
28P Ether Sol W-1.0-SXL 103 Ether Sol Opt A 21M Rear-Cab 1
28P_A Ether Sol W-0.8-SXL 52F Ether Start Relay 87 21F Cab-Rear 1
28T Ether Start Temp Sw W-1.0-SXL 97 Ether Temp Sw A 65M Eng-Rear (Ether Start) 1
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31L Pilot Lockout Signal Y-0.8-SXL 76 Instrument Cluster 29 37 Pilot Control Switch 3
32F Trans Filter Maint Sw Y-1.0-SXL 22M Cab-Transmission 31 31 Filter Maint Sw 1
32F_A Trans Filter Maint Sw Y-0.8-SXL 19F TECM 17 22F Cab-Transmission 31
32J_A FNR Lt Signal Y-0.8-SXL 198 FNR Switch 7 197M FNR-Main Cab 5
32J_B Trans Enable Lt Sig Y-0.8-SXL 197F Main Cab FNR 5 199F Trans Enable Sw 9
32J_C Trans Enable Lt Sig Y-0.8-SXL 19F TECM 5 199F Trans Enable Sw 9
33P Low Brake Pres Warning Y-1.0-SXL 88 Brk Warn Pr Sw A 21M Rear-Cab 4
33P_A Low Brake Pres Warning Y-0.8-SXL 21F Cab-Rear 4 13F Cab-Pedestal 3
33P_B Low Brake Pres Warning Y-0.8-SXL 76 Instrument Cluster 3 13M Pedestal-Cab 3
33R_A Redundant Brake Sw Signal Y-1.0-SXL 157 Redundant Brake Sw A SPL_E10 SPL_E10 1
33R_B Redundant Brake Sw Signal Y-1.0-SXL 86 Redundant Brake Sw A SPL_E10 SPL_E10 1
35X_E Sec Str Low Pres Sig Y-0.8-SXL 13F Cab-Pedestal 5 1 Cab-Frnt Chas K
35X_F Sec Str Low Pres Sig Y-0.8-SXL 76 Instrument Cluster 5 13M Pedestal-Cab 5
36C Eng Cool Temp Signal P-1.0-SXL 94M Engine Trans 13 138 Eng Cool Temp A
36C_A Eng Cool Temp Signal P-1.0-SXL 22M Cab-Transmission 4 94F Eng-Trans 13
36C_B Eng Cool Temp Signal P-0.8-SXL 22F Cab-Transmission 4 13F Cab-Pedestal 18
36C_C Eng Cool Temp Signal P-0.8-SXL 76 Instrument Cluster 18 13M Pedestal-Cab 18
36F Fuel Level Signal P-1.0-SXL 141 Fuel Sender 1 21M Rear-Cab 16
36F_A Fuel Level Signal P-0.8-SXL 21F Cab-Rear 16 13F Cab-Pedestal 19
36F_B Fuel Level Signal P-0.8-SXL 76 Instrument Cluster 19 13M Pedestal-Cab 19
36G Torque Conv Outpt Temp Signal P-1.0-SXL 22M Cab-Transmission 13 142 Torque Conv Temp Sender 1
36G_A Torque Conv Outpt Temp Signal P-1.0-SXL 19F TECM 49 22F Cab-Transmission 13
36H Hot Signal P-1.0-SXL 136 Hyd Oil Temp Send A 21M Rear-Cab 13
36H_A Hot Signal P-0.8-SXL 13F Cab-Pedestal 20 21F Cab-Rear 13
36H_B Hot Signal P-0.8-SXL 76 Instrument Cluster 20 13M Pedestal-Cab 20
36P Engine Oil Pressure Signal P-1.0-SXL 94M Engine Trans 6 148 Engine Oil Pressure Switch 1
36P_A Engine Oil Pressure Signal P-1.0-SXL 22M Cab-Transmission 6 94F Engine Trans 6
36P_B Engine Oil Pressure Signal P-0.8-SXL 22F Cab-Transmission 6 13F Cab-Pedestal 22
36P_C Engine Oil Pressure Signal P-0.8-SXL 76 Instrument Cluster 22 13M Pedestal-Cab 22
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42C_C RH Frnt Work Lt Pwr DU-1.0-SXL 78F RH Front Work Lt A SPL_M1 Frnt Work Lt Pwr 1
42C_D Front Work Lts Pwr DU-1.0-SXL 24F Roof-Cab H SPL_M1 Frnt Work Lt Pwr 1
42R_A Work Light Telltale Sig Y-0.8-SXL 76 Instrument Cluster 12 13M Pedestal-Cab 12
42R_B Rear Work Light Pwr DU-0.8-SXL 23F Cab-Roof H 32F Light Switch A
42R_C Rear Work Light Pwr DU-0.8-SXL 13F Cab-Pedestal 12 32F Light Switch A
42R_D LH Rear Work Lt Pwr DU-1.0-SXL 83F LH Rear Work Lt A SPL_M4 Rear Work Lt Pwr 1
42R_E RH Rear Work Lt Pwr DU-1.0-SXL 80F RH Rear Work Lt A SPL_M4 Rear Work Lt Pwr 1
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45B_A Right Turn Switch Power N-0.8-SXL 62M Flasher Module 9 13F Cab-Pedestal 70
45H Hazard Switch Power N-0.8-SXL 13M Pedestal-Cab 67 71 Hazard Switch 3
45H_A Hazard Switch Power N-0.8-SXL 62M Flasher Module 11 13F Cab-Pedestal 67
45L Left Turn Signal N-1.0-SXL 1 Cab-Frnt Chas A 6 Lights LH 5
45L_A Left Turn Signal N-1.0-SXL 125 LH Rear Comb Lt 2 21M Rear-Cab 10
45L_B Left Turn Signal N-0.8-SXL 21F Cab-Rear 10 SPL_D10 Left Turn Signal 1
45L_C Left Turn Signal N-0.8-SXL 1F Cab-Frnt Chas A SPL_D10 Left Turn Signal 1
45L_D Left Turn Signal N-0.8-SXL 62M Flasher Module 8 SPL_D10 Left Turn Signal 1
45L_E Left Turn Signal N-0.8-SXL 13F Cab-Pedestal 16 SPL_D10 Left Turn Signal 1
45L_F Left Turn Signal N-0.8-SXL 76 Instrument Cluster 16 13M Pedestal-Cab 16
45N_A Flasher Opp Side Cntrl N-0.8-SXL 64F Flasher Connector 1 62M Flasher Module 2
45N_B Flasher Opp Side Cntrl N-0.8-SXL 64M Flasher Connector 1 62M Flasher Module 12
45R Right Turn Signal N-1.0-SXL 1 Cab-Frnt Chas C 8 Lights RH 5
45R_A Right Turn Signal N-1.0-SXL 127 RH Rear Comb Lt 2 21M Rear-Cab 12
45R_B Right Turn Signal N-0.8-SXL 21F Cab-Rear 12 SPL_D20 Rt Turn Signal 1
45R_C Right Turn Signal N-0.8-SXL 13F Cab-Pedestal 17 SPL_D20 Rt Turn Signal 1
45R_D Right Turn Signal N-0.8-SXL 1F Cab-Frnt Chas C SPL_D20 Rt Turn Signal 1
45R_E Right Turn Signal N-0.8-SXL 62M Flasher Module 7 SPL_D20 Rt Turn Signal 1
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49_H Pilot Light S-0.8-SXL 210F Fan Reverser Sw 8 40F Pin Engage Sw 10
49_J Pilot Light S-0.8-SXL 34F Light Switch B SPL_D8 Pilot Lights 1
49_K Pilot Light S-1.0-SXL 39F Return To Travel Sw 8 34F Light Switch B
49_L Pilot Light S-0.8-SXL 45F Rear Wiper Sw 8 118F Backup Alarm Dis Sw 8
49_M Pilot Light S-1.0-SXL 39F Return To Travel Sw 8 36F Detent Switch 8
49_N Pilot Light S-1.0-SXL 36F Detent Switch 8 38F Declutch Switch 8
49_P Pilot Light S-1.0-SXL 40F Pin Engage Sw 10 44F Ride Control Sw 8
49_Q Pilot Light S-1.0-SXL 44F Ride Control Sw 8 41F Trans Auto Sw 8
49_R Pilot Light S-1.0-SXL 199F Trans Enable Sw 8 42F Beacon Sw 8
49_S Courtesy Pilot Lt S-1.0-SXL 24M Cab-Roof F SPL_D8 Pilot Lights 1
49_T Pilot Light S-1.0-SXL 42F Beacon Sw 8 118F Backup Alarm Dis Sw 8
49_U Pilot Light S-0.8-SXL 210F Fan Reverser Sw 8 SPL_D8 Pilot Lights 1
49_V Courtesy Pilot Lt S-0.8-SXL 24F Roof-Cab F 77F Courtesy Lt A
50G_A Can Ground Bk-0.8-SXL 13M Pedestal-Cab 34 SPL_K2 SPL_K2 1
50G_B Can Ground Bk-0_5-SXL SPL_K3 SPL_K3 1 SPL_K2 SPL_K2 1
50G_C Can Ground R-0_5-SXL SPL_K2 SPL_K2 1 SPL_K3 SPL_K3 1
50G_D Can Ground Bk-0.8-SXL 13F Cab-Pedestal 34 SPL_D6 Can Ground 1
50G_E Can Ground Bk-0_5-SXL SPL_D7 Can Ground 1 SPL_D6 Can Ground 1
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58_B Ride Cntrl Sol Pwr W-0.8-SXL 50F Ride Control Relay 87 44F Ride Control Sw 6
58_C Ride Cntrl Sol Pwr W-1.0-SXL SPL_A7 Ride Cntrl Sol Pwr SPL_A7 5F Ride Control Opt 1
58_D Ride Cntrl Sol Pwr W-1.0-SXL 202F Diode Module A SPL_A7 Ride Cntrl Sol Pwr SPL_A7
58_E Ride Cntrl Sol Pwr W-1.0-SXL 229M Diode Module A SPL_A7 Ride Cntrl Sol Pwr SPL_A7
58_F Float Switch Signal W-1.0-SXL 271M Frt Chs Rollbck Jmpr A 272F Rollbck Jmpr Press Sw B
61A AC High Pres Sw Or-1.0-SXL 94M Engine Trans 2 98 AC High Pres Sw A
61A_A AC High Pres Sw Or-1.0-SXL 22M Cab-Transmission 26 94F Eng-Trans 2
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63C_A Front Wiper Park Or-0.8-SXL 35F Wiper and Washer Sw 4 13F Cab-Pedestal 59
63H Front Wiper High Speed Or-0.8-SXL 13M Pedestal-Cab 57 61 Front-Wiper Motor A
63H_A Front Wiper High Speed Or-0.8-SXL 35F Wiper and Washer Sw 5 13F Cab-Pedestal 57
63H_B Front Wiper High Speed Or-0.8-SXL 35F Wiper and Washer Sw 5 140M Diode Module B
63L Front Wiper Low Speed Or-0.8-SXL 13M Pedestal-Cab 58 61 Front-Wiper Motor B
63L_A Front Wiper Low Speed Or-0.8-SXL 35F Wiper and Washer Sw 6 13F Cab-Pedestal 58
63L_B Front Wiper Low Speed Or-0.8-SXL 35F Wiper and Washer Sw 6 140M Diode Module A
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1 Alternator 1
Check Points Reading Possible Cause of Bad Reading
2
Check the 10 ampere fuse at 3 4
Good Bad fuse.
location 3 and 4C in the fuse block.
Check wire 1A between the starter terminal (21) and the
Terminal for wire 1A to ground 12 volts
alternator (1).
NOTE: If the readings are good, see Section 4004 and check the starter.
5
6
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.
11
13
7
6
4
10
12
1 14
8 3 5
1
9
BC00N140
1. BATTERIES 6. STARTER RELAY 11. ETHER START SWITCH
2. MASTER DISCONNECT SWITCH 7. FUEL RELAY 12. NEUTRAL START RELAY NO. 8
3. FUEL SHUTOFF SOLENOID 8. ETHER START TEMPERATURE SWITCH 13. IGNITION SWITCH
4. ALTERNATOR 9. ETHER START SOLENOID 14. IGNITION RELAY NO. 1
5. STARTER MOTOR 10. ETHER START RELAY NO. 6
NOTE: The battery must be at full charge and all connections clean and tight before doing any testing of the
electrical system. Use a Multimeter for the following tests.
1 Batteries
NOTE: See Section 4003 and check the batteries.
NOTE: Disconnect cables from both terminals of master disconnect switch (main contact). Put master disconnect
switch in ON position.
NOTE: Use the same method to check the master disconnect switch (auxiliary contact).
NOTE: Put the master disconnect switch in the ON position and the ignition switch in the ON position.
24 volts Check wire 13M and circuits 13C and 13K, also check circuit to
Terminal for wire 13M to ground
batteries. Bad master disconnect switch (2) or ignition switch.
NOTE: Have another person hold the ignition switch in the START position.
24 volts Check circuit 23F. Bad fuel relay (7), neutral start relay (12), or
Terminal for wire 23F to ground
no neutral signal from transmission.
NOTE: If the readings are good, replace the fuel shutoff solenoid (3).
4 Alternator
Check Points Reading Possible Cause of Bad Reading
Between the positive terminal of 24 volts Check circuit to positive post of left battery.
alternator and ground
Check circuit 14, 75 ohm resistor, and diode module. Bad fuse
Terminal for wire 14 to ground 20 volts
R. Check ignition relay No. 1, and 10 ampere circuit breaker A.
NOTE: If the readings are good, see Section 4007 to repair the alternator (4).
5 Starter Motor
Check Points Reading Possible Cause of Bad Reading
NOTE: Put the transmission in NEUTRAL. Have another person hold the ignition switch in the START position.
Bad starter relay (6). Also check wire 1_F between starter (5)
Terminal S to ground 24 volts
and starter relay (6).
NOTE: If the readings are good, see Section 4004 and repair the starter (5).
6 Starter Relay
Check Points Reading Possible Cause of Bad Reading
NOTE: Put the transmission in NEUTRAL. Have another person hold the ignition switch in the START position.
Terminal for wire 21C_B to ground 24 volts Check neutral start relay (12), also check circuit 21C.
Terminal for wire 1_F to ground 24 volts Bad starter relay (6).
7 Fuel Relay
Check Points Reading Possible Cause of Bad Reading
Terminal for wire 1_D to ground 24 volts Check wires 1_D and 1_E, also check circuit to batteries.
NOTE: Put the transmission in NEUTRAL. Have another person hold the ignition switch in the START position.
Terminal for wire 21C_A to ground 24 volts Check neutral start relay (12), also check circuit 21C.
Terminal for wire 23F_A to ground 24 volts Bad fuel relay (7).
NOTE: Disconnect the wires from the ether start temperature switch (8). Make sure the engine temperature is
below -3 C (27 F).
Between terminals A and B Continuity Bad ether start temperature switch (8).
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Have another person push in
and hold the ether start switch (11). Make sure the engine temperature is below -3 C (27 F).
Terminal for wire 28P to ground 24 volts Check the ether start relay (10). Also check circuit 28P.
NOTE: If the readings are good, replace the ether start solenoid (9).
NOTE: Put the master disconnect switch in the ON position and the ignition switch in ON position.
NOTE: Have an assistant depress and hold ether start switch (11). Make sure engine temperature is below -3 C
(27 F) and transmission is in neutral.
Terminal for wire 28C_A to ground 24 volts Bad ether start switch (11), also check circuit 28C.
Terminal for wire 28P_A to ground 24 volts Bad ether start relay (10).
NOTE: Disconnect the wires from the ether start switch (11).
Between terminals of switch Open Circuit Bad ether start switch (11).
NOTE: Have an assistant depress and hold ether start switch (11).
NOTE: Put the master disconnect switch and the ignition switch in the ON position and transmission in neutral.
NOTE: Put master disconnect switch and ignition switch in ON position. Make sure transmission is in NEUTRAL.
NOTE: Have another person hold the ignition switch in the START position.
Terminal for wire 21K_A to ground 24 volts Check circuit 21K_A and ignition switch.
Terminal for wire 21C_E to ground 24 volts Bad neutral start relay (12).
13 Ignition Switch
Check Points Reading Possible Cause of Bad Reading
Terminal for wire 1A to ground 24 volts Check circuit 1A to 10 ampere circuit breaker A.
NOTE: Disconnect the connector from the ignition switch (13). Turn the switch to ON.
NOTE: Put the master disconnect switch in the ON position. Turn the ignition switch to the ON position.
Terminal for wire 13K_A to ground 24 volts Check circuit 13K and ignition switch.
Terminal for wire 13P to ground 24 volts Bad ignition relay No. 1 (14)
18 15
16
17
BC00N140
15. IGNITION RELAY NO. 2 17. VOLTMETER RELAY NO. 12
16. ACCESSORY RELAY NO. 3 18. TIME DELAY MODULE
NOTE: Put the master disconnect switch in the ON position. Turn the ignition switch to the ON position.
Terminal for wire 13K to ground 24 volts Check circuit 13K and ignition switch.
Terminal for wire 13R to ground 24 volts Bad ignition relay No. 2 (15).
NOTE: Put the master disconnect switch in the ON position. Turn ignition switch to the Acc or the ON position.
Terminal for wire 12K to ground 24 volts Check circuit 12K and ignition switch.
Terminal for wire 12P_A to ground 24 volts Bad accessory relay (16).
Terminal for wire 1_P to ground 24 volts Check circuit 1 to starter motor B+ stud.
Terminal for wire 13K to ground 24 volts Check circuit 13K and ignition switch.
Terminal for wire 13V to ground 24 volts Bad voltmeter relay (17).
NOTE: Put the ignition switch in the ON position. Have another person press and hold the program/reset switch
(45) in RESET position.
Terminal for wire 37R_C to ground 24 volts Bad program/reset switch (45), also check circuit 37R.
Terminal for wire 13K_F to ground 24 volts Bad ignition switch (13), also check circuit 13K.
NOTE: Put the ignition switch in the ON position. Turn ignition switch to the OFF position. After 10 seconds time
delay an audible click will be heard.
27
32
25
24
37
29
23 26 30
33
28 31
20 34
35 36
21
22
19
BC00N140
19. OUTPUT SPEED SENSOR 29. TRANSMISSION KICK-DOWN SWITCH
20. ENGINE SPEED SENSOR 30. TRANSMISSION AUTO SWITCH
21. INTERMEDIATE SPEED SENSOR 31. DECLUTCH SWITCH
22. TURBINE SPEED SENSOR 32. BRAKE DECLUTCH PRESSURE SWITCH
23. FILTER MAINTENANCE SWITCH 33. TRANSMISSION ENABLE SWITCH
24. TORQUE CONVERTER OUTPUT TEMPERATURE SENDER 34. FNR SWITCH
25. TRANSMISSION SOLENOID VALVE AND TEMPERATURE SENSORS 35. BACK-UP ALARM RELAY NO. 7
26. TRANSMISSION ELECTRONIC CONTROL MODULE 36. BACK-UP ALARM DISABLE SWITCH
27. TRANSMISSION SHIFTER 37. BACK-UP ALARM
28. DIAGNOSTIC CONNECTOR
NOTE: If you have transmission shifting problems, see Section 6002 for complete troubleshooting information for
Items 19 through 34.
NOTE: Disconnect the transmission electronic control module (26) quick disconnect connector.
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
24 volts Bad fuse A, also check wires 19A_P, 13P_A, and ignition relay
Terminal for wire 19A_P to ground
No. 1 (14).
24 volts Bad fuse H, also check wires 19H and 13R and ignition relay
Terminal for wire 19H to ground
No. 2 (15).
NOTE: Put parking brake switch in OFF position. Depress brake pedal once and put gear selector in REVERSE.
Terminal for wire 35A_D to ground 24 volts Bad back-up alarm relay (35).
NOTE: Put the master disconnect switch and the ignition switch in the ON position and the park brake to the OFF
position. Depress brake pedal once. Move the transmission shift lever to REVERSE.
Terminal for wire 35A_E to ground 24 volts Bad back-up alarm relay (35), also check circuit 35A_E.
NOTE: Wires 35A_F and 35R_D are connected together and switch is removed in North American models. The
wires are disconnected and the switch is installed in TUV road approved (Germany) models.
37 Back-up Alarm
Check Points Reading Possible Cause of Bad Reading
NOTE: Put the master disconnect switch and the ignition switch in the ON position and the park brake to the OFF
position. Depress brake pedal once. Move the transmission shift lever to REVERSE. If machine is a TUV model,
depress back-up alarm switch to turn LED ON (back-up alarm enabled).
NOTE: If the readings are good, replace the back-up alarm (37).
44 39
43
45
38 46
42 47
48
41
49
40
BC00N140
38. BRAKE WARNING PRESSURE SWITCH 44. AIR FILTER RESTRICTION SWITCH
39. COOLANT LEVEL SENDER 45. PROGRAM/RESET SWITCH
40. FUEL LEVEL SENDER 46. PARKING BRAKE SWITCH
41. HYDRAULIC OIL TEMPERATURE SENDER 47. INSTRUMENT CLUSTER
42. HYDRAULIC FILTER RESTRICTION SWITCH 48. PILOT CONTROL SWITCH
43. ENGINE COOLANT TEMPERATURE SENDER 49. UP/DOWN COUNT SWITCH
NOTE: Brake warning pressure switch opens at 117.2 bar (1700 psi).
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Approximately
Terminal A for wire 33P to ground Check circuit 33P.
11.5 volts
NOTE: Disconnect the wires from the brake warning pressure switch (38).
Between terminals A and B of the Continuity Bad brake warning pressure switch (38).
switch
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Approximately
Terminal A for wire 31D to ground Check circuit 31D, also check the instrument cluster (47).
1.6 volts AC
NOTE: If the readings are correct replace the coolant level sender (39).
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Approximately
Terminal A for wire 36F to ground Check the instrument cluster (47).
5 volts
NOTE: Put the ignition switch and the master disconnect switch in the OFF position. Tag and disconnect the
wires from the fuel level sender.
NOTE: Disconnect the connector from the hydraulic oil temperature sender.
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Approximately
Terminal A for wire 36H to ground Check the instrument cluster (47).
5 volts
NOTE: Hydraulic filter restriction switch closes at 2.8 bar (40 psi).
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Approximately
Terminal A for wire 31H to ground. 11.5 volts Check the instrument cluster (47).
NOTE: If the readings are correct replace the hydraulic filter restriction switch (42).
NOTE: Disconnect the connector from the engine coolant temperature sender.
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Approximately
Terminal A for wire 36C to ground Check the instrument cluster (47).
5 volts
NOTE: Air filter restriction switch closes at -6.4 kPa (Gauge) (-0.928 psig).
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Approximately
Terminal A for wire 31F to ground Check the instrument cluster (47).
11.5 volts
NOTE: If the readings are correct replace the air filter restriction indicator switch (44).
45 Program/Reset Switch
Check Points Reading Possible Cause of Bad Reading
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Terminal for wire 1A_B to ground 24 volts Check 10 ampere circuit breaker A. Also check circuit 1A.
NOTE: Press and hold the program/reset switch in the reset position.
NOTE: Put the five position rotary lamp switch (114) in position 3, 4, or 5.
Bad rotary lamp switch. Also check fuse Z and circuit 49 and
Terminal for wire 49_E to ground 24 volts
19Z.
NOTE: If 24 volts between wire 49 and ground and program/reset switch is not illuminated, replace program/reset
switch.
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Terminal for wire 19A to ground 24 volts Check fuse A, also check circuit 19A.
Terminal for wire 33U to ground 24 volts Bad parking brake switch (46).
NOTE: Put the five position rotary lamp switch (114) in position 3, 4, or 5.
24 volts Bad rotary lamp switch. Also check fuse Z and circuits 49 and
Terminal for wire 49 to ground
19Z.
NOTE: If 24 volts between wire 49 and ground and parking brake switch is not illuminated, replace parking brake
switch.
47 Instrument Cluster
Check Points Reading Possible Cause of Bad Reading
Bad brake warning pressure switch (38). Also check circuit 33P
Connector terminal 3 to ground Continuity
and ground circuit at brake warning pressure switch.
Continuity Bad coolant level sender (39). Also check circuit 31D and
Connector terminal 4 to ground
ground circuit at coolant level sender.
Connector terminal 6 to ground Open Circuit Bad air filter restriction switch (44). Also check circuit 31F.
Connector terminal 7 to ground Open Circuit Bad hydraulic filter restriction switch. Also check circuit 31H.
Continuity Bad ground circuit. Check wires 0_KP, 0_DAV, 0_HC, and
Connector terminal 8 to ground
0_BG.
130 to 9500 Bad engine coolant temperature sender (43). Also check circuit
Connector terminal 18 to ground ohms circuit 36C and ground circuit at sender.
Bad fuel level sender (40). Also check circuit 36F and ground
Connector terminal 19 to ground 33 to 240 ohms
circuit at sender.
130 to 9500 Bad hydraulic oil temperature sender (41). Also check circuit
Connector terminal 20 to ground
ohms 36H and ground circuit at sender.
237 to 243 Bad engine oil pressure switch (50). Also check circuit 36P and
Connector terminal 22 to ground
ohms ground circuit.
Connector terminal 28 to ground Open Circuit Bad redundant brake switche(s) (57). Also check circuit 33R.
Check LH and RH stop lamps and circuit 44. Also check ground
Connector terminal 35 to ground Continuity
circuit at lamps.
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Connector terminal 1 to ground 24 volts Bad fuse V. Also check circuit 19V.
Connector terminal 2 to ground 24 volts Bad fuse S. Also check circuit 19S.
Connector terminal 9 to ground 24 volts Bad parking brake switch. Also check fuse A and circuit 19A.
NOTE: Put the five position rotary lamp switch in position four or five.
Connector terminal 13 to ground 24 volts Check rotating beacon switch and fuse X. Also check circuit 46.
NOTE: Put the five position rotary lamp switch in position four or five. Put the high/low beam switch in HIGH
BEAM position.
NOTE: Put the turn signal switch in the LEFT TURN position.
24 volts on and Check fuse B, turn signal switch, and flasher module. Also
Connector terminal 16 to ground off every 1-2 check wire 19B, circuit 45A to flasher module, and circuit 45L
seconds from flasher module to instrument cluster.
NOTE: Put the turn signal switch in the RIGHT TURN position.
24 volts on and Check fuse B, turn signal switch, and flasher module. Also
Connector terminal 17 to ground off every 1-2 check wire 19B, circuit 45B to flasher module, and circuit 45R
seconds from flasher module to instrument cluster.
24 volts Bad program/reset switch. Also check wire 37P and wire 1A_B
Connector terminal 24 to ground
to ignition switch.
NOTE: Press and hold the program/reset switch in the RESET position.
Bad pilot control switch or fuse C. Also check wire 31L and
Connector terminal 29 to ground 24 volts
circuit 19C.
Bad parking brake relay or fuse D. Also check circuits 52C and
Connector terminal 30 to ground 24 volts
19D.
Bad pilot control relay or fuse C. Also check circuits 53C and
Connector terminal 36 to ground 24 volts
19C.
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Terminal for wire 19C to ground 24 volts Bad fuse C, also check circuit 19C.
Terminal for wire 31L to ground 24 volts Bad pilot control switch (48).
NOTE: Put the five position rotary lamp switch (114) in position 3 or higher.
24 volts Check five position rotary lamp switch (114) and fuse Z. Also
Terminal for wire 49 to ground
check circuit 49.
NOTE: If the readings are correct replace the pilot control switch (48).
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Check fuse S and time delay module. Also check circuits 19S
Terminal for wire 19S to ground 24 volts
and 13D from time delay module to fuse S.
NOTE: Press and hold the up/down switch in the DOWN COUNT position.
Terminal for wire 37D to ground 24 volts Bad up/down count switch.
NOTE: Press and hold the up/down switch in the UP COUNT position.
Terminal for wire 37U to ground 24 volts Bad up/down count switch.
NOTE: Put the five position rotary lamp switch (114) in position 3 or higher.
Check five position rotary lamp switch (114) and fuse Z. Also
Terminal for wire 49 to ground 24 volts
check circuit 49.
53
57
56
55
54
51
52
58
50
BC00N140
50. ENGINE OIL PRESSURE SWITCH 55. FAN REVERSER SWITCH (OPTION)
51. PILOT CONTROL RELAY NO. 10 56. FAN REVERSING SOLENOID (OPTION)
52. PARKING BRAKE RELAY NO. 9 57. REDUNDANT BRAKE SWITCHES
53. PARKING BRAKE SOLENOID 58. RELAY SOCKET NO. 11
54. PILOT PRESSURE SOLENOID
Between engine oil pressure switch 90 to 92 ohms Bad ground connection or bad ground wire assembly.
(50) terminal NO and ground
NOTE: Disconnect wire 36P from terminal C of engine oil pressure switch. Put master disconnect switch and
ignition switch in ON position.
Approximately
Terminal for wire 36P to ground Bad instrument cluster (47) or bad circuit 36P.
5 volts
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure pilot control switch
(48) is OFF.
Terminal for wire 19C to ground 24 volts Bad fuse C, also check circuit 19C.
Terminal for wire 53C to ground 0 volt Bad instrument cluster (47). Also check circuit 53C.
Terminal for wire 53P to ground 24 volts Bad pilot control relay.
Terminal for wire 53C to ground 24 volts Bad instrument cluster (47). Also check circuit 53C.
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the parking brake
switch (46) is OFF.
Terminal for wire 19D_B to ground 24 volts Bad fuse D, also check circuit 19D.
Terminal for wire 52C to ground 0 volt Bad instrument cluster (47). Also check circuit 52C.
Terminal for wire 52P to ground 24 volts Bad parking brake relay.
Terminal for wire 52C to ground 24 volts Bad instrument cluster (47). Also check wire 52C.
NOTE: Put the master disconnect switch and ignition switch in ON position. Put parking brake switch in OFF
position.
Terminal 1 for wire 52P to ground 24 volts Bad parking brake relay (52). Also check circuit 52P
NOTE: If the readings are good, replace the parking brake solenoid (53).
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the pilot control
switch (48) is OFF.
Terminal A for wire 53P to ground 24 volts Bad pilot control relay (51), also check circuit 53P.
NOTE: If the readings are good, replace the pilot pressure solenoid (54).
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
NOTE: Put fan reversing switch in ON position (hold rocker in momentary position).
Terminal for wire 52_A to ground 24 volts Bad fan reversing switch.
NOTE: Disconnect wiring harness connector 158 from fan reversing solenoid.
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put fan reversing switch in
ON position (hold rocker in momentary position).
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Approximately
Terminal A for wire 33R to ground 11.5 volts Bad instrument cluster (47), also check circuit 33R.
NOTE: If the readings are good, replace the redundant brake pressure switch(es) (57).
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Terminal for wire 19F to ground 24 volts Bad fuse F. Also check circuit 19F to ignition relay No. 2 (15).
Terminal for wire 13K_B to ground 24 volts Check wire 13K_B to ignition relay No. 2 (15).
63
62
65
64
60
59
61
BC00N140
59. DETENT SWITCH 63. HEIGHT CONTROL/RETURN TO TRAVEL PROXIMITY
SWITCH
60. BUCKET CONTROL VALVES ELECTROMAGNETIC DETENTS 64. FLOAT PRESSURE SWITCH
61. RETURN TO TRAVEL/FLOAT SWITCH 65. FLOAT SOLENOID
62. RETURN TO DIG PROXIMITY SWITCH
59 Detent Switch
Check Points Reading Possible Cause of Bad Reading
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the pilot control switch (48) in
the OFF position.
Terminal for wire 53P_B to ground 24 volts Bad pilot control relay (51), also check circuit 53P_B.
Terminal for wire 56_H to ground 24 volts Bad detent switch (59).
NOTE: Put the five position rotary lamp switch (114) in position 3 or higher.
Bad circuit 49_M. Also check five position rotary lamp switch
Terminal for wire 49_M to ground 24 volts (114). If detent switch illumination LED does not turn ON with
24 volts at check point, replace detent switch (59).
NOTE: Disconnect the wiring harness connector from the control valve electromagnetic detents connector.
NOTE: Put the master disconnect switch and ignition switch in ON position. Put pilot control switch (48) in OFF
position and detent switch (59) in ON position.
Wiring harness connector 17M, pin 4 Bad detent switch (59). Also check wires 53P_B, 56_G, and
24 volts
to ground 56_H.
Wiring harness connector 17M, pin 6 24 volts Bad detent switch (59). Also check wires 56_E and 56_H.
to ground
Wiring harness connector 17M, pin 5 24 volts Bad detent switch (59). Also check wires 56_F and 56_H.
to ground
61 Return-To-Travel/Float Switch
Check Points Reading Possible Cause of Bad Reading
NOTE: Disconnect the wiring harness connector from the return-to-travel/float switch (61). Put the return-to-
travel/float switch (61) in FLOAT position.
NOTE: Put the master disconnect switch and ignition switch in ON position. Put pilot control switch (48) in OFF
position and detent switch (59) in ON position.
NOTE: Put ignition switch in OFF position. Connect wiring harness connector to return-to-travel/float switch (61).
Put ignition switch in ON position. Put five position rotary lamp switch (114) in position 3 or higher.
Bad circuit 49_K. Also check five position rotary lamp switch
(114). If return-to-travel/float switch illumination LED is not ON
Terminal for wire 49_K to ground 24 volts
with 24 volts at check point, replace return-to-travel/float
switch.
NOTE: Disconnect the connector from the return-to-dig proximity switch (62). Put the master disconnect switch
and the ignition switch in the ON position. Put the pilot control switch (48) in the OFF position and the detent
switch (59) in the ON position.
Terminal C for wire 56_D to ground 24 volts Bad detent switch (59), also check circuit 56.
NOTE: If the readings are good, replace the return-to-dig proximity switch (62).
NOTE: Disconnect the connector from the height control/return-to-travel proximity switch (63). Put the master
disconnect switch and the ignition switch in the ON position. Put the pilot control switch (48) in the OFF position
and the detent switch (59) in the ON position.
Terminal C for wire 56_A to ground 24 volts Bad detent switch (59). Also check circuit 56.
NOTE: If the readings are good, replace the height control/return-to-travel proximity switch (63).
NOTE: Disconnect the wiring harness connector 178M from the float pressure switch.
NOTE: Start and run engine at idle speed. Put return-to-travel/float switch in FLOAT position. Put loader control
lever in FLOAT position.
NOTE: Shut down engine. Put ignition switch in ON position. Put pilot control switch in OFF position (switch LED
OFF).
65 Float Solenoid
Check Points Reading Possible Cause of Bad Reading
NOTE: Disconnect the wiring harness connector 179F from the float solenoid.
NOTE: Start and run engine at idle speed. Put return-to-travel/float switch in FLOAT position. Put loader control
lever in FLOAT position.
Wiring harness connector 179F pin 1 24 volts Bad float pressure switch. Also check wires 53S_A and 53S_B.
to ground
71
69 70
67
66
68A 73
72
68
BC00N140
66. SECONDARY STEERING MODULE (OPTION) 70. PIN ENGAGE SOLENOID (OPTION)
67. SECONDARY STEERING PRESSURE SWITCH (OPTION) 71. RIDE CONTROL SWITCH
68. SECONDARY STEERING MOTOR (OPTION) 72. RIDE CONTROL RELAY NO. 4
68A.SECONDARY STEERING SOLENOID (OPTION) 73. RIDE CONTROL SOLENOID
69. PIN ENGAGE SWITCH (OPTION)
NOTE: Disconnect the wiring harness connector 90M from the secondary steering module.
NOTE: Put the master disconnect switch and the ignition switch in ON position.
Pin 3 of connector 90M to ground 24 volts Bad wire 1_W to secondary steering motor (68) B+ stud.
Pin 7 of connector 90M to ground 24 volts Bad fuse M or ignition switch. Also check circuits 19M and 12K.
Pin 9 of connector 90M to ground Continuity Bad secondary steering pressure switch.
NOTE: Put ignition switch in OFF position to stop engine. Connect wiring harness connector 90M to secondary
steering module. Disconnect wire 51_B from secondary steering motor (68) relay terminal. Start and run engine
at idle speed. Disconnect wiring harness connector 131F from secondary steering pressure switch (67). Apply a
ground to pin C of connector 131F.
Terminal for wire 51_B to ground 24 volts Bad secondary steering module.
NOTE: Disconnect wiring harness connector 131F from secondary steering pressure switch (67).
Pressure switch (67) pin B to pin C Continuity Bad secondary steering pressure switch.
Pressure switch (67) pin B to pin A Open Circuit Bad secondary steering pressure switch.
Pressure switch (67) pin A to pin C Open Circuit Bad secondary steering pressure switch.
Pressure switch (67) pin B to pin A Continuity Bad secondary steering pressure switch.
Pressure switch (67) pin B to pin C Open Circuit Bad secondary steering pressure switch.
NOTE: Start and run engine for two or three minutes while turning steering wheel left and right several times. DO
NOT TURN STEERING WHEEL TO STEERING STOPS. Turn ignition switch to OFF position to stop engine, then
immediately to ON position. Secondary steering motor should be heard operating. If motor is heard, problem is
associated pump; refer to Section 5002. If motor is not heard, leave ignition switch in ON position and disconnect
wire 51_B from secondary steering motor relay.
NOTE: Disconnect wire 51_B from secondary steering motor relay; make sure that wire does not touch any metal
part of machine during the remainder of this check. Put the master disconnect switch in ON position. Start and
run engine for two or three minutes while turning steering wheel left and right several times. DO NOT TURN
STEERING WHEEL TO STEERING STOPS. Turn ignition switch to OFF position to stop engine, then immediately
to ON position.
Between pin A of connector 264M Check secondary steering module (66) and secondary steering
24 volts
and ground pressure switch (67).
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put pin engage switch in OFF
position.
24 volts Bad fuse P or ignition relay No. 2. Also check circuits 19P_A
Terminal for wire 19P_A to ground
and 13P_B.
Terminal for wire 57_A to ground 0 volt Bad pin engage switch.
Terminal for wire 57_A to ground 24 volts Bad pin engage switch.
NOTE: Put the five position rotary lamp switch (114) in position 3 or higher.
Check the five position rotary lamp switch (114). Also check
Terminal for wire 49_P to ground 24 volts circuit 49. If LED in pin engage switch is not ON with 24 volts
at check point, replace pin engage switch.
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the pin engage switch
(69) in the ON position.
Terminal for wire 57 to ground 24 volts Bad pin engage switch (69), also check circuit 57.
NOTE: If the readings are good, replace the pin engage solenoid (70).
NOTE: Connect connector 44F to ride control switch (71). Put master disconnect switch and ignition switch in ON
position. Put ride control switch in OFF position.
Check fuse C and ignition relay No. 1. Also check circuits 19C
Terminal for wire 19C_B to ground 24 volts
and 13P_A.
Terminal for wire 58S to ground 0 volt Bad ride control switch.
Terminal for wire 58S to ground 24 volts Bad ride control switch.
NOTE: Put the five position rotary light switch (114) in position 3 or higher.
Check five position rotary lamp switch (114). Also check circuit
Terminal for wire 49_P to ground 24 volts 49. If LED in ride control switch is not ON with 24 volts at check
point, replace ride control switch.
NOTE: Put master disconnect switch and ignition switch in ON position. Put ride control switch in ON position.
Terminal for wire 58S to ground 24 volts Bad ride control switch. Also check wire 58S.
TROUBLESHOOTING WIPER/WASHER
74
79
75
77
78 76
BC00N140
74. FRONT WIPER MOTOR 77. REAR WIPER AND WASHER SWITCH
75. FRONT WIPER AND WASHER SWITCH 78. REAR WASHER PUMP MOTOR
76. FRONT WASHER PUMP MOTOR 79. REAR WIPER MOTOR
NOTE: Make sure the front wiper and washer switch (75) is in the OFF position.
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Terminal for wire 19J to ground 24 volts Check fuse J, also check circuit 19J.
NOTE: Put the front wiper and washer switch (75) in the LOW position.
Check fuse J, also check circuit 19J. Bad front wiper and
Terminal for wire 63L to ground 24 volts
washer switch (75).
Terminal for wire 63C to ground 0 volt Bad front wiper and washer switch (75)
NOTE: Put the front wiper and washer switch (75) in the HIGH position.
Check fuse J, also check circuit 19J. Bad front wiper and
Terminal for wire 63H to ground 24 volts
washer switch (75).
Terminal for wire 63C to ground 0 volt Bad front wiper and washer switch (75).
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 (75).
Terminal for wire 63C to ground 24 volts pulse Bad front wiper and washer switch (75).
NOTE: If the readings are good, replace the front wiper motor (74).
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the front wiper and
washer switch (75) is in the OFF position.
Terminal for wire 19J_A to ground 24 volts Check fuse J, also check circuit 19J.
NOTE: Put the front wiper and washer switch (75) in the LOW position.
Check fuse J, also check circuit 19J. Bad front wiper and
Terminal for wire 63L to ground 24 volts
washer switch (75).
Terminal for wire 63C to ground 0 volt Bad front rotary wiper and washer switch (75)
NOTE: Put the front wiper and washer switch (75) in the HIGH position.
Check fuse J, also check circuit 19J. Bad front rotary wiper and
Terminal for wire 63H to ground 24 volts
washer switch (75).
Terminal for wire 63C to ground 0 volt Bad front rotary wiper and washer switch (75).
NOTE: Put the front wiper and washer switch in the intermittent position.
Terminal for wire 63L_A to ground 24 volts pulse Bad front wiper and washer switch (75).
Terminal for wire 63C_A to ground 24 volts pulse Bad front wiper and washer switch (75).
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Connect volt meter to check
point then push down on front wiper and washer switch (75).
24 volts Bad front wiper and washer switch (75), also check wires 63W
Terminal for wire 63W to ground
and 63W_A.
NOTE: If the readings are good, replace the front washer pump motor (76).
Terminal for wire 19K_D to ground 24 volts Bad fuse K or ignition relay No. 2 (15). Also check circuit 19K.
Terminal for wire 19K_C to ground 24 volts Bad fuse K or ignition relay No. 2 (15). Also check circuit 19K.
NOTE: Put the rear wiper and washer switch in the ON position.
Terminal for wire 68L_A to ground 24 volts Bad rear wiper and washer switch (77).
NOTE: Press and hold the rear wiper and washer switch (77) in the WASH position.
Terminal for wire 68W_A to ground 24 volts Bad rear wiper and washer switch (77).
NOTE: Put the five position rotary lamp switch in position 3 or higher.
Check rotary lamp switch and circuit 49. If LEDs in rear wiper
Terminal for wire 49_L to ground 24 volts and washer switch are not ON with 24 volts at check point,
replace rear wiper and washer switch.
NOTE: Put master disconnect switch and ignition switch in ON position. Depress and hold rear wiper and washer
switch (77) in WASH position.
Bad rear wiper and washer switch (77) Also check wires
Terminal for wire 68W to ground 24 volts
68W_A and 68W.
NOTE: If the readings are good, replace the rear washer pump motor (78).
NOTE: Make sure the rear wiper and washer switch (77) is in the OFF position.
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Terminal for wire 19K to ground 24 volts Check fuse K, also check circuit 19K.
NOTE: Put the rear wiper and washer switch (77) in the ON position.
Terminal for wire 68L_C to ground 24 volts Bad rear wiper and washer switch (77).
Terminal for wire 68C_B to ground 0 volt Bad rear wiper and washer switch (77).
NOTE: If the readings are good, replace the rear wiper motor (79).
86
81
87
90
80 83
89 88
82
84
85
BC00N140
80. HORN RELAY NO. 5 86. A/C LOW PRESSURE SWITCH (IN CAB)
81. HORN 87. A/C HIGH PRESSURE SWITCH (IN REAR CHASSIS)
82. SEAT COMPRESSOR 88. THERMOSTAT SWITCH
83. BLOWER SWITCH 89. COMPRESSOR CLUTCH LOCKOUT RELAY NO. 14
84. SPEED RESISTOR 90. COMPRESSOR CLUTCH
85. BLOWER MOTOR
Terminal for wire 19U_B to ground 24 volts Check fuse U, also check wire 19U_B.
Terminal for wire 64C_A to ground 24 volts Bad horn relay (80).
NOTE: Have another person push and hold the horn switch.
Terminal for wire 64_A to ground 24 volts Bad horn relay (80).
81 Horn
Check Points Reading Possible Cause of Bad Reading
NOTE: Disconnect the wire 64 from the horn (81). Have an assistant push and hold the horn switch.
Terminal for wire 64 to ground. 24 volts Check the horn relay (80). Also check wires 64 and 64_A.
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Terminal for wire 19N_A at seat 24 volts Check fuse N and accessory relay (16). Also check wire 19N_A
switch and circuit 12P.
Terminal for wire from seat switch at Bad seat switch, also check circuit from seat switch to
24 volts
compressor compressor.
83 Blower Switch
Check Points Reading Possible Cause of Bad Reading
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
24 volts Check fuse G and ignition relay No. 2 (15). Also check circuits
Terminal for wire 19G to ground
19G and 13R.
Terminal for wire 62L to ground 24 volts Bad blower switch (83).
Terminal for wire 61T to ground 24 volts Bad blower switch (83).
Terminal for wire 62M to ground 24 volts Bad blower switch (83).
Terminal for wire 61T to ground 24 volts Bad blower switch (83).
Terminal for wire 62H to ground 24 volts Bad blower switch (83).
Terminal for wire 61T to ground 24 volts Bad blower switch (83).
NOTE: Disconnect the wiring harness connector 29M from the blower motor (85).
85 Blower Motor
Check Points Reading Possible Cause of Bad Reading
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Turn the blower switch (83) to
HIGH.
Terminal for wire 62H to ground 24 volts Check the blower switch (83).
NOTE: If the readings are correct and the blower motor (85) does not run, replace the blower motor (85). Turn the
blower switch (83) to LOW. If the blower motor (85) ran in HIGH but not in LOW or MEDIUM, check the blower
motor resistor (84).
NOTE: Put master disconnect switch and ignition switch in ON position. Put the blower switch (83) to HIGH and
the thermostat switch (88) to COLD.
Terminal B for wire 61A_E to ground 24 volts Check the thermostat switch (88), also check circuit 61A.
NOTE: Disconnect the wiring harness connector 27M from the A/C low pressure switch (86).
NOTE: Put master disconnect switch and ignition switch in ON position. Put blower switch (83) to HIGH and the
thermostat switch (88) to COLD.
Terminal for wire 61A to ground 24 volts Check the thermostat switch (88), also check circuit 61A.
NOTE: Disconnect wiring harness connector 98 from A/C high pressure switch (87).
Bad A/C high pressure switch (87), also check for excessive
Between terminals of A/C high
Open Circuit refrigerant pressure. (Switch closes at or above 27.6 bar (400
pressure switch (87)
psi)).
88 Thermostat Switch
Check Points Reading Possible Cause of Bad Reading
NOTE: Put master disconnect switch and ignition switch in ON position. Put blower switch (83) to HIGH.
Terminal for wire 61T to ground 24 volts Check the blower switch (83), also check wire 61T.
NOTE: Turn the thermostat switch (88) all the way to COLD.
Terminal for wire 61A_D to ground 24 volts Bad thermostat switch (88).
NOTE: Put master disconnect switch and ignition switch in ON position. Put blower switch (83) to HIGH and
thermostat switch (88) to COLD.
Terminal for wire 61A_B to ground 24 volts Check thermostat switch (88), also check wire 61A_C.
Check A/C low pressure switch (86) and A/C high pressure
Terminal for wire 61R_D to ground 0 volt
switch (87).
Terminal for wire 61C_B to ground 24 volts Bad compressor clutch lockout relay (89).
NOTE: Put ignition switch in OFF position. Disconnect wiring harness connector 98 from A/C high pressure
switch. Connect a jumper wire between pins A and B of connector 98. Put ignition switch in ON position.
Terminal for wire 61C_B to ground 0 volt Bad compressor clutch lockout relay (89).
90 Compressor Clutch
Check Points Reading Possible Cause of Bad Reading
NOTE: Put master disconnect switch and ignition switch in ON position. Put blower switch (83) to HIGH and
thermostat switch (88) to COLD.
24 volts Check the compressor clutch lockout relay (89), also check
Terminals for wire 61C to ground
circuit 61C.
97
98
94 92
95 93
96
91
BC00N140
91. CIGAR LIGHTER 94. REMOTE OR 24 VOLT RADIO 97. LEFT SPEAKER
92. POWER CONVERTER 95. 12 VOLT RADIO 98. RIGHT SPEAKER
93. POWER OUTLET 96. RADIO POWER CONVERTER
Terminal for wire 19W_A to ground 24 volts Check fuse W, also check circuit 19W.
NOTE: If the readings are good replace the cigar lighter (91).
Terminal for wire 1_V to ground 24 volts Check wire 1_V to cab power stud.
Terminal for wire 19L_B to ground 24 volts Bad fuse L, also check circuit 19L.
Terminal for wire 12V_B to ground 12 volts Bad power converter (92).
Terminal for wire 12V_A to ground 12 volts Bad power converter (92), also check wire 12V_A.
NOTE: If the readings are good replace the power outlet (93).
NOTE: Put master disconnect switch and ignition switch in ON position. Turn radio on. Put balance control for RH
and LH speakers to center position.
NOTE: Keep the ignition switch and radio ON. Disconnect wiring harness connectors at LH and RH speakers (97
and 98).
Pin A in wiring harness connector Voltage Bad circuit between the radio and the connector or bad radio
111M to ground (94).
Pin A in wiring harness connector Voltage Bad circuit between the radio and the connector or bad radio
112M to ground (94).
Terminal in radio connector for wire Check fuse L, also check circuit 19L and 65C. Also check the
12 volts
65C_A to ground radio power converter (96).
NOTE: Put master disconnect switch and ignition switch in ON position. Turn radio on.
Terminal for wire 65C to ground 12 volts Check fuse L and circuit 19L. Bad radio power converter (96).
NOTE: Disconnect connector from left speaker (97). Put master disconnect switch and ignition switch in ON
position. Turn radio (94) on. Put balance control for RH and LH speakers to center position.
Pin A in wiring harness connector Bad circuit between the left speaker (97) and the radio or a bad
Voltage
112M to ground radio (94).
NOTE: If the readings are good, replace the left speaker (97).
NOTE: Disconnect connector from right speaker (98). Put master disconnect switch and ignition switch in ON
position. Turn radio (94) on. Put balance control for RH and LH speakers to center position.
Pin A in wiring harness connector Bad circuit between the right speaker (98) and the radio or a
Voltage
111M to ground bad radio (94).
NOTE: If the readings are good, replace the right speaker (98).
100
103
101
99 104
102
105
BC00N140
99. BEACON SWITCH 102. BRAKE LAMPS RELAY NO. 15 104. TURN SIGNAL, HI/LOW BEAM, AND HORN SWITCH
100. ROTATING BEACON 103. HAZARD SWITCH 105. FLASHER MODULE
101. BRAKE LAMP PRESSURE
SWITCH
99 Beacon Switch
Check Points Reading Possible Cause of Bad Reading
NOTE: Put master disconnect switch in ON position and five position rotary lamp switch (114) in position 3 or
higher.
Check the five position rotary lamp switch (114), also check
Terminal for wire 49_R to ground 24 volts circuit 49. If LED in beacon switch is not ON with 24 volts at
check point, replace beacon switch.
Terminal for wire 19X to ground 24 volts Check fuse X, also check wire 19X.
Terminal for wire 46_C to ground 24 volts Bad beacon switch (99).
NOTE: Put master disconnect switch and beacon switch (99) in ON position.
Bad circuit between the beacon (100) and the beacon switch
Terminal for wire 46_D to ground 24 volts
(99). Also check the beacon switch (99).
Terminal for wire 1B_A to ground 24 volts Check circuit breaker B, also check wires 1B_A and 1B_D.
Terminal for wire 44 to ground 0 volt Bad brake lamp pressure switch (101).
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 (101).
Terminal for wire 1B_E to ground 24 volts Check circuit breaker B and wires 1B_E and 1B_F.
Terminal for wire 44A_B to ground 0 volt Bad brake lamp pressure switch (101).
Terminal for wire 44_E to ground 0 volt Bad brake lamps relay (102).
NOTE: Put ignition switch in ON position. Have another person press and hold down brake pedal.
Terminal for wire 44A_B to ground 24 volts Bad brake lamp pressure switch (101).
Terminal for wire 44_E to ground 24 volts Bad brake lamps relay (102).
Terminal for wire 1B to ground 24 volts Check circuit breaker B. Also check wires 1B and 1B_F.
NOTE: Put five position rotary lamp switch (114) in position 3 or higher.
Check five position rotary lamp switch (114). Also check circuit
Terminal for wire 49_A to ground 24 volts 49 to lamp switch (114). If hazard switch LED is not ON with 24
volts at check point, replace hazard switch.
HORN SWITCH
Check fuse U and horn relay (80). Also check wires 64C,
Terminal for wire 64C to ground 24 volts
64C_A, and 19U_C.
TURN SIGNAL
Check fuse B and ignition relay No. 1 (14). Also check wires
Terminal for wire 19B to ground 24 volts
19B and 19B_A.
Terminal for wire 45B to ground 24 volts Bad turn signal switch (104).
Terminal for wire 45A to ground 24 volts Bad turn signal switch (104).
NOTE: Put master disconnect switch and ignition switch in OFF position. Hold Hi/Low beam lever in HIGH beam
position.
Terminal for wire 64D to ground Continuity Bad hi/low beam switch (104).
NOTE: Wiring harness connectors 64F and 64M must be connected for North American Machines for opposite
side steady on operation and disconnected for European machines for opposite side off operation.
NOTE: Put ignition switch in the ON position. Put the hazard switch (103) ON.
Terminal for wire 45H_A to ground 24 volts Bad hazard switch (103). Also check wires 45H_A and 45H.
Intermittent 24
Terminal for wire 45L_D to ground Bad flasher module (105).
volts
Intermittent 24
Terminal for wire 45R_E to ground Bad flasher module (105).
volts
NOTE: Put hazard switch (103) in OFF position. Put turn signal switch (104) in RIGHT turn position.
Bad turn signal switch (104) or fuse B. Also check wires 45B_A
Terminal for wire 45B_A to ground 24 volts
and 45B.
Intermittent 24
Terminal for wire 45R_E to ground Bad flasher module (105).
volts
24 volts Bad turn signal switch (104) or fuse B. Also check wires 45A_A
Terminal for wire 45A_A to ground
and 45A.
Intermittent 24
Terminal for wire 45L_D to ground volts Bad flasher module (105).
117 112
113
118
110 108
115
114
111 109
106
116
107
BC00N140
106. LH REAR COMBINATION LAMP 113. RH FRONT WORK LAMP
107. RH REAR COMBINATION LAMP 114. FIVE POSITION ROTARY LAMP SWITCH
108. LH FRONT COMBINATION LAMP 115. HIGH/LOW BEAM RELAY NO. 13
109. RH FRONT COMBINATION LAMP 116. LICENSE PLATE LAMP
110. LH REAR WORK LAMP 117. DOME LAMP
111. RH REAR WORK LAMP 118. COURTESY LAMP
112. LH FRONT WORK LAMP
NOTE: Disconnect wiring harness connector 125 from LH rear combination lamp connector.
NOTE: Connect wiring harness connector 125 to LH rear combination lamp connector.
NOTE: Put master disconnect switch and ignition switch in ON position. Have another person press and hold
down the brake pedal.
NOTE: Have assistant put transmission in neutral. Put turn signal lever in LEFT turn position.
Intermittent 24 Check the turn signal switch (104) and flasher module (105).
Terminal for wire 45L_A to ground
volts Also check circuit 45L to flasher module.
Check fuse F and lamp switch (114). Also check wires 18F_A
Terminal for wire 18F_A to ground 24 volts and 18F_D to fuse F, and wire 41T_A from fuse F to lamp
switch (114).
NOTE: If all readings are good, and lamps still do not turn ON replace the LH rear combination lamp (106).
NOTE: Disconnect wiring harness connector 127 from RH rear combination lamp connector.
NOTE: Connect wiring harness connector 127 to RH rear combination lamp connector.
NOTE: Put master disconnect switch and ignition switch in ON position. Have another person press and hold
down the brake pedal.
NOTE: Have assistant put transmission in neutral. Put turn signal lever in RIGHT turn position.
Intermittent 24 Check the turn signal switch (104) and flasher module (105).
Terminal for wire 45R_A to ground
volts Also check circuit 45R to flasher module.
Check fuse G and lamp switch (114). Also check wires 18G_A,
Terminal for wire 18G_A to ground 24 volts 18G_D, and 18G_F to fuse G, and wire 41T_A from fuse G to
lamp switch (114).
NOTE: If all readings are good, and lamps still do not turn ON replace the RH rear combination lamp (107).
NOTE: Disconnect wiring harness connector 6 from LH front combination lamp connector.
NOTE: Put master disconnect switch in ON position and five position rotary lamp switch (114) in position 3.
Check fuse F and five position rotary lamp switch (114). Also
Terminal for wire 18F to ground 24 volts
check circuit 18F and wires 41T_A and 41T_B.
NOTE: Put ignition switch in ON position. Put turn signal lever in LEFT turn position.
Intermittent 24 Check the turn signal switch (104) and flasher module (105).
Terminal for wire 45L to ground
volts 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 (108).
NOTE: Disconnect wiring harness connector 8 from RH front combination lamp connector.
NOTE: Put master disconnect switch in ON position and five position rotary lamp switch (114) in position 3.
Check fuse G and five position rotary lamp switch (114). Also
Terminal for wire 18G to ground 24 volts
check circuit 18G and wires 41T_A and 41T_B.
NOTE: Put ignition switch in ON position. Put turn signal lever in RIGHT turn position.
Intermittent 24 Check the turn signal switch (104) and flasher module (105).
Terminal for wire 45R to ground
volts 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 (109).
NOTE: Disconnect wiring harness connector 83F from LH rear work lamp connector.
NOTE: Connect wiring harness connector 83F to LH rear work lamp connector.
NOTE: Put master disconnect switch in ON position. Put five position rotary lamp switch (114) in position 4 or 5.
Check fuse A and five position rotary lamp switch (114). Also
Terminal for wire 42R_D to ground 24 volts check circuit 42R from flood lamp to lamp switch (114) and wire
18A to fuse A.
NOTE: Disconnect wiring harness connector 80F from RH rear work lamp connector.
NOTE: Connect wiring harness connector 80F to RH rear work lamp connector.
NOTE: Put master disconnect switch in ON position. Put five position rotary lamp switch (114) in position 4 or 5.
Check fuse A and five position rotary lamp switch (114). Also
Terminal for wire 42R_E to ground 24 volts check circuit 42R from flood lamp to lamp switch (114) and wire
18A to fuse A.
NOTE: Disconnect wiring harness connector 79F from LH front work lamp connector.
NOTE: Connect wiring harness connector 79F to LH front work lamp connector.
NOTE: Put master disconnect switch in ON position. Put five position rotary lamp switch (114) in position 4 or 5.
Check fuse Z and five position rotary lamp switch (114). Also
Terminal for wire 42C_B to ground 24 volts check circuit 42C from flood lamp to lamp switch (114) and wire
19Z to fuse Z.
NOTE: Disconnect wiring harness connector 78F from RH front work lamp connector.
NOTE: Connect wiring harness connector 78F to RH front work lamp connector.
NOTE: Put master disconnect switch in ON position. Put five position rotary lamp switch (114) in position 4 or 5.
Check fuse Z and five position rotary lamp switch (114). Also
Terminal for wire 42C_C to ground 24 volts check circuit 42C from flood lamp to lamp switch (114) and wire
19Z to fuse Z.
Terminal for wire 19Z to ground 24 volts Check fuse Z, also check circuit 19Z.
Terminal for wire 18A to ground 24 volts Check fuse A, also check circuit 18A.
NOTE: Put the five position rotary lamp switch (114) in position 2.
Terminal for wire 41T to ground 24 volts Bad five position rotary lamp switch (114).
NOTE: Put the five position rotary lamp switch (114) in position 3.
Terminal for wire 41T to ground 24 volts Bad five position rotary lamp switch (114).
Terminal for wire 49 to ground 24 volts Bad five position rotary lamp switch (114).
NOTE: Put the five position rotary lamp switch (114) in position 4.
Terminal for wire 41J to ground 24 volts Bad five position rotary lamp switch (114).
Terminal for wire 42R to ground 24 volts Bad five position rotary lamp switch (114).
Terminal for wire 49 to ground 24 volts Bad five position rotary lamp switch (114).
Terminal for wire 42C to ground 24 volts Bad five position rotary lamp switch (114).
NOTE: Put the five position rotary lamp switch (114) in position 5.
Terminal for wire 42C to ground 24 volts Bad five position rotary lamp switch (114).
Terminal for wire 42R to ground 24 volts Bad five position rotary lamp switch (114).
Terminal for wire 49 to ground 24 volts Bad five position rotary lamp switch (114).
Check high/low beam switch (104). Also check circuits 64D and
Terminal for wire 64D_A to ground Continuity
0_KF to and through the high/low beam switch.
Bad five position rotary lamp switch (114). Also check wire
Terminal for wire 41J_A to ground 24 volts
41J_A.
Terminal for wire 41L_A to ground 24 volts Bad high/low beam relay (115).
Terminal for wire 41H to ground 24 volts Bad high/low beam relay (115).
NOTE: Put master disconnect switch in ON position. Put the five position rotary lamp switch (114) in position 2.
Check fuse G and five 5 position rotary lamp switch (114). Also
Terminal for wire 18G_E to ground 24 volts
check circuit 18G.
NOTE: Put master disconnect switch in ON position. Put dome lamp (118) switch in ON position.
Terminal for wire 19U_D to ground 24 volts Check fuse U, also check circuit 19U.
NOTE: Put master disconnect switch in ON position. Put five position rotary lamp switch (114) in position 2 or
higher.
Check circuit 49, also check five position rotary lamp switch
Terminal for wire 49_V to ground 24 volts
(114).
CONNECTORS
CONNECTOR 1 - FRONT CHASSIS HARNESS TO CONNECTOR 1F - MAIN CAB HARNESS TO
MAIN CAB HARNESS FRONT CHASSIS HARNESS
319148A1 291660A1
A 45L N-1.0 Left Turn Signal A 45L_C N-0.8 Left Turn Signal
B 53P_D W-1.0 Float Solenoid Power B 53P_C W-0.8 Pilot Control Signal
C 45R N-1.0 Right Turn Signal C 45R_D N-0.8 Right Turn Signal
D None D None
H 19M_B Or-1.0 Secondary Steer Accessory H 19M_A Or-0.8 Secondary Steer Accessory
J 19R_B Or-1.0 Secondary Steer Ignition J 19R_A Or-0.8 Secondary Steer Ignition
K 35X_B Y-1.0 Secondary Steer Low Pres Sig K 35X_E Y-0.8 Secondary Steer Low Pres Sig
Q 18C Or-1.0 High Beam RH Q 18C_A Or-0.8 High Beam Fused Pwr
R None R None
S None S None
T 56_C W-1.0 Prox Switch Pwr T 56_J W-0.8 Prox Switch Pwr
U 57 W-1.0 Pin Engage Sol Pwr U 57_A W-0.8 Pin Engage Sol Pwr
V 58 W-1.0 Ride Cntrl Sol Pwr V 58_A W-0.8 Ride Cntrl Sol Pwr
W None W None
X None X None
3227856R1 291718A1
225351C1
245482C1
245485C1
225351C1
CAV WIRE IDENT CIRCUIT
CAV WIRE IDENT CIRCUIT
A 53B W-1.0 RTD Signal
1 0_AG Bk-1.0 Lights Ground RH
B 0_AF Bk-1.0 RTD Ground
2 18E Or-1.0 Low Beam RH
C 56_B W-1.0 RTD Power
3 18C Or-1.0 High Beam RH
4 18G Or-1.0 Position RH
5 45R N-1.0 Right Turn Signal CONNECTOR 12M - RTD HARNESS FOR XT
CHASSIS TO FRONT CHASSIS HARNESS
6 None
245484C1
225351C1
232118A1
291661A1
374973A1
CAV WIRE IDENT CIRCUIT
1 28P_A W-0.8 Ether Solenoid CAV WIRE IDENT CIRCUIT
4 33P_A Y-0.8 Low Brake Pres Warning 3 31D Y-1.0 Coolant Level Signal
5 18F_D Or-0.8 Left Tail Pos 4 33P Y-1.0 Low Brake Pres Warning
7 35A_D Y-0.8 Backup Alarm Relay Out 6 35R_B Y-1.0 Backup Alarm Switch
9 18G_F Or-0.8 RH Tail Lic Lights 8 44_C T-1.0 Brake Light Signal
10 45L_B N-0.8 Left Turn Signal 9 18G_D Or-1.0 RH Tail Lic Lights
11 21C_E W-0.8 Starter Fuel Relay Signal 10 45L_A N-1.0 Left Turn Signal
12 45R_B N-0.8 Right Turn Signal 11 21C_D W-1.0 Starter Fuel Relay Signal
14 31H_A Y-0.8 Hyd Filter Rest Sw Signal 13 36H P-1.0 Hot Signal
15 33R_D Y-0.8 Red Brake Sw Signal 14 31H Y-1.0 Hyd Oil Filter Rest Sw Signal
16 36F_A P-0.8 Fuel Level Signal 15 33R_C Y-1.0 Red Brake Sw Signal
20 None 19 None
23 None 22 None
25 63W_A Or-0.8 Front Washer Pump 24 68W Or-1.0 Rear Washer Pump
291661A1
373358A1
CAV WIRE IDENT CIRCUIT
1 13C_D Or-0.8 Fuel Solenoid Power CAV WIRE IDENT CIRCUIT
4 36C_B P-0.8 ECT Signal 3 31F_A Y-1.0 Air Filter Rest Sw Signal
5 36T_A P-0.8 Valve Body Temp Signal 4 36C_A P-1.0 ECT Signal
6 36P_B P-0.8 EOP Signal 5 36T P-0.8 Valve Body Temp Signal
8 25B_A LU-0.8 Turb Speed Signal 7 25A W-0.8 Engine Speed Signal
9 25C_A LU-0.8 Int Speed Signal 8 25B W-0.8 Turb Speed Signal
10 25D_A LU-0.8 Output Speed Signal 9 25C W-0.8 Int Speed Signal
11 0_DM Bk-0.8 Speed Sensor Ground 10 25D LU-1.0 Output Speed Signal
12 36R_E P-0.8 Valve Body Temp Ret 11 0_HD Bk-1.0 Speed Sensor Ground
13 36G_A P-1.0 TCO Temp Signal 12 36R_A P-1.0 Valve Body Temp Ret
17 25L_A LU-0.8 Trans Solenoid Valve Y2 16 25K LU-0.8 Trans Solenoid Valve Y1
18 25M_A LU-0.8 Trans Solenoid Valve Y3 17 25L LU-0.8 Trans Solenoid Valve Y2
19 25N_A LU-0.8 Trans Solenoid Valve Y4 18 25M LU-0.8 Trans Solenoid Valve Y3
20 25P_A LU-0.8 Trans Solenoid Valve Y5 19 25N LU-0.8 Trans Solenoid Valve Y4
21 25J_A LU-0.8 Trans Solenoid Valve Y6 20 25P LU-0.8 Trans Solenoid Valve Y5
22 25S_A LU-0.8 Output Sw Power VPS1 21 25J LU-0.8 Trans Solenoid Valve Y6
28 0_DN Bk-0.8 Out Speed Sensor Ground 27 61R_A Or-1.0 AC High Pressure Switch
29 19A_M Or-0.8 Cab Switched Power 28 0_HE Bk-1.0 Out Speed Ground
31 32F_A Y-0.8 Trans Filter Maint Switch 30 0_HC Bk-1.0 Analog Ground
31 32F Y-1.0 Trans Filter Maint Switch
3195530R1
3195530R1
245430C1
255058C1
631801C1
CAV WIRE IDENT CIRCUIT
CAV WIRE IDENT CIRCUIT
1 62L Or-1.0 Blower Low Speed
A 41J_B K-2.0 Driving Light Signal
2 62M Or-2.0 Blower Medium Speed
3 62H Or-2.0 Blower High Speed
CONNECTOR 27M - AC LOW PRESSURE 4 0_DZ Bk-2.0 Blwr Wpr Seat Ground
SWITCH TO CAB MAIN HARNESS
245482C1
245482C1
266516C1
371614A1
225287C1
892136C1
382391A1
CAV WIRE IDENT CIRCUIT
CAV WIRE IDENT CIRCUIT
1 0_DAR Bk-1.0 Blower Wiper Seat Ground
1 None
19J_A Or-1.0
2 Front Wip Wash Fused Power 2 19C Or-0.8 Pilot Control Signal
19J_B Or-0.8
3 31L Y-0.8 Pilot Lockout Signal
3 63W_A Or-0.8 Front Washer Pump
4 None
4 63C_A Or-0.8 Front Wiper Park
5 None
63H_A Or-0.8
5 Front Wiper High Speed
63H_B Or-0.8 6 None
63L_A Or-0.8 0_KH Bk-0.8
6 Front Wiper Low Speed 7 Pilot Light Ground
63L_B Or-0.8 0_KJ Bk-0.8
49_B S-0.8
8 Pilot Light
49_C S-0.8
CONNECTOR 36F - DETENT SWITCH TO CAB 9 None
MAIN HARNESS
10 None
382391A1
382391A1
382391A1
382391A1
382391A1
382391A1
245731C1
CAV WIRE IDENT CIRCUIT
CAV WIRE IDENT CIRCUIT
1 68C_A Or-1.0 Rear Wiper Park
30 1_T R-3.0 Ign Relay No. 2 Power
68L_A Or-1.0
2 Rear Wiper Low Speed 0_DE Bk-0.8
68L_B Or-0.8 85 Relay Ground
0_DF Bk-0.8
3 19K_C Or-1.0 Rear Wip Wash Fused Power
13K_A Or-1.0
4 None 86 Ignition Switch Power
13K_B Or-1.0
5 19K_D Or-0.8 Rear Wip Wash Fused Power 87 13R Or-1.0 Ignition Relay 2 Out (5 Way)
6 68W_A Or-1.0 Rear Washer Pump 87A None
7 0_DW Bk-0.8 Ground
8 49_L S-0.8 Pilot Light
CONNECTOR 49F - ACCESSORY RELAY TO CAB
9 None
MAIN HARNESS
10 None
245731C1
13P_A Or-1.0
87 Ignition Relay 1 Out
13P_B Or-1.0
87A None
245731C1 245731C1
CONNECTOR 51F - HORN RELAY TO CAB MAIN CONNECTOR 53F - BACKUP ALARM RELAY TO
HARNESS CAB MAIN HARNESS
245731C1
245731C1
245731C1 245731C1
245731C1
245731C1
CAV WIRE IDENT CIRCUIT
CAV WIRE IDENT CIRCUIT
19D_A Or-1.0
30 Park Brake Relay Fused Power 13K_B Or-1.0
19D_B Or-1.0
30 13K_C Or-1.0 Ignition Switch Power
85 52C_A W-0.8 Parking Brake Signal 13K_D Or-0.8
86 19D_B Or-1.0 Park Brake Relay Fused Power 85 23C_A W-0.8 Engine Shutdown Signal
52P_B W-0.8 86 19F Or-1.0 Engine Shtdwn Rly Fused Pwr
87 Park Brake Relay Out
52P_A W-0.8
13C_B Or-0.8
87A None 87 13C_C Or-0.8 Fuel Solenoid Power
13C_D Or-0.8
87A None
245480C1
245731C1
CAV WIRE IDENT CIRCUIT
CAV WIRE IDENT CIRCUIT 1 0_KN Bk-0.8 Front Wiper Ground
30 1_P R-0.8 Voltmeter Relay Power
0_DG Bk-0.8
85 Relay Ground
0_DH Bk-0.8 CONNECTOR 61 - FRONT WIPER MOTOR TO
13K_C Or-1.0 PEDESTAL HARNESS
86 Ignition Switch Power
13K_E Or-0.8
87 13V Or-1.0 Voltmeter Relay Out
87A None
245715C1
225389C1 739070C1
631801C1
CONNECTOR 63M - TIME DELAY MODULE TO
CAB MAIN HARNESS CAV WIRE IDENT CIRCUIT
1 45N_B N-0.8 Flasher Opp Side Control
225351C1
1964527C1
1964527C1 225253C1
1964527C1
382391A1
245486C1
CAV WIRE IDENT CIRCUIT
CAV WIRE IDENT CIRCUIT
1 None
A 19A_H Or-0.8 Trans Control Power
19A_H Or-0.8
B 25F LU-0.8 Forward Signal 2 Trans Control Power
19A_G Or-0.8
C 25R LU-0.8 Reverse Signal
3 33U Y-0.8 Park Brake Signal
D 25T_A LU-0.8 Neutral Signal 4 None
5 None
382391A1
382391A1 382391A1
4 None 4 None
5 None 5 None
6 None 6 None
12 42R_A Y-0.8 Work Light Telltale Sig B 0_ML Bk-0.8 Courtesy Lamp Ground
245483C1
245483C1
245480C1
245483C1
A 42R_D DU-1.0 LH Rear Work Lamp Power CAV WIRE IDENT CIRCUIT
B 0_ME Bk-1.0 LH Rear Work Lamp Ground A 46_D K-1.0 Beacon Switched Power
B 0_MC Bk-1.0 Beacon Lamp Ground
245483C1
266516C1
CAV WIRE IDENT CIRCUIT
CAV WIRE IDENT CIRCUIT
A 33R_B Y-1.0 Redundant Brake Switch Sig
A 19U_D Or-1.0 Dome Lamp Fused Power
B 0_M Bk-1.0 Ground
0_MB Bk-0.8
B Dome Lamp Ground
0_MM Bk-0.8
C 0_MM Bk-0.8 Dome Lamp Ground CONNECTOR 87 - PARKING BRAKE SOLENOID
TO REAR CHASSIS HARNESS
291718A1
225389C1
222135A1
CAV WIRE IDENT CIRCUIT
CAV WIRE IDENT CIRCUIT
1 19R_C Or-1.0 Secondary Steering Ignition
A 33P Y-1.0 Low Brake Press Warning
2 51_A W-1.0 Secondary Steer Mtr Rel
B 0_N Bk-1.0 Brake Press Warning Switch
3 1_W R-1.0 Secondary Steer Module B+
4 0_CE Bk-1.0 Secondary Steer Chassis Grnd
CONNECTOR 89M - PILOT PRESSURE 5 None
SOLENOID TO CAB MAIN HARNESS 6 None
7 19M_C Or-1.0 Secondary Steer Accessory
8 35X_D Y-1.0 Secondary Steer Low Press Sig
9 51P_A W-1.0 Secondary Steer High Press
10 None
11 0_CA Bk-1.0 Secondary Steer Signal Grnd
12 0_CB Bk-1.0 Secondary Steer Signal Grnd
739070C1
245483C1
B 0_U Bk-2.0 Part Str Fuel Relay Ground CAV WIRE IDENT CIRCUIT
1 13C_A Or-1.0 Fuel Solenoid
2 61A_A Or-1.0 AC High Pressure Switch
CONNECTOR 93M - FUEL AND STARTER RELAY
HARNESS TO REAR CHASSIS HARNESS 3 61R-A Or-1.0 AC High Pressure Switch
4 61C_A Or-1.0 AC Comp Clutch
5 14_A LG-1.0 Alternator D+
6 36P_A P-1.0 EOP Sender
7 31F_A Y-1.0 Air Filter Rest Switch Signal
8 None
9 0_HA Bk-1.0 Signal Ground
10 None
11 0_HB Bk-1.0 Signal Ground
245482C1 12 None
CAV WIRE IDENT CIRCUIT 13 36C_A P-1.0 ECT Sender
A 21C_C W-1.0 Starter Fuel Relay Signal 14 None
B 0_GA Bk-2.0 Relay Ground 15 0_HC Bk-1.0 Analog Ground
16 None
17 None
18 None
19 None
291718A1
373356A1
CAV WIRE IDENT CIRCUIT
CAV WIRE IDENT CIRCUIT 1 0_HG Bk-0.8 Intermediate Speed Signal
1 13C Or-1.0 Fuel Solenoid 2 25C W-0.8 Intermediate Speed Signal
2 61A Or-1.0 AC High Pressure Switch
3 61R Or-1.0 AC High Pressure Switch
CONNECTOR 96 - TURBINE SPEED SENSOR TO
4 61C Or-1.0 AC Comp Clutch
TRANSMISSION HARNESS
5 14 LG-1.0 Alternator D+
6 36P P-1.0 EOP Sender
7 31F Y-1.0 Air Filter Rest Switch Signal
8 None
9 0_BF Bk-1.0 Signal Ground
10 None
11 0_BH Bk-1.0 Signal Ground
12 None
13 36C P-1.0 ECT Sender
14 None
291718A1
15 0_BG Bk-1.0 Analog Ground
CAV WIRE IDENT CIRCUIT
16 None
1 25B W-0.8 Turbine Speed Signal
17 None
2 0_HH Bk-0.8 Turbine Speed Ground
18 None
19 None
CONNECTOR 97 - ETHER START TEMPERATURE
SWITCH TO ENGINE HARNESS
245483C1
245482C1
245480C1
245483C1
194788A1
291730A1
245482C1
195552A1
195552A1
449797C1 382391A1
291718A1
225351C1
245484C1
225351C1
1 44_B T-1.0 Brake Light Signal A 18G_E Or-1.0 License Plate Light
2 45R_A N-1.0 Right Turn Signal B 35R_A Y-1.0 Backup Alarm Switch
245485C1
245481C1
194788A1
245483C1
245482C1
245483C1
CAV WIRE IDENT CIRCUIT A 33R_A Y-1.0 Red Brake Switch Signal
225316C1
222136A1
245482C1
245482C1
291718A1
739070C1
225350C1
CAV WIRE IDENT CIRCUIT
CAV WIRE IDENT CIRCUIT
1 28C W-0.8 Ether Start Control
1 19A_C Or-0.8 Transmission Enable Sw Power
2 26F_B LU-0.8 FNR Forward Signal
CONNECTOR 183 - TRANSMISSION SHIFTER TO 3 26N_B LU-0.8 FNR Neutral Signal
PEDESTAL HARNESS 4 26R_B LU-0.8 FNR Reverse Signal
5 32J_B Y-0.8 Trans Enable LT Signal
6 None
245487C1
245485C1
CAV WIRE IDENT CIRCUIT A 58_D W-1.0 Ride Control Solenoid Power
1 None B None
245731C1
199436A1
382391A1
CAV WIRE IDENT CIRCUIT
CAV WIRE IDENT CIRCUIT 1 19R_E Or-0.8 Cab Switched Power
1 None
2 19P_B Or-1.0 Fan Rev Pin Engage Fused Pwr
CONNECTOR 217F - ENGINE SHUTDOWN
3 52_A W-0.8 Fan Reverse Solenoid
JUMPER
4 None
5 None
6 None
0_DAF Bk-1.0
7 Switch Ground
0_DAY Bk-1.0
49_H S-0.8
8 Pilot Light
49_U S-0.8
9 None
10 None
739070C1
CONNECTOR 215F - ALTERNATOR RESISTOR CAV WIRE IDENT CIRCUIT
TO CAB MAIN HARNESS
A 13K_D Or-0.8 Ignition Switch Power
199436A1
631801C1
245488C1 3227856R1
245485C1
245481C1
225316C1
CAV WIRE IDENT CIRCUIT
CAV WIRE IDENT CIRCUIT 1 61C_D Or-1.0 AC Compressor Clutch
1 51_C W-1.0 Sec Steer Solenoid Power
2 0_CF Bk-1.0 Secondary Steering Ground
CONNECTOR 269 - RADIO FUSE HOLDER
(REMOTE RADIO ADAPTER HARNESS)
CONNECTOR 265F - AIR CONDITIONING DIODE CAV WIRE IDENT CIRCUIT
MODULE TO AIR CONDITIONING DIODE
1 1_X R-1.0 Radio Memory Power
HARNESS
2 18_H Or-0.8 Radio Memory Fused Power
245484C1
245480C1
245485C1
INDEX
Symbols Connector 117 ...................................................... 123
12 Volt Radio ..........................................................75 Connector 118F.................................................... 123
24 Volt Radio ..........................................................75 Connector 125 ...................................................... 123
Connector 127 ...................................................... 124
A Connector 128F.................................................... 124
A/C High Pressure Switch (In Rear Chassis) .........72 Connector 128M ...................................................124
A/C Low Pressure Switch (In Cab) .........................72 Connector 12F........................................................ 91
Accessory Relay No. 3 ...........................................42 Connector 12M....................................................... 91
Air Filter Restriction Switch.....................................49 Connector 131F.................................................... 124
Alarm Connector 133F.................................................... 124
Back-up ..............................................................45 Connector 133M ...................................................125
Back-up, Disable Switch ....................................45 Connector 134 ...................................................... 125
Back-up, Relay No. 7 .........................................44 Connector 136 ...................................................... 125
Alternator ................................................................37 Connector 138 ...................................................... 125
Connector 139F.................................................... 125
B Connector 139M ...................................................125
Back-up Alarm ........................................................45 Connector 13F........................................................ 92
Back-up Alarm Disable Switch ...............................45 Connector 13M....................................................... 93
Back-up Alarm Relay No. 7 ....................................44 Connector 140M ...................................................126
Batteries .................................................................36 Connector 142 ...................................................... 126
Beacon Switch ........................................................77 Connector 157 ...................................................... 126
Beacon, Rotating ....................................................78 Connector 158 ...................................................... 126
Blower Motor ..........................................................72 Connector 159 ...................................................... 126
Blower Motor Speed Resistors with Thermal Fuse 72 Connector 168 ...................................................... 127
Blower Switch .........................................................71 Connector 178M ...................................................127
Brake Lamp Pressure Switch .................................78 Connector 179F.................................................... 127
Brake Lamps Relay No. 15.....................................78 Connector 17M....................................................... 94
Brake Warning Pressure Switch .............................47 Connector 180F.................................................... 127
Bucket Control Valve Electromagnet Detents ........58 Connector 180M ...................................................127
Bulb Connector 182 ...................................................... 128
See Lamp ...........................................................78 Connector 183 ...................................................... 128
Connector 197F.................................................... 128
C Connector 197M ...................................................128
Cigar Lighter ...........................................................74 Connector 198 ...................................................... 129
Cluster, Instrument .....................................50, 51, 52 Connector 199F.................................................... 129
Compressor Clutch .................................................73 Connector 19F........................................................ 97
Compressor Clutch Lockout Relay No. 14 .............73 Connector 1F..........................................................89
Compressor, Seat...................................................71 Connector 2 ............................................................90
Connector 1 ............................................................89 Connector 200 ...................................................... 129
Connector 10 ..........................................................91 Connector 202F.................................................... 129
Connector 100 ......................................................120 Connector 203F.................................................... 130
Connector 101 ......................................................120 Connector 204F.................................................... 130
Connector 102 ......................................................120 Connector 207F.................................................... 130
Connector 103 ......................................................121 Connector 208F.................................................... 130
Connector 104 ......................................................121 Connector 209F.................................................... 130
Connector 107M ...................................................121 Connector 209M ...................................................130
Connector 108F....................................................121 Connector 20M....................................................... 97
Connector 109M ...................................................121 Connector 210F.................................................... 131
Connector 110F....................................................122 Connector 215F.................................................... 131
Connector 111M ...................................................122 Connector 216F.................................................... 131
Connector 112M ...................................................122 Connector 217F.................................................... 131
Connector 113 ......................................................122 Connector 217M ...................................................131
Connector 114F....................................................122 Connector 21F........................................................ 98
Connector 114M ...................................................123 Connector 21M....................................................... 98
Connector 229M ...................................................132
Bur 6-40782 Revised 6-02 Printed in U.S.A.
Copyright
4002-136
Connector 22F........................................................99 Connector 6 ............................................................ 90
Connector 22M .......................................................99 Connector 60........................................................ 109
Connector 23F......................................................100 Connector 61........................................................ 109
Connector 23M .....................................................100 Connector 62M..................................................... 110
Connector 246M ...................................................132 Connector 63M..................................................... 110
Connector 24F......................................................100 Connector 64F...................................................... 110
Connector 24M .....................................................100 Connector 64M..................................................... 110
Connector 253F....................................................132 Connector 65F...................................................... 110
Connector 259F....................................................132 Connector 65M..................................................... 111
Connector 25F......................................................101 Connector 66........................................................ 111
Connector 260M ...................................................132 Connector 67........................................................ 111
Connector 262F....................................................132 Connector 68........................................................ 111
Connector 264M ...................................................133 Connector 69........................................................ 111
Connector 265F....................................................133 Connector 70........................................................ 112
Connector 266M ...................................................133 Connector 71........................................................ 112
Connector 267F....................................................133 Connector 72........................................................ 112
Connector 269 ......................................................133 Connector 74........................................................ 113
Connector 270F....................................................133 Connector 75........................................................ 113
Connector 271M ...................................................133 Connector 76........................................................ 114
Connector 272F....................................................134 Connector 77F...................................................... 114
Connector 273F....................................................134 Connector 78F...................................................... 114
Connector 274F....................................................134 Connector 79F...................................................... 115
Connector 275M ...................................................134 Connector 8 ............................................................ 91
Connector 27M .....................................................101 Connector 80F...................................................... 115
Connector 28M .....................................................101 Connector 81M..................................................... 115
Connector 29M .....................................................101 Connector 82M..................................................... 115
Connector 3 ............................................................90 Connector 83F...................................................... 116
Connector 30F......................................................101 Connector 84F...................................................... 116
Connector 31 ........................................................102 Connector 85F...................................................... 116
Connector 32F......................................................102 Connector 86........................................................ 116
Connector 33F......................................................102 Connector 87........................................................ 116
Connector 34F......................................................102 Connector 88........................................................ 117
Connector 35F......................................................103 Connector 89M..................................................... 117
Connector 36F......................................................103 Connector 90M..................................................... 117
Connector 37 ........................................................103 Connector 92........................................................ 117
Connector 38F......................................................104 Connector 93F...................................................... 118
Connector 39F......................................................104 Connector 93M..................................................... 118
Connector 4 ............................................................90 Connector 94F...................................................... 118
Connector 40F......................................................104 Connector 94M..................................................... 119
Connector 41F......................................................105 Connector 95........................................................ 119
Connector 42F......................................................105 Connector 96........................................................ 119
Connector 44F......................................................105 Connector 97........................................................ 119
Connector 45F......................................................106 Connector 98........................................................ 120
Connector 47F......................................................106 Connector 99........................................................ 120
Connector 48F......................................................106 Connector, Diagnostic ............................................ 44
Connector 49F......................................................106 Converter, Radio Power (24 volts to 12 volts)........ 76
Connector 50F......................................................107 Coolant Level Sender .............................................47
Connector 51F......................................................107 Courtesy Lamp ....................................................... 88
Connector 52F......................................................107
Connector 53F......................................................107 D
Connector 54F......................................................108 Declutch Brake Switch ........................................... 44
Connector 55F......................................................108 Declutch Switch...................................................... 44
Connector 56F......................................................108 Detent Switch ......................................................... 57
Connector 57F......................................................108 Diagnostic Connector .............................................44
Connector 58F......................................................109 Dome Lamp ............................................................ 88
Connector 59F......................................................109
Connector 5F..........................................................90
T
Thermal Fuse
Blower Motor ......................................................72
Thermostat .............................................................73
Thermostat Switch ..................................................73
Time Delay Module.................................................42
Torque Converter Output Temperature Sender .....44
Transmission Auto Switch ......................................44
Transmission Electronic Control Module ................44
Transmission Enable Switch ..................................44
Transmission Kick-down Switch .............................44
Transmission Shifter ...............................................44
Transmission Solenoid Valve and Temperature
Sensors .....................................................44
Turbine Speed Sensor............................................44
Turn Signal Switch..................................................79
U
Understanding the Troubleshooting Tables............31
Up/down Count Switch ...........................................52
V
Voltmeter Relay No. 12 ..........................................42
W
Wiper
Front Motor.........................................................67
Front Switch .......................................................68
Front Washer Pump Motor .................................68
Front Washer Switch ..........................................68
Rear Motor .........................................................69
Rear Switch ........................................................69
Rear Washer Pump Motor .................................69
Rear Washer Switch ..........................................69
4002
Section
4002
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright 2003 Case Corporation
3350 South Service Road Printed in U.S.A.
Burlington, ON L7N 3M6 CANADA Bur 6-48930 February, 2003
Copyright
NOTES
Copyright
4002-3
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ELECTRICAL WIRE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
UNDERSTANDING THE TROUBLESHOOTING TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
LOCATING COMPONENTS ON THE SCHEMATIC POSTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
TROUBLESHOOTING BATTERIES, ENGINE FUEL SOLENOID, CHARGING, STARTING,
ALTERNATOR, FUEL FILTER HEATER, GRID HEATER, IGNITION SWITCH AND RELAYS . . . . . . . . . . . 36
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Master Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Engine Fuel Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Starting Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Fuel Filter Heater Relay No. 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Fuel Filter Heater Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
First Fuel Filter Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Second Fuel Filter Heater (621D Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Grid Heater Relay No. 15 (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Grid Heater (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Grid Heater Temperature Sensor (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Grid Heater Controller (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Neutral Start Relay No. 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Ignition Relay No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
TROUBLESHOOTING IGNITION RELAY, ACCESSORY RELAY, VOLTMETER RELAY, AND TIME DELAY
MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Ignition Relay No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Accessory Relay No. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Voltmeter Relay No. 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Time Delay Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
TROUBLESHOOTING TRANSMISSION SOLENOIDS, SENSORS AND SWITCHES, CONTROL MODULE,
SHIFTER, DIAGNOSTIC CONNECTOR, AND BACK-UP ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Output Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Engine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Intermediate Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Turbine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Filter Maintenance Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Torque Converter Output Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Transmission Solenoid Valve and Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Transmission Electronic Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Transmission Shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Diagnostic Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Transmission Kick-down Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Transmission Auto Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Declutch Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Brake Declutch Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Transmission Enable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
FNR Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Back-up Alarm Relay No. 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Back-up Alarm Disable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Back-up Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
SPECIFICATIONS
Electrical System ............................................................ Two 12 volt batteries connected in series, negative ground
System Voltage............................................................................................................................................... 24 volts
Batteries
Specifications are the same for production battery and replacement battery.
Production Battery Case P/N ................................................................................................................... A176482
Replacement Battery Case P/N ............................................................................................................... A180406
Group Size .......................................................................................................................................................... 31
Reserve Capacity ................................................................................................................................ 170 minutes
Cold Cranking Capacity At -17C (0F) for 60 Seconds At 6.0 Volts .................................................700 amperes
Load of Capacity (Load) Test .............................................................................................................400 amperes
Plates per Cell ..................................................................................................................................................... 17
Approximate weight with electrolyte ..................................................................................... 25.9 kg (57.1 pounds)
Nonspill caps ............................................................................................................................................ Standard
Alternator ..................................................................................................................................... 24 volt, 45 amperes
Voltage Regulator ............................................................................................................. Solid State, Not Adjustable
Starter................................................................................................................................ 24 volt, Solenoid Actuated
Bucket Control Valve (Joystick) Detent Electromagnets Resistance at 20C (68F) (Nominal) ................ 68.2 ohms
Bucket Control Valve (Single Axis) Detent Electromagnets Resistance at 20C (68F) (Nominal) ............ 305 ohms
Fuel Level Sender .............................................................................................................................. 33 to 240 ohms
Coolant, Torque Converter, and Hydraulic Temperature Sender 20C (68F) .......................................... 3521 ohms
Coolant and Hydraulic Temperature Sender (Yellow Line) 105C (221F) ................................................. 154 ohms
Coolant and Hydraulic Temperature Sender (Red Line) 110 C (230F) .................................................. 133.9 ohms
Transmission Filter Restriction Switch with 510 ohms Internal Resistor (Normally Open)
Closing Setpoint ............................................................................................................................. 2.8 Bar (40 psi)
Hydraulic Filter Restriction Switch (Normally Open) Closing Setpoint ............................................... 2.8 Bar (40 psi)
Air Filter Restriction Switch (Normally Open) Closing Setpoint .................................. -6.4 kPa (Gauge) (-0.928 psig)
Brake Warning Pressure Switch (Normally Closed) Opening Setpoint ...................................... 117.2 Bar (1700 psi)
A/C High Pressure Switch (Normally Open) Closing Setpoint..................... 27.6 Bar (400 psi) (increasing pressure)
A/C Low Pressure Switch (Normally Closed) Opening Setpoint .................... 1.4 Bar (20 psi) (decreasing pressure)
Thermostat Switch
Contacts 2 to 3 close at initial turn of the switch. Contacts 1 to 2 close with thermal setting.
Engine Oil Pressure Switch (Normally Closed) Opening Setpoint ................................................... 0.69 Bar (10 psi)
Fuel Solenoid Resistance At 20C (68F) (Nominal) ................................................................................ 12.7 Ohms
Brake Declutch Pressure Switch (Normally Closed) Opening Setpoint............................................. 24 Bar (350 psi)
Redundant Brake Pressure Switches (Normally Open) Closing Setpoint ......................................... 62 Bar (900 psi)
Brake Lamp Pressure Switch (Normally Open) Closing Setpoint....................................................... 4.1 Bar (60 psi)
Float Pressure Switch (Normally Open) Closing Setpoint ................................................................. 19 Bar (275 psi)
Secondary Steering Pressure Switch (Form C) Closing Setpoint ...................................................... 2.4 Bar (35 psi)
Fuel Filter Heater Switch
Opens.................................................................................................................................. 13 3C (55.4 5.4F)
Closes ............................................................................................................................. 1.5 4.5C (34.7 8.1F)
Fuel Filters Heater Resistance At 20 C (68F) (Nominal)............................................................................ 1.9 ohms
Grid Heater Temperature Sensor Resistance At:
80C (176F)................................................................................................................................ 304 to 342 ohms
20C (68F)............................................................................................................................ 2,262 to 2,760 ohms
-10C (14F) ........................................................................................................................ 8,244 to 10,661 ohms
1 Alternator 1
Check Points Reading Possible Cause of Bad Reading
2
Check the 10 ampere fuse at 3 4
Good Bad fuse.
location 3 and 4C in the fuse block.
Check wire 1A between the starter terminal (21) and the
Terminal for wire 1A to ground 12 volts
alternator (1).
NOTE: If the readings are good, see Section 4004 and check the starter.
5
6
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.
13
7
11
5
4 6
11C
12
14
1
11A
3 11B
1
8 9 10
BC00N140
1. BATTERIES 7. FUEL FILTER HEATER RELAY NO. 16 11B.GRID HEATER TEMPERATURE
2. MASTER DISCONNECT SWITCH 8. FUEL FILTER HEATER SWITCH SENSOR (OPTION)
3. ENGINE FUEL SOLENOID 9. FIRST FUEL HEATER 11C.GRID HEATER CONTROLLER
4. ALTERNATOR 10. SECOND FUEL FILTER HEATER (621D ONLY) (OPTION)
5. STARTER MOTOR 11. GRID HEATER RELAY NO. 15 (OPTION) 12. NEUTRAL START RELAY NO. 8
6. STARTING RELAY 11A.GRID HEATER (OPTION) 13. IGNITION SWITCH
14. IGNITION RELAY NO. 1
NOTE: The battery must be at full charge and all connections clean and tight before doing any testing of the
electrical system. Use a Multimeter for the following tests.
1 Batteries
NOTE: See Section 4003 and check the batteries.
NOTE: Disconnect cables from both terminals of master disconnect switch (main contact). Put master disconnect
switch in ON position.
NOTE: Use the same method to check the master disconnect switch (auxiliary contact).
Check wire 13M and circuits 13C and 13K, also check circuit to
Terminal for wire 13M to ground 24 volts batteries. Bad master disconnect switch (2) or ignition switch
(13).
NOTE: If the readings are good, replace the fuel solenoid (3).
4 Alternator
Check Points Reading Possible Cause of Bad Reading
Between the B+ terminal of Check circuit to positive post of left battery. Bad master
24 volts
alternator and ground disconnect switch.
Check circuit 14, 75 ohm resistor, and diode module. Bad fuse
Terminal for wire 14 to ground 20 volts R. Check ignition relay No. 1, and 12.5 ampere circuit breaker
A.
NOTE: If the readings are good, see Section 4007 to repair the alternator (4).
5 Starter Motor
Check Points Reading Possible Cause of Bad Reading
NOTE: Put the transmission in NEUTRAL. Have another person hold the ignition switch in the START position.
Bad starting relay (6). Also check wire 1_F between starter (5)
Terminal S to ground 24 volts
and starting relay (6).
NOTE: If the readings are good, see Section 4004 and repair the starter (5).
6 Starting Relay
Check Points Reading Possible Cause of Bad Reading
NOTE: Put the transmission in NEUTRAL. Have another person hold the ignition switch in the START position.
Terminal for wire 21C_D to ground 24 volts Check neutral start relay (12), also check circuit 21C.
Terminal for wire 1_F to ground 24 volts Bad starting relay (6).
Terminal for wire 31U_X to ground Continuity Bad ground circuit or bad fuel filter heater switch (8).
Terminal for wire 13C_H to ground 24 volts Check ignition switch (13), also check circuits 13C and 13K.
Terminal for wires 1Y_D and 1Y_E 24 volts Bad fuel filter relay (7).
to ground
NOTE: The fuel filter heater switch opens at 13 3 C (55 5 F) and closes at 1.5 4 C (34 8 F).
NOTE: Disconnect the connector from the fuel filter heater switch (8). Make sure the engine temperature is below
-3 C (27 F).
NOTE: If the readings are good, check circuit 1Y between first fuel filter heater connector 288 and fuel filter
heater relay connector 280.
NOTE: If the readings are good, check circuit 1Y between second fuel filter heater connector 287 and fuel filter
heater relay connector 280.
NOTE: Put the master disconnect switch in the ON position and the ignition switch in ON position.
Terminal for wire 1_DA to ground 24 volts Bad 150 ampere fuse. Check wires 1_DA and 1_D.
NOTE: Have an assistant put the transmission in neutral and the ignition switch in the START position. Make
sure engine temperature is below -3 C (27 F).
Terminal for wire 28GC_C to ground 24 volts Bad grid heater controller (11C), also check circuit 28GC.
Terminal for wire 1Z to ground 24 volts Bad grid heater relay (11).
Between terminals of grid heater Resistance If an open or short circuit is obtained, replace the grid heater.
2.26 to 2.76 K
Between terminals A and B of grid
ohms at 20C Bad grid heater temperature sensor.
heater temperature sensor
(68F)
NOTE: Resistance of grid heater temperature sensor decreases as temperature increases and increases as
temperature decreases.
110 to 140 Bad grid heater relay (11). Also check circuit 28GC, and wires
Connector terminal 3 to ground
ohms 28GP, 0_UC, 0_UA, and 0_U.
110 to 140 Bad grid heater relay (11). Also check circuit 28GC, and wires
Connector terminal 6 to ground ohms 0_UC, 0_UA, and 0_U.
Connector terminal 8 to ground Continuity Bad ground circuit. Check wire 0_DBB.
2.26 to 2.76 K
Bad grid heater temperature sensor (11B). Also check circuit
Connector terminal 10 to ground ohms at 20C
31T and wire 0_BC.
(68F)
NOTE: Put master disconnect switch in ON position and ignition switch in ON position.
20 volts Bad fuse R. Check 75 ohms resistor and diode module. Check
Connector terminal 4 to ground
ignition relay No. 1 (14) and 12.5 ampere circuit breaker A.
24 volts Bad fuse E. Check wire 19E. Also check ignition relay (14) and
Connector terminal 7 to ground
12.5 ampere circuit breaker A.
NOTE: Have an assistant put transmission in neutral and ignition switch in START position.
Bad neutral start relay (12). Also check ignition switch (13) and
Connector terminal 5 to ground 24 volts
wire 21C_G.
NOTE: If all readings are good, replace the grid heater controller.
NOTE: Put master disconnect switch and ignition switch in ON position. Make sure transmission is in NEUTRAL.
NOTE: Have another person hold the ignition switch in the START position.
Terminal for wire 21K_A to ground 24 volts Check circuit 21K_A and ignition switch.
Terminal for wire 21C_E to ground 24 volts Bad neutral start relay (12).
13 Ignition Switch
Check Points Reading Possible Cause of Bad Reading
Terminal for wire 1A to ground 24 volts Check circuit 1A to 12.5 ampere circuit breaker A.
NOTE: Disconnect the connector from the ignition switch (13). Turn the switch to ON.
NOTE: Put the master disconnect switch in the ON position. Turn the ignition switch to the ON position.
Terminal for wire 13K_A to ground 24 volts Check circuit 13K and ignition switch.
Terminal for wire 13P to ground 24 volts Bad ignition relay No. 1 (14)
18 15
16
17
BC00N140
15. IGNITION RELAY NO. 2 17. VOLTMETER RELAY NO. 12
16. ACCESSORY RELAY NO. 3 18. TIME DELAY MODULE
NOTE: Put the master disconnect switch in the ON position. Turn the ignition switch to the ON position.
Terminal for wire 13K to ground 24 volts Check circuit 13K and ignition switch.
Terminal for wire 13R to ground 24 volts Bad ignition relay No. 2 (15).
NOTE: Put the master disconnect switch in the ON position. Turn ignition switch to the Acc or the ON position.
Terminal for wire 12K to ground 24 volts Check circuit 12K and ignition switch.
Terminal for wire 12P_A to ground 24 volts Bad accessory relay (16).
Terminal for wire 1_P to ground 24 volts Check circuit 1 to starter motor B+ stud.
Terminal for wire 13K to ground 24 volts Check circuit 13K and ignition switch.
Terminal for wire 13V to ground 24 volts Bad voltmeter relay (17).
24 volts Bad 12.5 ampere circuit breaker A. Check wire 1_l to SPL_D17
Terminal for wire 1A_E to ground
and wire 1_J to B+ stud.
NOTE: Put the ignition switch in the ON position. Have another person press and hold the program/reset switch
(45) in RESET position.
Terminal for wire 37R_C to ground 24 volts Bad program/reset switch (45), also check circuit 37R.
Terminal for wire 13K_F to ground 24 volts Bad ignition switch (13), also check circuit 13K.
NOTE: Put the ignition switch in the ON position. Turn ignition switch to the OFF position. After 10 seconds time
delay an audible click will be heard.
27
32
25
24
37
29
23 26 30
33
28 31
20 34
35 36
21
22
19
BC00N140
19. OUTPUT SPEED SENSOR 29. TRANSMISSION KICK-DOWN SWITCH
20. ENGINE SPEED SENSOR 30. TRANSMISSION AUTO SWITCH
21. INTERMEDIATE SPEED SENSOR 31. DECLUTCH SWITCH
22. TURBINE SPEED SENSOR 32. BRAKE DECLUTCH PRESSURE SWITCH
23. FILTER MAINTENANCE SWITCH 33. TRANSMISSION ENABLE SWITCH
24. TORQUE CONVERTER OUTPUT TEMPERATURE SENDER 34. FNR SWITCH
25. TRANSMISSION SOLENOID VALVE AND TEMPERATURE 35. BACK-UP ALARM RELAY NO. 7
SENSORS
26. TRANSMISSION ELECTRONIC CONTROL MODULE 36. BACK-UP ALARM DISABLE SWITCH
27. TRANSMISSION SHIFTER 37. BACK-UP ALARM
28. DIAGNOSTIC CONNECTOR
NOTE: If you have transmission shifting problems, see Section 6002 for complete troubleshooting information for
Items 19 through 34.
NOTE: Disconnect the transmission electronic control module (26) quick disconnect connector.
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
24 volts Bad fuse A, also check wires 19A_P, 13P_A, and ignition relay
Terminal for wire 19A_P to ground
No. 1 (14).
24 volts Bad fuse H, also check wires 19H and 13R and ignition relay
Terminal for wire 19H to ground
No. 2 (15).
NOTE: Put parking brake switch in OFF position. Depress brake pedal once and put gear selector in REVERSE.
Terminal for wire 35A_D to ground 24 volts Bad back-up alarm relay (35).
NOTE: Put the master disconnect switch and the ignition switch in the ON position and the park brake to the OFF
position. Depress brake pedal once. Move the transmission shift lever to REVERSE.
Terminal for wire 35A_E to ground 24 volts Bad back-up alarm relay (35), also check circuit 35A_E.
NOTE: Wires 35A_F and 35R_D are connected together and switch is removed in North American models. The
wires are disconnected and the switch is installed in TUV road approved (Germany) models.
37 Back-up Alarm
Check Points Reading Possible Cause of Bad Reading
NOTE: Put the master disconnect switch and the ignition switch in the ON position and the park brake to the OFF
position. Depress brake pedal once. Move the transmission shift lever to REVERSE. If machine is a TUV model,
depress back-up alarm switch to turn LED ON (back-up alarm enabled).
NOTE: If the readings are good, replace the back-up alarm (37).
44 39
43
45
38 46
42 47
48
41
49
40
BC00N140
38. BRAKE WARNING PRESSURE SWITCH 44. AIR FILTER RESTRICTION SWITCH
39. COOLANT LEVEL SENDER 45. PROGRAM/RESET SWITCH
40. FUEL LEVEL SENDER 46. PARKING BRAKE SWITCH
41. HYDRAULIC OIL TEMPERATURE SENDER 47. INSTRUMENT CLUSTER
42. HYDRAULIC FILTER RESTRICTION SWITCH 48. PILOT CONTROL SWITCH
43. ENGINE COOLANT TEMPERATURE 49. UP/DOWN COUNT SWITCH
SENDER
NOTE: Brake warning pressure switch opens at 117.2 bar (1700 psi).
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Approximately
Terminal A for wire 33P to ground Check circuit 33P.
11.5 volts
NOTE: Disconnect the wires from the brake warning pressure switch (38).
Between terminals A and B of the Continuity Bad brake warning pressure switch (38).
switch
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Approximately
Terminal A for wire 31D to ground Check circuit 31D, also check the instrument cluster (47).
1.6 volts AC
NOTE: If the readings are correct replace the coolant level sender (39).
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Approximately
Terminal A for wire 36F to ground Check the instrument cluster (47).
5 volts
NOTE: Put the ignition switch and the master disconnect switch in the OFF position. Tag and disconnect the
wires from the fuel level sender.
NOTE: Disconnect the connector from the hydraulic oil temperature sender.
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Approximately
Terminal A for wire 36H to ground Check the instrument cluster (47).
5 volts
NOTE: Hydraulic filter restriction switch closes at 2.8 bar (40 psi).
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Approximately
Terminal A for wire 31H to ground. 11.5 volts Check the instrument cluster (47).
NOTE: If the readings are correct replace the hydraulic filter restriction switch (42).
NOTE: Disconnect the connector from the engine coolant temperature sender.
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Approximately
Terminal A for wire 36C to ground Check the instrument cluster (47).
5 volts
NOTE: Air filter restriction switch closes at -6.4 kPa (Gauge) (-0.928 psig).
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Approximately
Terminal for wire 31F to ground Check the instrument cluster (47).
11.5 volts
NOTE: If the readings are correct replace the air filter restriction indicator switch (44).
45 Program/Reset Switch
Check Points Reading Possible Cause of Bad Reading
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Terminal for wire 1A_B to ground 24 volts Check 12.5 ampere circuit breaker A. Also check circuit 1A.
NOTE: Press and hold the program/reset switch in the reset position.
NOTE: Put the five position rotary lamp switch (114) in position 3, 4, or 5.
Bad rotary lamp switch. Also check fuse Z and circuit 49 and
Terminal for wire 49_E to ground 24 volts
19Z.
NOTE: If 24 volts between wire 49 and ground and program/reset switch is not illuminated, replace program/reset
switch.
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Terminal for wire 19A to ground 24 volts Check fuse A, also check circuit 19A.
Terminal for wire 33U to ground 24 volts Bad parking brake switch (46).
NOTE: Put the five position rotary lamp switch (114) in position 3, 4, or 5.
24 volts Bad rotary lamp switch. Also check fuse Z and circuits 49 and
Terminal for wire 49 to ground
19Z.
NOTE: If 24 volts between wire 49 and ground and parking brake switch is not illuminated, replace parking brake
switch.
47 Instrument Cluster
Check Points Reading Possible Cause of Bad Reading
Bad brake warning pressure switch (38). Also check circuit 33P
Connector terminal 3 to ground Continuity
and ground circuit at brake warning pressure switch.
Continuity Bad coolant level sender (39). Also check circuit 31D and
Connector terminal 4 to ground
ground circuit at coolant level sender.
Connector terminal 6 to ground Open Circuit Bad air filter restriction switch (44). Also check circuit 31F.
Connector terminal 7 to ground Open Circuit Bad hydraulic filter restriction switch. Also check circuit 31H.
Continuity Bad ground circuit. Check wires 0_KP, 0_DAV, 0_HC, and
Connector terminal 8 to ground
0_BG.
130 to 9500 Bad engine coolant temperature sender (43). Also check circuit
Connector terminal 18 to ground ohms circuit 36C and ground circuit at sender.
Bad fuel level sender (40). Also check circuit 36F and ground
Connector terminal 19 to ground 33 to 240 ohms
circuit at sender.
130 to 9500 Bad hydraulic oil temperature sender (41). Also check circuit
Connector terminal 20 to ground
ohms 36H and ground circuit at sender.
237 to 243 Bad engine oil pressure switch (50). Also check circuit 36P and
Connector terminal 22 to ground
ohms ground circuit.
Connector terminal 28 to ground Open Circuit Bad redundant brake switche(s) (57). Also check circuit 33R.
Check LH and RH stop lamps and circuit 44. Also check ground
Connector terminal 35 to ground Continuity
circuit at lamps.
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Connector terminal 1 to ground 24 volts Bad fuse V. Also check circuit 19V.
Connector terminal 2 to ground 24 volts Bad fuse S. Also check circuit 19S.
Connector terminal 9 to ground 24 volts Bad parking brake switch. Also check fuse A and circuit 19A.
NOTE: Put the five position rotary lamp switch in position four or five.
Connector terminal 13 to ground 24 volts Check rotating beacon switch and fuse X. Also check circuit 46.
NOTE: Put the five position rotary lamp switch in position four or five. Put the high/low beam switch in HIGH
BEAM position.
NOTE: Put the turn signal switch in the LEFT TURN position.
24 volts on and Check fuse B, turn signal switch, and flasher module. Also
Connector terminal 16 to ground off every 1-2 check wire 19B, circuit 45A to flasher module, and circuit 45L
seconds from flasher module to instrument cluster.
NOTE: Put the turn signal switch in the RIGHT TURN position.
24 volts on and Check fuse B, turn signal switch, and flasher module. Also
Connector terminal 17 to ground off every 1-2 check wire 19B, circuit 45B to flasher module, and circuit 45R
seconds from flasher module to instrument cluster.
24 volts Bad program/reset switch. Also check wire 37P and wire 1A_B
Connector terminal 24 to ground
to ignition switch.
NOTE: Press and hold the program/reset switch in the RESET position.
Bad pilot control switch or fuse C. Also check wire 31L and
Connector terminal 29 to ground 24 volts
circuit 19C.
Bad parking brake relay or fuse D. Also check circuits 52C and
Connector terminal 30 to ground 24 volts
19D.
Bad pilot control relay or fuse C. Also check circuits 53C and
Connector terminal 36 to ground 24 volts
19C.
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Terminal for wire 19C to ground 24 volts Bad fuse C, also check circuit 19C.
Terminal for wire 31L to ground 24 volts Bad pilot control switch (48).
NOTE: Put the five position rotary lamp switch (114) in position 3 or higher.
24 volts Check five position rotary lamp switch (114) and fuse Z. Also
Terminal for wire 49 to ground
check circuit 49.
NOTE: If the readings are correct replace the pilot control switch (48).
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Check fuse S and time delay module. Also check circuits 19S
Terminal for wire 19S to ground 24 volts
and 13D from time delay module to fuse S.
NOTE: Press and hold the up/down switch in the DOWN COUNT position.
Terminal for wire 37D to ground 24 volts Bad up/down count switch.
NOTE: Press and hold the up/down switch in the UP COUNT position.
Terminal for wire 37U to ground 24 volts Bad up/down count switch.
NOTE: Put the five position rotary lamp switch (114) in position 3 or higher.
Check five position rotary lamp switch (114) and fuse Z. Also
Terminal for wire 49 to ground 24 volts
check circuit 49.
53
57
56
55
54
51
52
58
50
BC00N140
50. ENGINE OIL PRESSURE SWITCH 55. FAN REVERSER SWITCH (OPTION)
51. PILOT CONTROL RELAY NO. 10 56. FAN REVERSING SOLENOID (OPTION)
52. PARKING BRAKE RELAY NO. 9 57. REDUNDANT BRAKE SWITCHES
53. PARKING BRAKE SOLENOID 58. RELAY SOCKET NO. 11
54. PILOT PRESSURE SOLENOID
Between engine oil pressure switch 90 to 92 ohms Bad ground connection or bad ground wire assembly.
(50) terminal NO and ground
NOTE: Disconnect wire 36P from terminal C of engine oil pressure switch. Put master disconnect switch and
ignition switch in ON position.
Approximately
Terminal for wire 36P to ground Bad instrument cluster (47) or bad circuit 36P.
5 volts
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure pilot control switch
(48) is OFF.
Terminal for wire 19C to ground 24 volts Bad fuse C, also check circuit 19C.
Terminal for wire 53C to ground 0 volt Bad instrument cluster (47). Also check circuit 53C.
Terminal for wire 53P to ground 24 volts Bad pilot control relay.
Terminal for wire 53C to ground 24 volts Bad instrument cluster (47). Also check circuit 53C.
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the parking brake
switch (46) is OFF.
Terminal for wire 19D_B to ground 24 volts Bad fuse D, also check circuit 19D.
Terminal for wire 52C to ground 0 volt Bad instrument cluster (47). Also check circuit 52C.
Terminal for wire 52P to ground 24 volts Bad parking brake relay.
Terminal for wire 52C to ground 24 volts Bad instrument cluster (47). Also check wire 52C.
NOTE: Put the master disconnect switch and ignition switch in ON position. Put parking brake switch in OFF
position.
Terminal 1 for wire 52P to ground 24 volts Bad parking brake relay (52). Also check circuit 52P
NOTE: If the readings are good, replace the parking brake solenoid (53).
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the pilot control
switch (48) is OFF.
Terminal A for wire 53P to ground 24 volts Bad pilot control relay (51), also check circuit 53P.
NOTE: If the readings are good, replace the pilot pressure solenoid (54).
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
NOTE: Put fan reversing switch in ON position (hold rocker in momentary position).
Terminal for wire 52_A to ground 24 volts Bad fan reversing switch.
NOTE: Disconnect wiring harness connector 158 from fan reversing solenoid.
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put fan reversing switch in
ON position (hold rocker in momentary position).
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Approximately
Terminal A for wire 33R to ground 11.5 volts Bad instrument cluster (47), also check circuit 33R.
NOTE: If the readings are good, replace the redundant brake pressure switch(es) (57).
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Terminal for wire 19F to ground 24 volts Bad fuse F. Also check circuit 19F to ignition relay No. 2 (15).
Terminal for wire 13K_B to ground 24 volts Check wire 13K_B to ignition relay No. 2 (15).
63
62
65
64
60
59
61
BC00N140
59. DETENT SWITCH 63. HEIGHT CONTROL/RETURN TO TRAVEL PROXIMITY
SWITCH
60. BUCKET CONTROL VALVES ELECTROMAGNETIC DETENTS 64. FLOAT PRESSURE SWITCH
61. RETURN TO TRAVEL/FLOAT SWITCH 65. FLOAT SOLENOID
62. RETURN TO DIG PROXIMITY SWITCH
59 Detent Switch
Check Points Reading Possible Cause of Bad Reading
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the pilot control switch (48) in
the OFF position.
Terminal for wire 53P_B to ground 24 volts Bad pilot control relay (51), also check circuit 53P_B.
Terminal for wire 56_H to ground 24 volts Bad detent switch (59).
NOTE: Put the five position rotary lamp switch (114) in position 3 or higher.
Bad circuit 49_M. Also check five position rotary lamp switch
Terminal for wire 49_M to ground 24 volts (114). If detent switch illumination LED does not turn ON with
24 volts at check point, replace detent switch (59).
NOTE: Disconnect the wiring harness connector from the control valve electromagnetic detents connector.
NOTE: Put the master disconnect switch and ignition switch in ON position. Put pilot control switch (48) in OFF
position and detent switch (59) in ON position.
Wiring harness connector 17M, pin 4 Bad detent switch (59). Also check wires 53P_B, 56_G, and
24 volts
to ground 56_H.
Wiring harness connector 17M, pin 6 24 volts Bad detent switch (59). Also check wires 56_E and 56_H.
to ground
Wiring harness connector 17M, pin 5 24 volts Bad detent switch (59). Also check wires 56_F and 56_H.
to ground
61 Return-To-Travel/Float Switch
Check Points Reading Possible Cause of Bad Reading
NOTE: Disconnect the wiring harness connector from the return-to-travel/float switch (61). Put the return-to-
travel/float switch (61) in FLOAT position.
NOTE: Put the master disconnect switch and ignition switch in ON position. Put pilot control switch (48) in OFF
position and detent switch (59) in ON position.
NOTE: Put ignition switch in OFF position. Connect wiring harness connector to return-to-travel/float switch (61).
Put ignition switch in ON position. Put five position rotary lamp switch (114) in position 3 or higher.
Bad circuit 49_K. Also check five position rotary lamp switch
(114). If return-to-travel/float switch illumination LED is not ON
Terminal for wire 49_K to ground 24 volts
with 24 volts at check point, replace return-to-travel/float
switch.
NOTE: Disconnect the connector from the return-to-dig proximity switch (62). Put the master disconnect switch
and the ignition switch in the ON position. Put the pilot control switch (48) in the OFF position and the detent
switch (59) in the ON position.
Terminal C for wire 56_D to ground 24 volts Bad detent switch (59), also check circuit 56.
NOTE: If the readings are good, replace the return-to-dig proximity switch (62).
NOTE: Disconnect the connector from the height control/return-to-travel proximity switch (63). Put the master
disconnect switch and the ignition switch in the ON position. Put the pilot control switch (48) in the OFF position
and the detent switch (59) in the ON position.
Terminal C for wire 56_A to ground 24 volts Bad detent switch (59). Also check circuit 56.
NOTE: If the readings are good, replace the height control/return-to-travel proximity switch (63).
NOTE: Disconnect the wiring harness connector 178M from the float pressure switch.
NOTE: Start and run engine at idle speed. Put return-to-travel/float switch in FLOAT position. Put loader control
lever in FLOAT position.
NOTE: Shut down engine. Put ignition switch in ON position. Put pilot control switch in OFF position (switch LED
OFF).
65 Float Solenoid
Check Points Reading Possible Cause of Bad Reading
NOTE: Disconnect the wiring harness connector 179F from the float solenoid.
NOTE: Start and run engine at idle speed. Put return-to-travel/float switch in FLOAT position. Put loader control
lever in FLOAT position.
Wiring harness connector 179F pin 1 24 volts Bad float pressure switch. Also check wires 53S_A and 53S_B.
to ground
71
69 70
67
66
68A 73
72
68
BC00N140
66. SECONDARY STEERING MODULE (OPTION) 70. PIN ENGAGE SOLENOID (OPTION)
67. SECONDARY STEERING PRESSURE SWITCH (OPTION) 71. RIDE CONTROL SWITCH
68. SECONDARY STEERING MOTOR (OPTION) 72. RIDE CONTROL RELAY NO. 4
68A.SECONDARY STEERING SOLENOID (OPTION) 73. RIDE CONTROL SOLENOID
69. PIN ENGAGE SWITCH (OPTION)
NOTE: Disconnect the wiring harness connector 90M from the secondary steering module.
NOTE: Put the master disconnect switch and the ignition switch in ON position.
Pin 3 of connector 90M to ground 24 volts Bad wire 1_W to secondary steering motor (68) B+ stud.
Pin 7 of connector 90M to ground 24 volts Bad fuse M or ignition switch. Also check circuits 19M and 12K.
Pin 9 of connector 90M to ground Continuity Bad secondary steering pressure switch.
NOTE: Put ignition switch in OFF position to stop engine. Connect wiring harness connector 90M to secondary
steering module. Disconnect wire 51_B from secondary steering motor (68) relay terminal. Start and run engine
at idle speed. Disconnect wiring harness connector 131F from secondary steering pressure switch (67). Apply a
ground to pin C of connector 131F.
Terminal for wire 51_B to ground 24 volts Bad secondary steering module.
NOTE: Disconnect wiring harness connector 131F from secondary steering pressure switch (67).
Pressure switch (67) pin B to pin C Continuity Bad secondary steering pressure switch.
Pressure switch (67) pin B to pin A Open Circuit Bad secondary steering pressure switch.
Pressure switch (67) pin A to pin C Open Circuit Bad secondary steering pressure switch.
Pressure switch (67) pin B to pin A Continuity Bad secondary steering pressure switch.
Pressure switch (67) pin B to pin C Open Circuit Bad secondary steering pressure switch.
NOTE: Start and run engine for two or three minutes while turning steering wheel left and right several times. DO
NOT TURN STEERING WHEEL TO STEERING STOPS. Turn ignition switch to OFF position to stop engine, then
immediately to ON position. Secondary steering motor should be heard operating. If motor is heard, problem is
associated pump; refer to Section 5002. If motor is not heard, leave ignition switch in ON position and disconnect
wire 51_B from secondary steering motor relay.
NOTE: Disconnect wire 51_B from secondary steering motor relay; make sure that wire does not touch any metal
part of machine during the remainder of this check. Put the master disconnect switch in ON position. Start and
run engine for two or three minutes while turning steering wheel left and right several times. DO NOT TURN
STEERING WHEEL TO STEERING STOPS. Turn ignition switch to OFF position to stop engine, then
immediately to ON position.
Between pin A of connector 264M Check secondary steering module (66) and secondary steering
24 volts
and ground pressure switch (67).
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put pin engage switch in OFF
position.
24 volts Bad fuse P or ignition relay No. 2. Also check circuits 19P_A
Terminal for wire 19P_A to ground
and 13P_B.
Terminal for wire 57_A to ground 0 volt Bad pin engage switch.
Terminal for wire 57_A to ground 24 volts Bad pin engage switch.
NOTE: Put the five position rotary lamp switch (114) in position 3 or higher.
Check the five position rotary lamp switch (114). Also check
Terminal for wire 49_P to ground 24 volts circuit 49. If LED in pin engage switch is not ON with 24 volts
at check point, replace pin engage switch.
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the pin engage switch
(69) in the ON position.
Terminal for wire 57 to ground 24 volts Bad pin engage switch (69), also check circuit 57.
NOTE: If the readings are good, replace the pin engage solenoid (70).
NOTE: Connect connector 44F to ride control switch (71). Put master disconnect switch and ignition switch in ON
position. Put ride control switch in OFF position.
Check fuse C and ignition relay No. 1. Also check circuits 19C
Terminal for wire 19C_B to ground 24 volts
and 13P_A.
Terminal for wire 58S to ground 0 volt Bad ride control switch.
Terminal for wire 58S to ground 24 volts Bad ride control switch.
NOTE: Put the five position rotary light switch (114) in position 3 or higher.
Check five position rotary lamp switch (114). Also check circuit
Terminal for wire 49_P to ground 24 volts 49. If LED in ride control switch is not ON with 24 volts at check
point, replace ride control switch.
NOTE: Put master disconnect switch and ignition switch in ON position. Put ride control switch in ON position.
Terminal for wire 58S to ground 24 volts Bad ride control switch. Also check wire 58S.
TROUBLESHOOTING WIPER/WASHER
74
79
75
77
78 76
BC00N140
74. FRONT WIPER MOTOR 77. REAR WIPER AND WASHER SWITCH
75. FRONT WIPER AND WASHER SWITCH 78. REAR WASHER PUMP MOTOR
76. FRONT WASHER PUMP MOTOR 79. REAR WIPER MOTOR
NOTE: Make sure the front wiper and washer switch (75) is in the OFF position.
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Terminal for wire 19J to ground 24 volts Check fuse J, also check circuit 19J.
NOTE: Put the front wiper and washer switch (75) in the LOW position.
Check fuse J, also check circuit 19J. Bad front wiper and
Terminal for wire 63L to ground 24 volts
washer switch (75).
Terminal for wire 63C to ground 0 volt Bad front wiper and washer switch (75)
NOTE: Put the front wiper and washer switch (75) in the HIGH position.
Check fuse J, also check circuit 19J. Bad front wiper and
Terminal for wire 63H to ground 24 volts
washer switch (75).
Terminal for wire 63C to ground 0 volt Bad front wiper and washer switch (75).
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 (75).
Terminal for wire 63C to ground 24 volts pulse Bad front wiper and washer switch (75).
NOTE: If the readings are good, replace the front wiper motor (74).
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the front wiper and
washer switch (75) is in the OFF position.
Terminal for wire 19J_A to ground 24 volts Check fuse J, also check circuit 19J.
NOTE: Put the front wiper and washer switch (75) in the LOW position.
Check fuse J, also check circuit 19J. Bad front wiper and
Terminal for wire 63L to ground 24 volts
washer switch (75).
Terminal for wire 63C to ground 0 volt Bad front rotary wiper and washer switch (75)
NOTE: Put the front wiper and washer switch (75) in the HIGH position.
Check fuse J, also check circuit 19J. Bad front rotary wiper and
Terminal for wire 63H to ground 24 volts
washer switch (75).
Terminal for wire 63C to ground 0 volt Bad front rotary wiper and washer switch (75).
NOTE: Put the front wiper and washer switch in the intermittent position.
Terminal for wire 63L_A to ground 24 volts pulse Bad front wiper and washer switch (75).
Terminal for wire 63C_A to ground 24 volts pulse Bad front wiper and washer switch (75).
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Connect volt meter to check
point then push down on front wiper and washer switch (75).
24 volts Bad front wiper and washer switch (75), also check wires 63W
Terminal for wire 63W to ground
and 63W_A.
NOTE: If the readings are good, replace the front washer pump motor (76).
Terminal for wire 19K_D to ground 24 volts Bad fuse K or ignition relay No. 2 (15). Also check circuit 19K.
Terminal for wire 19K_C to ground 24 volts Bad fuse K or ignition relay No. 2 (15). Also check circuit 19K.
NOTE: Put the rear wiper and washer switch in the ON position.
Terminal for wire 68L_A to ground 24 volts Bad rear wiper and washer switch (77).
NOTE: Press and hold the rear wiper and washer switch (77) in the WASH position.
Terminal for wire 68W_A to ground 24 volts Bad rear wiper and washer switch (77).
NOTE: Put the five position rotary lamp switch in position 3 or higher.
Check rotary lamp switch and circuit 49. If LEDs in rear wiper
Terminal for wire 49_L to ground 24 volts and washer switch are not ON with 24 volts at check point,
replace rear wiper and washer switch.
NOTE: Put master disconnect switch and ignition switch in ON position. Depress and hold rear wiper and washer
switch (77) in WASH position.
Bad rear wiper and washer switch (77) Also check wires
Terminal for wire 68W to ground 24 volts
68W_A and 68W.
NOTE: If the readings are good, replace the rear washer pump motor (78).
NOTE: Make sure the rear wiper and washer switch (77) is in the OFF position.
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Terminal for wire 19K to ground 24 volts Check fuse K, also check circuit 19K.
NOTE: Put the rear wiper and washer switch (77) in the ON position.
Terminal for wire 68L_C to ground 24 volts Bad rear wiper and washer switch (77).
Terminal for wire 68C_B to ground 0 volt Bad rear wiper and washer switch (77).
NOTE: If the readings are good, replace the rear wiper motor (79).
86
81
87
90
80 83
89 88
82
84
85
BC00N140
80. HORN RELAY NO. 5 86. A/C LOW PRESSURE SWITCH (IN CAB)
81. HORN 87. A/C HIGH PRESSURE SWITCH (IN REAR CHASSIS)
82. SEAT COMPRESSOR 88. THERMOSTAT SWITCH
83. BLOWER SWITCH 89. COMPRESSOR CLUTCH LOCKOUT RELAY NO. 14
84. SPEED RESISTOR 90. COMPRESSOR CLUTCH
85. BLOWER MOTOR
Terminal for wire 19U_B to ground 24 volts Check fuse U, also check wire 19U_B.
Terminal for wire 64C_A to ground 24 volts Bad horn relay (80).
NOTE: Have another person push and hold the horn switch.
Terminal for wire 64_A to ground 24 volts Bad horn relay (80).
81 Horn
Check Points Reading Possible Cause of Bad Reading
NOTE: Disconnect the wire 64 from the horn (81). Have an assistant push and hold the horn switch.
Terminal for wire 64 to ground. 24 volts Check the horn relay (80). Also check wires 64 and 64_A.
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Terminal for wire 19N_A at seat 24 volts Check fuse N and accessory relay (16). Also check wire 19N_A
switch and circuit 12P.
Terminal for wire from seat switch at Bad seat switch, also check circuit from seat switch to
24 volts
compressor compressor.
83 Blower Switch
Check Points Reading Possible Cause of Bad Reading
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
24 volts Check fuse G and ignition relay No. 2 (15). Also check circuits
Terminal for wire 19G to ground
19G and 13R.
Terminal for wire 62L to ground 24 volts Bad blower switch (83).
Terminal for wire 61T to ground 24 volts Bad blower switch (83).
Terminal for wire 62M to ground 24 volts Bad blower switch (83).
Terminal for wire 61T to ground 24 volts Bad blower switch (83).
Terminal for wire 62H to ground 24 volts Bad blower switch (83).
Terminal for wire 61T to ground 24 volts Bad blower switch (83).
NOTE: Disconnect the wiring harness connector 29M from the blower motor (85).
85 Blower Motor
Check Points Reading Possible Cause of Bad Reading
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Turn the blower switch (83) to
HIGH.
Terminal for wire 62H to ground 24 volts Check the blower switch (83).
NOTE: If the readings are correct and the blower motor (85) does not run, replace the blower motor (85). Turn
the blower switch (83) to LOW. If the blower motor (85) ran in HIGH but not in LOW or MEDIUM, check the blower
motor resistor (84).
NOTE: Put master disconnect switch and ignition switch in ON position. Put the blower switch (83) to HIGH and
the thermostat switch (88) to COLD.
Terminal B for wire 61A_E to ground 24 volts Check the thermostat switch (88), also check circuit 61A.
NOTE: Disconnect the wiring harness connector 27M from the A/C low pressure switch (86).
NOTE: Put master disconnect switch and ignition switch in ON position. Put blower switch (83) to HIGH and the
thermostat switch (88) to COLD.
Terminal for wire 61A to ground 24 volts Check the thermostat switch (88), also check circuit 61A.
NOTE: Disconnect wiring harness connector 98 from A/C high pressure switch (87).
Bad A/C high pressure switch (87), also check for excessive
Between terminals of A/C high
Open Circuit refrigerant pressure. (Switch closes at or above 27.6 bar (400
pressure switch (87)
psi)).
88 Thermostat Switch
Check Points Reading Possible Cause of Bad Reading
NOTE: Put master disconnect switch and ignition switch in ON position. Put blower switch (83) to HIGH.
Terminal for wire 61T to ground 24 volts Check the blower switch (83), also check wire 61T.
NOTE: Turn the thermostat switch (88) all the way to COLD.
Terminal for wire 61A_D to ground 24 volts Bad thermostat switch (88).
NOTE: Put master disconnect switch and ignition switch in ON position. Put blower switch (83) to HIGH and
thermostat switch (88) to COLD.
Terminal for wire 61A_B to ground 24 volts Check thermostat switch (88), also check wire 61A_C.
Check A/C low pressure switch (86) and A/C high pressure
Terminal for wire 61R_D to ground 0 volt
switch (87).
Terminal for wire 61C_B to ground 24 volts Bad compressor clutch lockout relay (89).
NOTE: Put ignition switch in OFF position. Disconnect wiring harness connector 98 from A/C high pressure
switch. Connect a jumper wire between pins A and B of connector 98. Put ignition switch in ON position.
Terminal for wire 61C_B to ground 0 volt Bad compressor clutch lockout relay (89).
90 Compressor Clutch
Check Points Reading Possible Cause of Bad Reading
NOTE: Put master disconnect switch and ignition switch in ON position. Put blower switch (83) to HIGH and
thermostat switch (88) to COLD.
24 volts Check the compressor clutch lockout relay (89), also check
Terminals for wire 61C to ground
circuit 61C.
97
98
94 92
95 93
96
91
BC00N140
91. CIGAR LIGHTER 94. REMOTE OR 24 VOLT RADIO 97. LEFT SPEAKER
92. POWER CONVERTER 95. 12 VOLT RADIO 98. RIGHT SPEAKER
93. POWER OUTLET 96. RADIO POWER CONVERTER
Terminal for wire 19W_A to ground 24 volts Check fuse W, also check circuit 19W.
NOTE: If the readings are good replace the cigar lighter (91).
Terminal for wire 1_V to ground 24 volts Check wire 1_V to cab power stud.
Terminal for wire 19L_B to ground 24 volts Bad fuse L, also check circuit 19L.
Terminal for wire 12V_B to ground 12 volts Bad power converter (92).
Terminal for wire 12V_A to ground 12 volts Bad power converter (92), also check wire 12V_A.
NOTE: If the readings are good replace the power outlet (93).
NOTE: Put master disconnect switch and ignition switch in ON position. Turn radio on. Put balance control for RH
and LH speakers to center position.
NOTE: Keep the ignition switch and radio ON. Disconnect wiring harness connectors at LH and RH speakers (97
and 98).
Pin A in wiring harness connector Voltage Bad circuit between the radio and the connector or bad radio
111M to ground (94).
Pin A in wiring harness connector Voltage Bad circuit between the radio and the connector or bad radio
112M to ground (94).
Terminal in radio connector for wire Check fuse L, also check circuit 19L and 65C. Also check the
12 volts
65C_A to ground radio power converter (96).
NOTE: Put master disconnect switch and ignition switch in ON position. Turn radio on.
Terminal for wire 65C to ground 12 volts Check fuse L and circuit 19L. Bad radio power converter (96).
NOTE: Disconnect connector from left speaker (97). Put master disconnect switch and ignition switch in ON
position. Turn radio (94) on. Put balance control for RH and LH speakers to center position.
Pin A in wiring harness connector Bad circuit between the left speaker (97) and the radio or a bad
Voltage
112M to ground radio (94).
NOTE: If the readings are good, replace the left speaker (97).
NOTE: Disconnect connector from right speaker (98). Put master disconnect switch and ignition switch in ON
position. Turn radio (94) on. Put balance control for RH and LH speakers to center position.
Pin A in wiring harness connector Bad circuit between the right speaker (98) and the radio or a
Voltage
111M to ground bad radio (94).
NOTE: If the readings are good, replace the right speaker (98).
100
103
101
99 104
102
105
BC00N140
99. BEACON SWITCH 102. BRAKE LAMPS RELAY NO. 6 104. TURN SIGNAL, HI/LOW BEAM, AND HORN SWITCH
100. ROTATING BEACON 103. HAZARD SWITCH 105. FLASHER MODULE
101. BRAKE LAMP PRESSURE
SWITCH
99 Beacon Switch
Check Points Reading Possible Cause of Bad Reading
NOTE: Put master disconnect switch in ON position and five position rotary lamp switch (114) in position 3 or
higher.
Check the five position rotary lamp switch (114), also check
Terminal for wire 49_R to ground 24 volts circuit 49. If LED in beacon switch is not ON with 24 volts at
check point, replace beacon switch.
Terminal for wire 19X to ground 24 volts Check fuse X, also check wire 19X.
Terminal for wire 46_C to ground 24 volts Bad beacon switch (99).
NOTE: Put master disconnect switch and beacon switch (99) in ON position.
Bad circuit between the beacon (100) and the beacon switch
Terminal for wire 46_D to ground 24 volts
(99). Also check the beacon switch (99).
Terminal for wire 1B_A to ground 24 volts Check circuit breaker B, also check wires 1B_A and 1B_D.
Terminal for wire 44 to ground 0 volt Bad brake lamp pressure switch (101).
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 (101).
Terminal for wire 1B_E to ground 24 volts Check circuit breaker B and wires 1B_E and 1B_F.
Terminal for wire 44A_B to ground 0 volt Bad brake lamp pressure switch (101).
Terminal for wire 44_E to ground 0 volt Bad brake lamps relay (102).
NOTE: Put ignition switch in ON position. Have another person press and hold down brake pedal.
Terminal for wire 44A_B to ground 24 volts Bad brake lamp pressure switch (101).
Terminal for wire 44_E to ground 24 volts Bad brake lamps relay (102).
Terminal for wire 1B to ground 24 volts Check circuit breaker B. Also check wires 1B and 1B_F.
NOTE: Put five position rotary lamp switch (114) in position 3 or higher.
Check five position rotary lamp switch (114). Also check circuit
Terminal for wire 49_A to ground 24 volts 49 to lamp switch (114). If hazard switch LED is not ON with 24
volts at check point, replace hazard switch.
HORN SWITCH
Check fuse U and horn relay (80). Also check wires 64C,
Terminal for wire 64C to ground 24 volts
64C_A, and 19U_C.
TURN SIGNAL
Check fuse B and ignition relay No. 1 (14). Also check wires
Terminal for wire 19B to ground 24 volts
19B and 19B_A.
Terminal for wire 45B to ground 24 volts Bad turn signal switch (104).
Terminal for wire 45A to ground 24 volts Bad turn signal switch (104).
NOTE: Put master disconnect switch and ignition switch in OFF position. Hold Hi/Low beam lever in HIGH beam
position.
Terminal for wire 64D to ground Continuity Bad hi/low beam switch (104).
NOTE: Wiring harness connectors 64F and 64M must be connected for North American Machines for opposite
side steady on operation and disconnected for European machines for opposite side off operation.
NOTE: Put ignition switch in the ON position. Put the hazard switch (103) ON.
Terminal for wire 45H_A to ground 24 volts Bad hazard switch (103). Also check wires 45H_A and 45H.
Intermittent 24
Terminal for wire 45L_D to ground Bad flasher module (105).
volts
Intermittent 24
Terminal for wire 45R_E to ground Bad flasher module (105).
volts
NOTE: Put hazard switch (103) in OFF position. Put turn signal switch (104) in RIGHT turn position.
Bad turn signal switch (104) or fuse B. Also check wires 45B_A
Terminal for wire 45B_A to ground 24 volts
and 45B.
Intermittent 24
Terminal for wire 45R_E to ground Bad flasher module (105).
volts
24 volts Bad turn signal switch (104) or fuse B. Also check wires 45A_A
Terminal for wire 45A_A to ground
and 45A.
Intermittent 24
Terminal for wire 45L_D to ground volts Bad flasher module (105).
117 112
113
118
110 108
115
114
111 109
106
116
107
BC00N140
106. LH REAR COMBINATION LAMP 113. RH FRONT WORK LAMP
107. RH REAR COMBINATION LAMP 114. FIVE POSITION ROTARY LAMP SWITCH
108. LH FRONT COMBINATION LAMP 115. HIGH/LOW BEAM RELAY NO. 13
109. RH FRONT COMBINATION LAMP 116. LICENSE PLATE LAMP
110. LH REAR WORK LAMP 117. DOME LAMP
111. RH REAR WORK LAMP 118. COURTESY LAMP
112. LH FRONT WORK LAMP
NOTE: Disconnect wiring harness connector 125 from LH rear combination lamp connector.
NOTE: Connect wiring harness connector 125 to LH rear combination lamp connector.
NOTE: Put master disconnect switch and ignition switch in ON position. Have another person press and hold
down the brake pedal.
NOTE: Have assistant put transmission in neutral. Put turn signal lever in LEFT turn position.
Intermittent 24 Check the turn signal switch (104) and flasher module (105).
Terminal for wire 45L_A to ground
volts Also check circuit 45L to flasher module.
Check fuse F and lamp switch (114). Also check wires 18F_A
Terminal for wire 18F_A to ground 24 volts and 18F_D to fuse F, and wire 41T_A from fuse F to lamp
switch (114).
NOTE: If all readings are good, and lamps still do not turn ON replace the LH rear combination lamp (106).
NOTE: Disconnect wiring harness connector 127 from RH rear combination lamp connector.
NOTE: Connect wiring harness connector 127 to RH rear combination lamp connector.
NOTE: Put master disconnect switch and ignition switch in ON position. Have another person press and hold
down the brake pedal.
NOTE: Have assistant put transmission in neutral. Put turn signal lever in RIGHT turn position.
Intermittent 24 Check the turn signal switch (104) and flasher module (105).
Terminal for wire 45R_A to ground
volts Also check circuit 45R to flasher module.
Check fuse G and lamp switch (114). Also check wires 18G_A,
Terminal for wire 18G_A to ground 24 volts 18G_D, and 18G_F to fuse G, and wire 41T_A from fuse G to
lamp switch (114).
NOTE: If all readings are good, and lamps still do not turn ON replace the RH rear combination lamp (107).
NOTE: Disconnect wiring harness connector 6 from LH front combination lamp connector.
NOTE: Put master disconnect switch in ON position and five position rotary lamp switch (114) in position 3.
Check fuse F and five position rotary lamp switch (114). Also
Terminal for wire 18F to ground 24 volts
check circuit 18F and wires 41T_A and 41T_B.
NOTE: Put ignition switch in ON position. Put turn signal lever in LEFT turn position.
Intermittent 24 Check the turn signal switch (104) and flasher module (105).
Terminal for wire 45L to ground
volts 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 (108).
NOTE: Disconnect wiring harness connector 8 from RH front combination lamp connector.
NOTE: Put master disconnect switch in ON position and five position rotary lamp switch (114) in position 3.
Check fuse G and five position rotary lamp switch (114). Also
Terminal for wire 18G to ground 24 volts
check circuit 18G and wires 41T_A and 41T_B.
NOTE: Put ignition switch in ON position. Put turn signal lever in RIGHT turn position.
Intermittent 24 Check the turn signal switch (104) and flasher module (105).
Terminal for wire 45R to ground
volts 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 (109).
NOTE: Disconnect wiring harness connector 83F from LH rear work lamp connector.
NOTE: Connect wiring harness connector 83F to LH rear work lamp connector.
NOTE: Put master disconnect switch in ON position. Put five position rotary lamp switch (114) in position 4 or 5.
Check fuse A and five position rotary lamp switch (114). Also
Terminal for wire 42R_D to ground 24 volts check circuit 42R from flood lamp to lamp switch (114) and wire
18A to fuse A.
NOTE: Disconnect wiring harness connector 80F from RH rear work lamp connector.
NOTE: Connect wiring harness connector 80F to RH rear work lamp connector.
NOTE: Put master disconnect switch in ON position. Put five position rotary lamp switch (114) in position 4 or 5.
Check fuse A and five position rotary lamp switch (114). Also
Terminal for wire 42R_E to ground 24 volts check circuit 42R from flood lamp to lamp switch (114) and wire
18A to fuse A.
NOTE: Disconnect wiring harness connector 79F from LH front work lamp connector.
NOTE: Connect wiring harness connector 79F to LH front work lamp connector.
NOTE: Put master disconnect switch in ON position. Put five position rotary lamp switch (114) in position 4 or 5.
Check fuse Z and five position rotary lamp switch (114). Also
Terminal for wire 42C_B to ground 24 volts check circuit 42C from flood lamp to lamp switch (114) and wire
19Z to fuse Z.
NOTE: Disconnect wiring harness connector 78F from RH front work lamp connector.
NOTE: Connect wiring harness connector 78F to RH front work lamp connector.
NOTE: Put master disconnect switch in ON position. Put five position rotary lamp switch (114) in position 4 or 5.
Check fuse Z and five position rotary lamp switch (114). Also
Terminal for wire 42C_C to ground 24 volts check circuit 42C from flood lamp to lamp switch (114) and wire
19Z to fuse Z.
Terminal for wire 19Z to ground 24 volts Check fuse Z, also check circuit 19Z.
Terminal for wire 18A to ground 24 volts Check fuse A, also check circuit 18A.
NOTE: Put the five position rotary lamp switch (114) in position 2.
Terminal for wire 41T to ground 24 volts Bad five position rotary lamp switch (114).
NOTE: Put the five position rotary lamp switch (114) in position 3.
Terminal for wire 41T to ground 24 volts Bad five position rotary lamp switch (114).
Terminal for wire 49 to ground 24 volts Bad five position rotary lamp switch (114).
NOTE: Put the five position rotary lamp switch (114) in position 4.
Terminal for wire 41J to ground 24 volts Bad five position rotary lamp switch (114).
Terminal for wire 42R to ground 24 volts Bad five position rotary lamp switch (114).
Terminal for wire 49 to ground 24 volts Bad five position rotary lamp switch (114).
Terminal for wire 42C to ground 24 volts Bad five position rotary lamp switch (114).
NOTE: Put the five position rotary lamp switch (114) in position 5.
Terminal for wire 42C to ground 24 volts Bad five position rotary lamp switch (114).
Terminal for wire 42R to ground 24 volts Bad five position rotary lamp switch (114).
Terminal for wire 49 to ground 24 volts Bad five position rotary lamp switch (114).
Check high/low beam switch (104). Also check circuits 64D and
Terminal for wire 64D_A to ground Continuity
0_KF to and through the high/low beam switch.
Bad five position rotary lamp switch (114). Also check wire
Terminal for wire 41J_A to ground 24 volts
41J_A.
Terminal for wire 41L_A to ground 24 volts Bad high/low beam relay (115).
Terminal for wire 41H to ground 24 volts Bad high/low beam relay (115).
NOTE: Put master disconnect switch in ON position. Put the five position rotary lamp switch (114) in position 2.
Check fuse G and five 5 position rotary lamp switch (114). Also
Terminal for wire 18G_E to ground 24 volts
check circuit 18G.
NOTE: Put master disconnect switch in ON position. Put dome lamp (118) switch in ON position.
Terminal for wire 19U_D to ground 24 volts Check fuse U, also check circuit 19U.
NOTE: Put master disconnect switch in ON position. Put five position rotary lamp switch (114) in position 2 or
higher.
Check circuit 49, also check five position rotary lamp switch
Terminal for wire 49_V to ground 24 volts
(114).
CONNECTORS
CONNECTOR 1 - FRONT CHASSIS HARNESS TO CONNECTOR 1F - MAIN CAB HARNESS TO
MAIN CAB HARNESS FRONT CHASSIS HARNESS
319148A1 291660A1
A 45L N-1.0 Left Turn Signal A 45L_C N-0.8 Left Turn Signal
B 53P_D W-1.0 Float Solenoid Power B 53P_C W-0.8 Pilot Control Signal
C 45R N-1.0 Right Turn Signal C 45R_D N-0.8 Right Turn Signal
D None D None
H 19M_B Or-1.0 Secondary Steer Accessory H 19M_A Or-0.8 Secondary Steer Accessory
J 19R_B Or-1.0 Secondary Steer Ignition J 19R_A Or-0.8 Secondary Steer Ignition
K 35X_B Y-1.0 Secondary Steer Low Pres Sig K 35X_E Y-0.8 Secondary Steer Low Pres Sig
Q 18C Or-1.0 High Beam RH Q 18C_A Or-0.8 High Beam Fused Pwr
R None R None
S None S None
T 56_C W-1.0 Prox Switch Pwr T 56_J W-0.8 Prox Switch Pwr
U 57 W-1.0 Pin Engage Sol Pwr U 57_A W-0.8 Pin Engage Sol Pwr
V 58 W-1.0 Ride Cntrl Sol Pwr V 58_A W-0.8 Ride Cntrl Sol Pwr
W None W None
X None X None
3227856R1 291718A1
225351C1
245482C1
245485C1
225351C1
CAV WIRE IDENT CIRCUIT
CAV WIRE IDENT CIRCUIT
A 53B W-1.0 RTD Signal
1 0_AG Bk-1.0 Lights Ground RH
B 0_AF Bk-1.0 RTD Ground
2 18E Or-1.0 Low Beam RH
C 56_B W-1.0 RTD Power
3 18C Or-1.0 High Beam RH
4 18G Or-1.0 Position RH
5 45R N-1.0 Right Turn Signal CONNECTOR 12M - RTD HARNESS FOR XT
CHASSIS TO FRONT CHASSIS HARNESS
6 None
245484C1
225351C1
232118A1
291661A1
374973A1
CAV WIRE IDENT CIRCUIT
1 None CAV WIRE IDENT CIRCUIT
2 None 1 None
4 33P_A Y-0.8 Low Brake Pres Warning 3 31D Y-1.0 Coolant Level Signal
5 18F_D Or-0.8 Left Tail Pos 4 33P Y-1.0 Low Brake Pres Warning
7 35A_D Y-0.8 Backup Alarm Relay Out 6 35R_B Y-1.0 Backup Alarm Switch
9 18G_F Or-0.8 RH Tail Lic Lights 8 44_C T-1.0 Brake Light Signal
10 45L_B N-0.8 Left Turn Signal 9 18G_D Or-1.0 RH Tail Lic Lights
11 21C_E W-0.8 Starter Fuel Relay Signal 10 45L_A N-1.0 Left Turn Signal
12 45R_B N-0.8 Right Turn Signal 11 21C_D W-1.0 Starter Fuel Relay Signal
14 31H_A Y-0.8 Hyd Filter Rest Sw Signal 13 36H P-1.0 Hot Signal
15 33R_D Y-0.8 Red Brake Sw Signal 14 31H Y-1.0 Hyd Oil Filter Rest Sw Signal
16 36F_A P-0.8 Fuel Level Signal 15 33R_C Y-1.0 Red Brake Sw Signal
21 1_P R-0.8 Voltmeter Relay Power 20 28GC_B W-1.0 Grid Heater Signal
25 63W_A Or-0.8 Front Washer Pump 24 68W Or-1.0 Rear Washer Pump
291661A1
373358A1
CAV WIRE IDENT CIRCUIT
1 13C_D Or-0.8 Fuel Solenoid Power CAV WIRE IDENT CIRCUIT
4 36C_B P-0.8 ECT Signal 3 31F_A Y-1.0 Air Filter Rest Sw Signal
5 36T_A P-0.8 Valve Body Temp Signal 4 36C_A P-1.0 ECT Signal
6 36P_B P-0.8 EOP Signal 5 36T P-0.8 Valve Body Temp Signal
8 25B_A LU-0.8 Turb Speed Signal 7 25A W-0.8 Engine Speed Signal
9 25C_A LU-0.8 Int Speed Signal 8 25B W-0.8 Turb Speed Signal
10 25D_A LU-0.8 Output Speed Signal 9 25C W-0.8 Int Speed Signal
11 0_DM Bk-0.8 Speed Sensor Ground 10 25D LU-1.0 Output Speed Signal
12 36R_E P-0.8 Valve Body Temp Ret 11 0_HD Bk-1.0 Speed Sensor Ground
13 36G_A P-1.0 TCO Temp Signal 12 36R_A P-1.0 Valve Body Temp Ret
17 25L_A LU-0.8 Trans Solenoid Valve Y2 16 25K LU-0.8 Trans Solenoid Valve Y1
18 25M_A LU-0.8 Trans Solenoid Valve Y3 17 25L LU-0.8 Trans Solenoid Valve Y2
19 25N_A LU-0.8 Trans Solenoid Valve Y4 18 25M LU-0.8 Trans Solenoid Valve Y3
20 25P_A LU-0.8 Trans Solenoid Valve Y5 19 25N LU-0.8 Trans Solenoid Valve Y4
21 25J_A LU-0.8 Trans Solenoid Valve Y6 20 25P LU-0.8 Trans Solenoid Valve Y5
22 25S_A LU-0.8 Output Sw Power VPS1 21 25J LU-0.8 Trans Solenoid Valve Y6
28 0_DN Bk-0.8 Out Speed Sensor Ground 27 61R_A Or-1.0 AC High Pressure Switch
29 19A_M Or-0.8 Cab Switched Power 28 0_HE Bk-1.0 Out Speed Ground
31 32F_A Y-0.8 Trans Filter Maint Switch 30 0_HC Bk-1.0 Analog Ground
31 32F Y-1.0 Trans Filter Maint Switch
3195530R1
3195530R1
245430C1
255058C1
631801C1
CAV WIRE IDENT CIRCUIT
CAV WIRE IDENT CIRCUIT
1 62L Or-1.0 Blower Low Speed
A 41J_B K-2.0 Driving Light Signal
2 62M Or-2.0 Blower Medium Speed
3 62H Or-2.0 Blower High Speed
CONNECTOR 27M - AC LOW PRESSURE 4 0_DZ Bk-2.0 Blwr Wpr Seat Ground
SWITCH TO CAB MAIN HARNESS
245482C1
245482C1
266516C1
371614A1
225287C1
892136C1
382391A1
CAV WIRE IDENT CIRCUIT
CAV WIRE IDENT CIRCUIT
1 0_DAR Bk-1.0 Blower Wiper Seat Ground
1 None
19J_A Or-1.0
2 Front Wip Wash Fused Power 2 19C Or-0.8 Pilot Control Signal
19J_B Or-0.8
3 31L Y-0.8 Pilot Lockout Signal
3 63W_A Or-0.8 Front Washer Pump
4 None
4 63C_A Or-0.8 Front Wiper Park
5 None
63H_A Or-0.8
5 Front Wiper High Speed
63H_B Or-0.8 6 None
63L_A Or-0.8 0_KH Bk-0.8
6 Front Wiper Low Speed 7 Pilot Light Ground
63L_B Or-0.8 0_KJ Bk-0.8
49_B S-0.8
8 Pilot Light
49_C S-0.8
CONNECTOR 36F - DETENT SWITCH TO CAB 9 None
MAIN HARNESS
10 None
382391A1
382391A1
382391A1
382391A1
382391A1
382391A1
245731C1
CAV WIRE IDENT CIRCUIT
CAV WIRE IDENT CIRCUIT
1 68C_A Or-1.0 Rear Wiper Park
30 1_T R-3.0 Ign Relay No. 2 Power
68L_A Or-1.0
2 Rear Wiper Low Speed 0_DE Bk-0.8
68L_B Or-0.8 85 Relay Ground
0_DF Bk-0.8
3 19K_C Or-1.0 Rear Wip Wash Fused Power
13K_A Or-1.0
4 None 86 Ignition Switch Power
13K_B Or-1.0
5 19K_D Or-0.8 Rear Wip Wash Fused Power 87 13R Or-1.0 Ignition Relay 2 Out (5 Way)
6 68W_A Or-1.0 Rear Washer Pump 87A None
7 0_DW Bk-0.8 Ground
8 49_L S-0.8 Pilot Light
CONNECTOR 49F - ACCESSORY RELAY TO CAB
9 None
MAIN HARNESS
10 None
245731C1
13P_A Or-1.0
87 Ignition Relay 1 Out
13P_B Or-1.0
87A None
245731C1 245731C1
CONNECTOR 51F - HORN RELAY TO CAB MAIN CONNECTOR 54F - NEUTRAL START RELAY TO
HARNESS CAB MAIN HARNESS
245731C1
245731C1
245731C1
245731C1
CAV WIRE IDENT CIRCUIT
CAV WIRE IDENT CIRCUIT
13K_B Or-1.0
19D_A Or-1.0
30 Park Brake Relay Fused Power 30 13K_C Or-1.0 Ignition Switch Power
19D_B Or-1.0
13K_D Or-0.8
85 52C_A W-0.8 Parking Brake Signal
85 23C_A W-0.8 Engine Shutdown Signal
86 19D_B Or-1.0 Park Brake Relay Fused Power
86 19F Or-1.0 Engine Shtdwn Rly Fused Pwr
52P_B W-0.8
87 Park Brake Relay Out 13C_B Or-0.8
52P_A W-0.8
87 13C_C Or-0.8 Fuel Solenoid Power
87A None 13C_D Or-0.8
87A None
245731C1
194791A1
245480C1
225389C1
CAV WIRE IDENT CIRCUIT
CAV WIRE IDENT CIRCUIT
1 0_KN Bk-0.8 Front Wiper Ground
1 1B_B R-0.8 Flasher Module Power
2 45N_A N-0.8 Flasher Opp Side Control
3 0_DAN Bk-0.8 Flasher Module Ground
4 0_DAQ Bk-0.8 Flasher Module Ground
5 None
6 None
7 45R_E N-0.8 Right Turn Signal
8 45L_D N-0.8 Left Turn Signal
9 45B_A N-0.8 Right Turn Switch Power
10 45A_A N-0.8 Left Turn Switch Power
11 45H_A N-0.8 Hazard Switch Power
12 45N_B N-0.8 Flasher Opp Side Control
225351C1
631801C1
CAV WIRE IDENT CIRCUIT
1 13D Or-1.0 Delay Power (2 Way) CAV WIRE IDENT CIRCUIT
2 1A_E R-0.8 Time Delay Power 1 45N_B N-0.8 Flasher Opp Side Control
1964527C1
1964527C1
1964527C1
225253C1
382391A1 382391A1
282763A1
245483C1
245715C1
245483C1
CAV WIRE IDENT CIRCUIT
CAV WIRE IDENT CIRCUIT
A None
A 42C_C DU-1.0 RH Front Work Lamp Power
B 68L_C Or-1.0 Rear Wiper Low Speed
B 0_MJ Bk-1.0 RH Front Work Lamp Ground
C 19K_E Or-1.0 Rear Wpr Wash Fused Power
D 68C_B Or-1.0 Rear Wiper Park
CONNECTOR 79F - LH FRONT WORK LAMP TO
CAB MAIN HARNESS
CONNECTOR 82M - REAR WIPER MOTOR TO
CAB MAIN HARNESS
245483C1
245483C1
A 42R_D DU-1.0 LH Rear Work Lamp Power CAV WIRE IDENT CIRCUIT
B 0_ME Bk-1.0 LH Rear Work Lamp Ground A 46_D K-1.0 Beacon Switched Power
B 0_MC Bk-1.0 Beacon Lamp Ground
245483C1
266516C1
CAV WIRE IDENT CIRCUIT
CAV WIRE IDENT CIRCUIT
A 33R_B Y-1.0 Redundant Brake Switch Sig
A 19U_D Or-1.0 Dome Lamp Fused Power
B 0_M Bk-1.0 Ground
0_MB Bk-0.8
B Dome Lamp Ground
0_MM Bk-0.8
C 0_MM Bk-0.8 Dome Lamp Ground CONNECTOR 87 - PARKING BRAKE SOLENOID
TO REAR CHASSIS HARNESS
291718A1
225389C1
222135A1
CAV WIRE IDENT CIRCUIT
CAV WIRE IDENT CIRCUIT
1 19R_C Or-1.0 Secondary Steering Ignition
A 33P Y-1.0 Low Brake Press Warning
2 51_A W-1.0 Secondary Steer Mtr Rel
B 0_N Bk-1.0 Brake Press Warning Switch
3 1_W R-1.0 Secondary Steer Module B+
4 0_CE Bk-1.0 Secondary Steer Chassis Grnd
CONNECTOR 89M - PILOT PRESSURE 5 None
SOLENOID TO CAB MAIN HARNESS 6 None
7 19M_C Or-1.0 Secondary Steer Accessory
8 35X_D Y-1.0 Secondary Steer Low Press Sig
9 51P_A W-1.0 Secondary Steer High Press
10 None
11 0_CA Bk-1.0 Secondary Steer Signal Grnd
12 0_CB Bk-1.0 Secondary Steer Signal Grnd
739070C1
291659A1
373356A1
CAV WIRE IDENT CIRCUIT
1 13C_A Or-1.0 Fuel Solenoid CAV WIRE IDENT CIRCUIT
3 61R-A Or-1.0 AC High Pressure Switch 2 61A Or-1.0 AC High Pressure Switch
7 31F_A Y-1.0 Air Filter Rest Switch Signal 6 36P P-1.0 EOP Sender
17 None 16 None
18 None 17 None
19 None 18 None
19 None
245781C1
291718A1
CAV WIRE IDENT CIRCUIT
CAV WIRE IDENT CIRCUIT
A None
1 25C W-0.8 Intermediate Speed Signal
B None
2 0_HG Bk-0.8 Intermediate Speed Signal
C None
D 31Y_B Y-0.8 Lamp Signal
CONNECTOR 96 - TURBINE SPEED SENSOR TO E 18L_D Bk-0.8 Lamp Ground
TRANSMISSION HARNESS
F None
291718A1
245480C1
291719A1
194788A1
291730A1
245426C1
291663A1
195552A1
195552A1
2 0_QB Bk-0.8 Right Speaker Ground 1 65L_A Or-0.8 Left Speaker Signal
8 None
9 65R_A Or-0.8 Right Speaker Signal
10 None
11 65L_A Or-0.8 Left Speaker Signal
12 None
13 None
14 65C_B Or-0.8 Radio Power
225351C1
291718A1
CAV WIRE IDENT CIRCUIT
382391A1
245485C1
245485C1
CAV WIRE IDENT CIRCUIT
CAV WIRE IDENT CIRCUIT
A 18G_C Or-1.0 License Plate Light
A 51P_B W-1.0 Secondary Steer High Pressure
B 35R_B Y-1.0 Backup Alarm Switch
B 0_AN Bk-1.0 Secondary Steer Signal Ground
C 0_J Bk-1.0 Hood Grounds
C 35X_A Y-1.0 Secondary Steer Low Press Sig
245484C1
194788A1
194788A1
245483C1
291718A1
245482C1
245483C1
225316C1
245482C1
225351C1
291718A1
CAV WIRE IDENT CIRCUIT
CAV WIRE IDENT CIRCUIT
1 19M_C Or-1.0 Secondary Steering Accessory
1 53S_B W-1.0 Float Solenoid Signal
2 19R_C Or-1.0 Secondary Steering Ignition
2 0_AP Bk-1.0 Float Solenoid Ground
3 35X_D Y-1.0 Sec Steer Low Pressure Signal
4 51P_A W-1.0 Sec Steer High Pressure
CONNECTOR 180F - FRONT CHASSIS HARNESS 5 0_CC Bk-1.0 Sec Steer Signal Ground
TO SECONDARY STEERING MODULE HARNESS
6 None
225350C1
3 35X_C Y-1.0 Sec Steer Low Pressure Signal CAV WIRE IDENT CIRCUIT
4 51P_B W-1.0 Sec Steer High Pressure 1 28C W-0.8 Ether Start Control
5 0_AN Bk-1.0 Sec Steer Signal Ground
6 None
245487C1 225351C1
B 25W LU-0.8 3rd and 4th Gear Signal 2 26F_A LU-0.8 FNR Forward Signal
C 25Z LU-0.8 1st and 4th Gear Signal 3 26N_A LU-0.8 FNR Neutral Signal
D 25Y LU-0.8 Transmission Kick Down Signal 4 26R_A LU-0.8 FNR Reverse Signal
5 32J_A Y-0.8 FNR LT Signal
6 None
CONNECTOR 197F - CAB MAIN HARNESS TO
FNR HARNESS
CONNECTOR 198 - FNR SWITCH TO FNR
HARNESS
225350C1
382391A1
8 0_DBB Bk-0.8 Ground
9 None
CAV WIRE IDENT CIRCUIT
1 None 10 31T Y-0.8 Grid Heater Temp Sndr Signal
19A_D Or-0.8
2 Trans Enable Switched Power
19A_E Or-0.8
CONNECTOR 202F - DIODE MODULE TO FRONT
3 26E LU-0.8 Trans Enable Signal
CHASSIS HARNESS
4 None
5 None
6 None
0_DAE Bk-1.0
7 Ground
0_DAP Bk-1.0
49_G S-0.8
8 Pilot Light
49_R S-1.0
32J_B Y-0.8
9 Trans Enable LT Signal
32J_C Y-0.8
245485C1
19A_C Or-0.8
10 None
19A_E Or-0.8 CAV WIRE IDENT CIRCUIT
A 58_D W-1.0 Ride Control Solenoid Power
B None
CONNECTOR 200 - RETURN-TO-DIG PROXIMITY
SWITCH TO RETURN-TO-DIG HARNESS FOR XT C 53S_C W-1.0 Float Switch Signal
CHASSIS
245484C1
245731C1
199436A1
382391A1
CAV WIRE IDENT CIRCUIT
CAV WIRE IDENT CIRCUIT 1 19R_E Or-0.8 Cab Switched Power
1 None
2 19P_B Or-1.0 Fan Rev Pin Engage Fused Pwr
CONNECTOR 217F - ENGINE SHUTDOWN
3 52_A W-0.8 Fan Reverse Solenoid
JUMPER
4 None
5 None
6 None
0_DAF Bk-1.0
7 Switch Ground
0_DAY Bk-1.0
49_H S-0.8
8 Pilot Light
49_U S-0.8
9 None
10 None
739070C1
CONNECTOR 215F - ALTERNATOR RESISTOR CAV WIRE IDENT CIRCUIT
TO CAB MAIN HARNESS
A 13K_D Or-0.8 Ignition Switch Power
199436A1
631801C1
245488C1 3227856R1
245485C1
245481C1
225316C1
CAV WIRE IDENT CIRCUIT
CAV WIRE IDENT CIRCUIT 1 61C_D Or-1.0 AC Compressor Clutch
1 51_C W-1.0 Sec Steer Solenoid Power
2 0_CF Bk-1.0 Secondary Steering Ground
CONNECTOR 269 - RADIO FUSE HOLDER
(REMOTE RADIO ADAPTER HARNESS)
CONNECTOR 265F - AIR CONDITIONING DIODE CAV WIRE IDENT CIRCUIT
MODULE TO AIR CONDITIONING DIODE
1 1_X R-1.0 Radio Memory Power
HARNESS
2 18_H Or-0.8 Radio Memory Fused Power
245484C1
245480C1
194788A1
245483C1
CAV WIRE IDENT CIRCUIT
CAV WIRE IDENT CIRCUIT
A 31D_C Y-0.8 Coolant Level Signal
A 58A_A W-1.0 Float Switch Signal
B 0_VA Y-0.8 Fuel Red Br Coolant Ground
B 58_F W-1.0 Ride Control Solenoid Power
245483C1
245482C1
245731C1
239451A1
CONNECTOR 287 - SECOND FUEL FILTER
CAV WIRE IDENT CIRCUIT
HEATER TO ENGINE HARNESS
1 1Y_E R-2.0 Fuel Filter Heater Power
2 1Y_D R-2.0 Fuel Filter Heater Power
3 31U_X W-1.0 Fuel Filter Heater Signal
4 13C_H Or-1.0 Fuel Filter Heater Signal Power
182069A1
3227856R1
182069A1
A 1Y_C R-2.0 Fuel Filter Heater Power CAV WIRE IDENT CIRCUIT
B 0_BC Bk-2.0 Fuel Solenoid Ground A 31U W-1.0 Fuel Filter Heater Signal
B 0_BM Bk-1.0 Signal Ground
256340A1
INDEX
Symbols Connector 118F.................................................... 123
12 Volt Radio ..........................................................76 Connector 125 ...................................................... 123
24 Volt Radio ..........................................................76 Connector 127 ...................................................... 123
Connector 128F.................................................... 124
A Connector 128M ...................................................124
A/C High Pressure Switch (In Rear Chassis) .........73 Connector 12F........................................................ 92
A/C Low Pressure Switch (In Cab) .........................73 Connector 12M....................................................... 92
Accessory Relay No. 3 ...........................................43 Connector 131F.................................................... 124
Air Filter Restriction Switch.....................................50 Connector 133M ...................................................124
Alarm Connector 136 ...................................................... 124
Back-up ..............................................................46 Connector 138 ...................................................... 125
Back-up, Disable Switch ....................................46 Connector 139F.................................................... 125
Back-up, Relay No. 7 .........................................45 Connector 139M ...................................................125
Alternator ................................................................37 Connector 13F........................................................ 93
Connector 13M....................................................... 94
B Connector 140M ...................................................125
Back-up Alarm ........................................................46 Connector 142 ...................................................... 125
Back-up Alarm Disable Switch ...............................46 Connector 154 ...................................................... 126
Back-up Alarm Relay No. 7 ....................................45 Connector 157 ...................................................... 126
Batteries .................................................................36 Connector 158 ...................................................... 126
Beacon Switch ........................................................78 Connector 159 ...................................................... 126
Beacon, Rotating ....................................................79 Connector 168 ...................................................... 126
Blower Motor ..........................................................73 Connector 178M ...................................................126
Blower Motor Speed Resistors with Thermal Fuse 73 Connector 179F.................................................... 127
Blower Switch .........................................................72 Connector 17M....................................................... 95
Brake Lamp Pressure Switch .................................79 Connector 180F.................................................... 127
Brake Lamps Relay No. 6.......................................79 Connector 180M ...................................................127
Brake Warning Pressure Switch .............................48 Connector 182 ...................................................... 127
Bucket Control Valve Electromagnet Detents ........59 Connector 183 ...................................................... 128
Bulb Connector 197F.................................................... 128
See Lamp ...........................................................79 Connector 197M ...................................................128
Connector 198 ...................................................... 128
C Connector 199F.................................................... 129
Cigar Lighter ...........................................................75 Connector 19F........................................................ 98
Cluster, Instrument .....................................51, 52, 53 Connector 1F..........................................................90
Compressor Clutch .................................................74 Connector 2 ............................................................91
Compressor Clutch Lockout Relay No. 14 .............74 Connector 200 ...................................................... 129
Compressor, Seat...................................................72 Connector 201 ...................................................... 129
Connector 1 ............................................................90 Connector 202F.................................................... 129
Connector 10 ..........................................................92 Connector 203F.................................................... 130
Connector 100 ......................................................120 Connector 204F.................................................... 130
Connector 101 ......................................................120 Connector 207F.................................................... 130
Connector 102 ......................................................120 Connector 208F.................................................... 130
Connector 104 ......................................................121 Connector 209F.................................................... 130
Connector 107M ...................................................121 Connector 209M ...................................................130
Connector 108F....................................................121 Connector 20M....................................................... 98
Connector 109M ...................................................121 Connector 210F.................................................... 131
Connector 110F....................................................121 Connector 215F.................................................... 131
Connector 111M ...................................................122 Connector 216F.................................................... 131
Connector 112M ...................................................122 Connector 217F.................................................... 131
Connector 113 ......................................................122 Connector 217M ...................................................131
Connector 114F....................................................122 Connector 21F........................................................ 99
Connector 114M ...................................................122 Connector 21M....................................................... 99
Connector 117 ......................................................123 Connector 229M ...................................................132
Connector 22F...................................................... 100
Bur 6-48930 Issued 2-03 Printed in U.S.A.
Copyright
4002-138
Connector 22M .....................................................100 Connector 51F...................................................... 108
Connector 23F......................................................101 Connector 53F...................................................... 108
Connector 23M .....................................................101 Connector 54F...................................................... 108
Connector 246M ...................................................132 Connector 55F...................................................... 109
Connector 24F......................................................101 Connector 56F...................................................... 109
Connector 24M .....................................................101 Connector 57F...................................................... 109
Connector 253F....................................................132 Connector 58F...................................................... 109
Connector 259F....................................................132 Connector 59F...................................................... 110
Connector 25F......................................................102 Connector 5F.......................................................... 91
Connector 260M ...................................................132 Connector 6 ............................................................ 91
Connector 262F....................................................132 Connector 60........................................................ 110
Connector 264M ...................................................133 Connector 61........................................................ 110
Connector 265F....................................................133 Connector 62M..................................................... 110
Connector 266M ...................................................133 Connector 63M..................................................... 111
Connector 267F....................................................133 Connector 64F...................................................... 111
Connector 269 ......................................................133 Connector 64M..................................................... 111
Connector 270F....................................................133 Connector 66........................................................ 111
Connector 271M ...................................................133 Connector 67........................................................ 111
Connector 272F....................................................134 Connector 68........................................................ 112
Connector 273F....................................................134 Connector 69........................................................ 112
Connector 274F....................................................134 Connector 70........................................................ 112
Connector 275M ...................................................134 Connector 71........................................................ 112
Connector 276F....................................................134 Connector 72........................................................ 113
Connector 276M ...................................................134 Connector 74........................................................ 113
Connector 277F....................................................135 Connector 75........................................................ 114
Connector 277M ...................................................135 Connector 76........................................................ 114
Connector 279M ...................................................135 Connector 77F...................................................... 115
Connector 27M .....................................................102 Connector 78F...................................................... 115
Connector 280 ......................................................135 Connector 79F...................................................... 115
Connector 287 ......................................................136 Connector 8 ............................................................ 92
Connector 288 ......................................................136 Connector 80F...................................................... 115
Connector 289 ......................................................136 Connector 81M..................................................... 115
Connector 28M .....................................................102 Connector 82M..................................................... 115
Connector 290 ......................................................136 Connector 83F...................................................... 116
Connector 291 ......................................................136 Connector 84F...................................................... 116
Connector 29M .....................................................102 Connector 85F...................................................... 116
Connector 3 ............................................................91 Connector 86........................................................ 116
Connector 30F......................................................102 Connector 87........................................................ 116
Connector 31 ........................................................103 Connector 88........................................................ 117
Connector 32F......................................................103 Connector 89M..................................................... 117
Connector 33F......................................................103 Connector 90M..................................................... 117
Connector 34F......................................................103 Connector 92........................................................ 117
Connector 35F......................................................104 Connector 94F...................................................... 118
Connector 36F......................................................104 Connector 94M..................................................... 118
Connector 37 ........................................................104 Connector 95........................................................ 119
Connector 38F......................................................105 Connector 96........................................................ 119
Connector 39F......................................................105 Connector 97........................................................ 119
Connector 4 ............................................................91 Connector 98........................................................ 119
Connector 40F......................................................105 Connector 99........................................................ 120
Connector 41F......................................................106 Connector, Diagnostic ............................................ 45
Connector 42F......................................................106 Controller
Connector 44F......................................................106 Grid Heater ........................................................ 40
Connector 45F......................................................107 Converter, Radio Power (24 volts to 12 volts)........ 77
Connector 47F......................................................107 Coolant Level Sender .............................................48
Connector 48F......................................................107 Courtesy Lamp ....................................................... 89
Connector 49F......................................................107
Connector 50F......................................................108
T
Temperature Sensor
Grid Heater.........................................................40
Thermal Fuse
Blower Motor ......................................................73
Thermostat .............................................................74
Thermostat Switch ..................................................74
Time Delay Module.................................................43
Torque Converter Output Temperature Sender .....45
Transmission Auto Switch ......................................45
Transmission Electronic Control Module ................45
Transmission Enable Switch ..................................45
Transmission Kick-down Switch .............................45
Transmission Shifter ...............................................45
Transmission Solenoid Valve and Temperature
Sensors .....................................................45
Turbine Speed Sensor............................................45
Turn Signal Switch..................................................80
Section
4003
4003
BATTERIES
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright 2001 Case Corporation
3350 South Service Road Printed in U.S.A.
Burlington, ON L7N 3M6 CANADA Bur 6-42330 August, 2001
Copyright
4003-2
TABLE OF CONTENTS
SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Electrolyte Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspecting and Cleaning a Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
BATTERY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Visual Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Specific Gravity Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Capacity (Load) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CHARGING A BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CHARGING GUIDE FOR MAINTENANCE FREE BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
PREPARING A DRY CHARGED BATTERY FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CHARGING GUIDE FOR BATTERIES OTHER THAN
MAINTENANCE FREE BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SAFETY RULES
Never try to charge the battery if the electrolyte in the Battery acid causes severe burns. Batteries contain
! battery is frozen. sulfuric acid. Avoid contact with skin, eyes, or clothing.
47-83A Antidote: EXTERNAL-Flush with water. INTERNAL-
Drink large quantities of water or milk. Follow with milk
of magnesia, beaten egg, or vegetable oil. Call physi-
Never cause sparks to occur or smoke near batteries
cian immediately. Eyes: Flush with water for 15 min-
! that are charging or have been recently charged.
13-8A
utes and get prompt medical attention.
! Batteries produce explosive gases. Keep sparks,
Disconnect the ground cable first when the battery flame, and cigarettes away. Ventilate when charging or
cables are disconnected from the battery. using in enclosed area. Always shield eyes when work-
ing near batteries.
! Connect the ground cable last when the battery cables
are connected to the battery. Keep out of reach of children.
47-55A
D-47-53A
SPECIAL TOOLS
B795328M
MAINTENANCE
If the battery is a maintenance free battery, check Inspecting and Cleaning a Battery
the level of the electrolyte every 1000 hours of
operation or six months, whichever occurs first. For If damage causes an electrolyte leak, replace the
all other batteries, check the level of the electrolyte battery.
every 250 hours of operation.
Inspect the battery at regular intervals for dirt,
NOTE: Before checking the electrolyte level in the corrosion, and damage. Electrolyte and dirt on the
battery, the battery must have been idle for at least top of the battery can cause the battery to discharge
16 hours. During charging the level of the liquid may by making a passage for the current to flow.
raise.
If the battery must be cleaned, remove the battery
Check the level of the electrolyte more often from the battery carrier and clean the battery, cable
during hot weather. The use of a large amount of terminals, and the battery carrier. When available,
water by the battery can be caused by high battery use Case Battery Saver and Cleaner according to
temperature or a voltage regulator setting that is too the instructions on the container. Case Battery Saver
high. Keep the electrolyte level above the top of the and Cleaner also helps prevent corrosion. If Case
plates in the battery at all times to prevent damage to Battery Saver and Cleaner is not available, use
the battery. baking soda and water as a cleaner. DO NOT permit
any type of cleaner to enter the cells of the battery.
If the level of the electrolyte is low, add distilled
water or other clean water until the electrolyte is just Install the battery in the machine and make sure
below the cell well bottom, approximztely 5 mm (3/16 the fasteners are tight. Apply Case Battery Saver and
inch).Do not add more water than is needed. Too Cleaner or Urethane Seal Coat to the cable terminals
much water can cause bad performance, a short to prevent corrosion. See the Parts Counter Catalog.
service life, and corrosion around the battery. DO NOT apply grease.
BATTERY TEST
NOTE: To correctly test a battery, do each part of the
battery test until you know the condition of the 1 2
battery.
Visual Checks
1. Make sure the cable connections are clean and
tight. Clean foreign material from the top of the
battery.
2. Inspect the battery case, battery posts, and
cables for damage.
3. Check the electrolyte level. See page 4003-4.
4. If you added water to the battery, the battery
must be charged for 15 minutes at 15 to 25
amperes to mix the water with the electrolyte.
B. Make sure the load control knob is in the OFF 8. Compare the test reading and the temperature of
position. the electrolyte to the chart below.
TEMPERATURE OF MINIMUM
C. Select the ammeter range that will measure 0
ELECTROLYTE VOLTAGE
to 1000 amperes.
21C (70F) and above . . . . . . . . . . . . . . . . . . . . . 9.6
D. Move the volt lead switch to the INT. position. 16C (60F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
3. Connect the tester to the battery as shown. 10C (50F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
4C (40F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
-1C (30F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
2 -7C (20F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9
-12C (10F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.7
-18C (0F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
A. If the test result is equal to or more than the
voltage shown, the battery is in good
condition.
1 B. If the test result is less than the voltage
shown, discard the battery.
B790499J
CHARGING A BATTERY
Before you charge the battery, check the level of 1. Too much gas causes the electrolyte to flow from
the electrolyte. the cells.
It is difficult to give an e xa ct cha rgin g rate 2. The temperature of the electrolyte rises above
because of the following variable conditions: (1) 52C (125 F).
temperature of the electrolyte, (2) level of charge,
NOTE: For the best charge, use the slow charging
and (3) condition of the battery. Use the charging
rates.
guide for the correct charging rate and time.
The battery is fully charged when, over a three
Se e Sp ecifica tio ns in Se ctio n 4 002 for th e
hour period at a low charging rate, no cell is giving
reserve capacity of the battery in this machine.
too much gas, and the specific gravity does not
The charging rate must be decreased if: change.
NOTE: A maintenance free battery will have the words Maintenance Free on the decal on the top of the battery. If
the center part of the decal has been removed to get access to the battery caps, it is possible the words
Maintenance Free will have been removed from the decal.
6 Hours at 40 Amperes
Above 250 Minutes 24 Hours at 10 Amperes
4 Hours at 60 Amperes
Section
4005
4005
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright 2001 Case Corporation
3350 South Service Road Printed in U.S.A.
Burlington, ON L7N 3M6 CANADA Bur 6-42351 August, 2001 (Revised November, 2001)
Copyright
4005-2
TABLE OF CONTENTS
INFORMATION AND DIAGNOSTIC CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Self-Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Power Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Indicators and Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Stop Master Indicator (Red) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Caution Master Indicator (Yellow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Beacon Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Work Light Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pilot Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Low Coolant Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Brake Pressure Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Secondary Steering Indicator (If equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Parking Brake Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Air Conditioning Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Air Filter Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Hydraulic Oil Filter Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Transmission Oil Filter Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Transmission Oil Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Hydraulic Oil Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Voltmeter Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fuel Level Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Engine Oil Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Engine Coolant Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Service Indicator Icon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
WARNING DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Critical Warning Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Non-Critical Warning Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6 7 8
5 9 10
4 11
3 12
2 13
1
20
14
19
15
18 16
17
RD98K316
1. BEACON INDICATOR 11. HYDRAULIC OIL FILTER INDICATOR
2. WORK LIGHT INDICATOR 12. AIR FILTER INDICATOR
3. PILOT CONTROL INDICATOR 13. TRANSMISSION OIL FILTER INDICATOR
4. LOW COOLANT INDICATOR 14. TRANSMISSION OIL TEMPERATURE GAUGE
5. BRAKE PRESSURE INDICATOR 15. HYDRAULIC OIL TEMPERATURE GAUGE
6. STOP MASTER INDICATOR 16. VOLTMETER GAUGE
7. CAUTION MASTER INDICATOR 17. FUEL LEVEL GAUGE
8. SECONDARY STEERING INDICATOR 18. ENGINE OIL PRESSURE
9. PARKING BRAKE INDICATOR 19. ENGINE COOLANT TEMPERATURE GAUGE
10. AIR-CONDITIONING INDICATOR 20. SERVICE INDICATOR ICON
Self-Test
IMPORTANT: During operation, if the stop master 3. All LEDs (Light Emitting Diodes) will illuminate
indicator (on the front console) flashes, and the for 2 - 3 seconds.
warning alarm is continuous, stop the machine, stop
4. Six bar graphs will energize for 2 - 3 seconds.
the engine, and find the problem.
5. The warning alarm will sound for 2 - 3 seconds.
1. Turn the ignition (key) switch to the ON position.
6. If there is an open circuit between a sensor and
2. The information center will automatically check
the information center, the LED will flash and the
each monitored system.
warning alarm will sound for 5 seconds.
8. If only some of the LEDs illuminate, replace the 1. The warning alarm sounds for three seconds.
information center. 2. The indicator turns yellow and one or more of the
9. If the LEDs illuminate, but the warning alarm following conditions exist:
does not sound, replace the information center. A. Parking brake engaged when shifting into
forward or reverse.
10. If the warning alarm sounds but the LEDs do not
illuminate, replace the information center. B. High engine coolant temperature.
11. If the warning alarm does not sound and the C. High hydraulic oil temperature.
LEDs do not illuminate on the information center, D. High transmission oil temperature.
do the following steps to test the power circuit: E. High or low air conditioning pressure.
F. Air filter restriction.
Power Circuit Test
G. Transmission filter restriction.
A. Check the 7.5 amp fuse V. If the fuse is bad,
replace the fuse and repeat Self-Test steps 1 H. Hydraulic filter restriction.
through 7. If the fuse is good, do the next step. I. Alternator malfunction.
B. Check wire 19V for continuity. Repair/replace J. Low fuel.
the wire as required. If continuity is found do
the next step. Beacon Indicator
C. Check wire 13V for continuity. Repair/replace The beacon indicator illuminates when the Beacon (if
the wire as required. If continuity is found, do equipped) is in the ON position.
the next step.
Work Light Indicator
D. Check the voltmeter relay #12 for proper
operation, see Section 4002. If voltmeter The work light indicator illuminates when the work
operates properly, do the next step. lights are ON.
When the stop master indicator illuminates: 2. The stop master indicator will be red.
1. Stop the machine immediately. 3. Stop the engine and add coolant to the radiator.
2. The stop master indicator will be red. Indicates normal operating temperature, 20 to 120
C (68 to 248 F).
3. Stop the engine and correct the problem.
Yellow Zone:
Parking Brake Indicator
1. Transmission oil temperature is too low, 20 C or
The parking brake indicator illuminates when the below (68 F or below), or it has increased, 120
parking brake is applied. If the transmission is shifted to 125 C (248 to 257 F).
into FORWARD or REVERSE when the parking
brake is applied: 2. The indicator bars flash.
1. The warning alarm sounds for 3 seconds. 3. The warning alarm sounds for 3 seconds.
2. The caution master indicator turns yellow. 4. The yellow caution master indicator turns on.
The transmission oil filter indicator illuminates when 1. Hydraulic oil temperature has decreased, 20 C
the transmission filter(s) are restricted. or below (68 F or below), or it has increased
105 to 110 C (221 to 230 F).
1. The warning alarm sounds for 3 seconds.
2. The indicator bars flash.
2. The caution master indicator turns yellow.
Bur 6-42351 Revised 11-01 Printed in U.S.A.
Copyright
4005-8
3. The warning alarm sounds for 3 seconds. 2. The warning alarm sounds for 3 seconds.
4. The yellow caution master indicator turns on. 3. The yellow caution master indicator turns on.
Red Zone: Engine Oil Pressure Gauge
NOTE: The machine must not be operated when the The engine oil pressure gauge is shown as an
temperature is in the red zone. indicator bar with a green or red zone.
1. Hydraulic oil temperature continues to increase Green Zone:
110 C and above (230 F and above).
Indicates normal operating pressure, 110 kPa (16
2. The indicator bar flashes. psi) and over.
3. The warning alarm sounds continuously. Red Zone:
4. The red stop master indicator turns on. NOTE: The machine must not be operated when the
5. Stop the machine and correct the problem. oil pressure is in the red zone.
1. Engine oil pressure decreased to less than 70
Voltmeter Gauge
kPa (less than 10 psi).
The voltmeter gauge is shown as an indicator bar
2. The indicator bar flashes.
with a green or yellow zone.
3. The warning alarm sounds continuously.
Green Zone:
4. The red stop master indicator turns on.
Indicates normal operating range:
5. Stop the machine and correct the problem.
A. 26 to 32 volts above low idle = normal
operating range. Engine Coolant Temperature
B. 18 to 24 volts stopped or at low idle = low to The engine coolant temperature gauge is shown as
normal battery charge. an indicator bar with a green, yellow, or red zone.
C. 18 to 24 volts at above low idle = problem in Green Zone:
charging system.
Indicates normal operating temperature, 20 to 105
Yellow Zone: C (68 to 221 F).
Voltage has increased or decreased: Yellow Zone:
A. 0 to 18 volts stopped or at low idle = very low 1. Engine coolant temperature has decreased 20
battery charge. C or below (68 or below), or increased 105 to
B. 32 volts and above = problem in charging 110 C (221 to 230 F).
system (overcharging). 2. The indicator bars flash.
1. The indicator bars flash. 3. The warning alarm sounds for 3 seconds.
2. The warning alarm sounds for 3 seconds. 4. The yellow caution master indicator turns on.
4. Stop the machine and correct the problem. NOTE: The machine must not be operated when the
temperature is in the red zone.
Fuel Level Gauge
1. Engine coolant temperature continues to
The fuel level gauge is shown as an indicator bar increase, 110 C or above (230 F or above).
with a green or yellow zone.
Green Zone:
Indicates normal operating range, 5 percent and
above.
Yellow Zone:
The tank is almost empty, 5 percent and below.
1. The indicator bars flash.
WARNING DISPLAYS
2
4
1
RD98K316
1. DIRECTION (F-N-R) 4. REQUESTED GEAR (1, 2, 3, 4)
2. TRANSMISSION DISPLAY 5. ACTUAL GEAR BARS
3. DISPLAY CENTER 6. TRANSMISSION MODE (A OR BLANK)
Requested Gear
Th e gea r positio n on sh ift lever, sh own in the
center of the gear symbol:
1 1st gear
2 2nd gear
3 3rd gear
4 4th gear
Actual Gear
Shown with bars to the right of the gear symbol. The
number of bars indicates the gear the transmission is
actually in.
Transmission Mode (Automatic or
Manual)
Shown in the lower left of the display center:
A Automatic Mode
No symbol will be displayed when
transmission is in Manual Mode.
3 4 5 6
2
1
RD98K316
1. INFORMATION CENTER 3. UP COUNT 5. PROGRAM
2. DISPLAY CENTER 4. DOWN COUNT 6. RESET
NOTE: The machine must be OFF prior to 3. Press the program/reset switch to program.
programming the information center. 4. Press the up/down count switch to up count
Two switches are used during the programming of program location 010.
the information center: the up/down count switch and 5. Center the program/reset switch to OFF.
th e program/reset switch. The se sw itch es are
located on the right hand side of the information 6. Note the gauge display setting that is displayed,
center, refer to Figure 3. 01, 02, 03, 04, or 05. If the desired setting has
already been selected go to step 7.
For an up count press the left side of the up/down
count switch. For a down count press the right side of 7. Press the up/down count switch to up count to
the up/down count switch. The center position is OFF choose one of the following gauge disp lay
or NEUTRAL. settings:
1. Press the up count switch one time to display the NOTE: The Transmission Control Module will
Tachometer. disconnect the transmission if any gear other than
3rd is used.
2. Press the up count switch again to display the
Speedometer (km/h). 1. Turn the machine ON.
3. Press the up count switch again to display the 2. Make sure the transmission is in the manual shift
Hourmeter. mode, the gear selector is in 3rd neutral gear,
and the park brake switch is ON.
Automatically Scrolling Gauge Displays
3. Set the park brake calibration as follows:
(03 or 04)
A. Press the program/reset switch to program.
If the Information Center has been programmed with
one of the automatic scrolling displays the gauge B. Press the up/down count switch to up count
display will automatically scroll through after starting until the display reads 011.
the machine. The up/down count switch has no effect C. Put the program/reset switch in the OFF
on the display. (center) position.
07 Low engine RPM. 5. The Information Center will display 00 and sound
the alarm, when the machine is being checked,
08 High engine RPM. while all systems are normal. If there is a fault in
the system that would cause the alarm to sound,
Setting Display Center Lighting the Information Center will display 01 while the
alarm is being checked. The alarm will sound
Do the following procedures to set the brightness intermittently.
of the display lighting:
Coolant Level Check
1. Press the program/reset switch to program.
Do the following procedures to check the coolant
2. Press the up/down count switch to up count until
level indicator light and the coolant level switch.
the display reads 012 (for working lights OFF) or
013 (for working lights ON). 1. Press the program/reset switch to program.
3. Place the program/reset switch in the OFF 2. Press the up/down count switch to up count until
(center) position. the display reads 016.
4. Increase the brightness by pressing the up/down 3. The coolant light will flash intermittently.
count switch to the up count position.
4. Place the program/reset switch in the OFF
5. Decrease the brightness by pressing the (center) position.
up/down count switch to the down count position.
5. The Information Center will display 00, when the
NOTE: The brightness can be varied between 001 machine is being checked, if the coolant level is
and 100, with 100 being the brightest. The factory set normal. If the coolant level is low, the Information
brightness is 070 for working lights OFF and 020 for Center will display 01 while the coolant level
working lights ON. switch is being checked. The coolant light will
flash intermittently on the Information Center.
6. Press the program/reset switch to reset
(m o m e n ta r ily, 0 . 2 5 s e c o n d s) to e n te r t h e
selected brightness setting. Brake Pressure
Do the following procedures to check the brake
Voltmeter at Key ON Position pressure indicator light and the brake pressure
switch.
Do the following procedures to read the system
voltage at the key ON position. 1. Press the program/reset switch to program.
1. Press the program/reset switch to program. 2. Press the up/down count switch to up count until
the display reads 017. The brake pressure light
2. Press the up/down count switch to up count until
will flash intermittently.
the display reads 014.
3. Place the program/reset switch in the OFF
3. Place the program/reset switch in the OFF
(center) position.
(center) position.
4. The Information Center will display 01, when the
4. The system voltage is displayed at the key ON
machine is being checked, if the brake pressure
position.
is normal. If the brake pressure is low, the
5. Press the program/reset switch to reset to exit Information Center will display 00 while the brake
the monitoring mode. pressure switch is being checked. The brake
pressure light will flash intermittently on the
Alarm Check Information Center.
4. The Information Center will display 00, when the 2. Press the up/down count switch to up count until
Information Center is not activating the park the display reads 022. The air filter restriction
brake relay. The Information Center will display indicator light will flash intermittently.
01 when it is activating the park brake relay. The 3. Place the program/reset switch in the OFF
park brake light will flash intermittently on the (center) position.
Information Center.
4. The Information Center will display 01, when the
Pilot Lockout Information Output Check ma ch in e is b e ing ch ec ke d , if th e a ir filte r
restriction switch is not activated. If the air filter
Do the following procedures to check the pilot lockout restriction switch is activated, the Information
indicator light and the status of the signal that the C e n te r w il l d i s p la y 0 0 w h ile th e a ir f i lt e r
Information Center is sending to the pilot lockout restriction switch is being checked. The air filter
relay (to engage or disengage). restriction indicator light will flash intermittently
1. Press the program/reset switch to program. on the Information Center.
2. Press the up/down count switch to up count until Work Lights Check
the display reads 020. The pilot lockout light will
flash intermittently. Do the following procedures to check the work lights
indicator light and the work light electrical signal
3. Place the program/reset switch in the OFF coming into the Information Center.
(center) position.
1. Press the program/reset switch to program.
Bur 6-42351 Revised 11-01 Printed in U.S.A.
Copyright
4005-19
2. Press the up/down count switch to up count until 4. The Information Center will display 00, when the
the display reads 023. The work lights indicator machine is being checked, if the transmission
light will flash intermittently. filter restriction switch is not activated. If the
transmission filter restriction switch is activated,
3. Place the program/reset switch in the OFF
the Information Center will display 01 while the
(center) position.
transmission filter restriction switch is being
4. The Information Center will display 00 when the checked. The transmission filter restriction
work lights are OFF and 01 when the work lights indicator light will flash intermittently on the
are ON. The work lights ind icator lig ht will Information Center.
continue to flash intermittently and the numbers
on the display will change in accordance with the High Beam Check
status of the work lights. Do the following procedures to check the high beam
indicator light and the high beam switch.
Air Conditioning Switch Check
1. Press the program/reset switch to program.
Do th e fo llow in g p ro c ed u r es to ch e ck th e a ir
2. Press the up/down count switch to up count until
conditioning indicator light and the air conditioning
the display reads 027. The high beam indicator
high/low pressure switch.
light will flash intermittently.
1. Press the program/reset switch to program.
3. Place the program/reset switch in the OFF
2. Press the up/down count switch to up count until (center) position.
the display reads 025. The a ir con ditioning
4. The Information Center will display 00 when the
indicator light will flash intermittently.
high beam lights are OFF and 01 when the high
3. Place the program/reset switch in the OFF beam lights are ON. The high beam indicator
(center) position. light will continue to flash intermittently and the
numbers on the display w ill change in
4. The Information Center will display 00, when the
accordance with the status of the high beam
machine is being checked, if the air conditioning
lights.
high/low pressure switch is not activated. If the
air conditioning high/low pressure switch is
activated, the Information Center will display 01 Requested Gear Check
while the air conditioning high/low pressure Do the following procedures to check that the gear
switch is being checked. The air conditioning being requested by the shifter is the same gear that
indicator light will flash intermittently on the the Information Center is reading.
Information Center.
1. Press the program/reset switch to program.
Transmission Filter Restriction Switch 2. Press the up/down count switch to up count until
Check the display reads 028. The F, N or R indicator in
the transmission display will flash intermittently.
Do the follow ing procedures to check the
transmission filter restriction indicator light and the 3. Place the program/reset switch in the OFF
transmission filter restriction switch. (center) position.
1. Press the program/reset switch to program. 4. Place the gear shifter in all positions and verify
that the code in each position corresponds to the
2. Press the up/down count switch to up count until
codes in the table below
the display reads 026. The transmission filter :
3. Place the program/reset switch in the OFF 7. The Information Center will read 001 while the
(center) position. shift is being made.
4. The Information Center will read 00. 8. The Information Center will read 000 if the
transmission does not engage the drive line or
Actual Gear Check 010 if the transmission does engage the drive
line; 010 also indicates the transmission is in
Do the following procedures to check that the gear Normal Mode.
engaged in the transmission is the same gear that
the Information Center is reading. 9. The Information Center will read 110 if the
transmission is in Substitute Clutch Control
1. With the engine running put the transmission in Mode.
manual mode and release the parking brake.
10. The Information Center will read 210 if the
2. Press the program/reset switch to program. transmission is in Limp Home Mode.
3. Press the up/down count switch to up count until 11. The Information Center will read 300 if the
the display reads 030. The bars that outline the transmission is in Shutdown Mode.
large gear in the transmission display will flash
intermittently. 12. The Information Center will read 400 if the
transmission is in TECM Shutdown Mode.
4. Place the program/reset switch in the OFF
(center) position. Hourmeter Indicator Status
5. Place the gear selector in all positions and verify Do the following procedures to check the status of
that the code in each position corresponds to the the hourmeter indicator.
codes in the table below.
: 1. Press the program/reset switch to program.
Forward 1- Neutral 1- Reverse 1- 2. Press the up/down count switch to up count until
Code 101 Code 201 Code 301 the display reads 032. The hourmeter indicator
Forward 2- Neutral 2- Reverse 2- flashes intermittently.
Code 102 Code 202 Code 302 3. Place the program/reset switch in the OFF
Forward 3- Neutral 3- Reverse 3- (center) position.
Code 103 Code 203 Code 303 4. The Information Center will read 00.
Forward 4- Neutral 4-
Code 104 Code 204 Tachometer Indicator Status
Limp Home Limp Home Limp Home Do the following procedures to check the status of
Mode - 115 Mode - 215 Mode - 315 the tachometer indicator.
1. Press the program/reset switch to program.
Drive Line Shift Status 2. Press the up/down count switch to up count until
Do the following procedures to check the drive line the display reads 033. The tachometer indicator
shift status. flashes intermittently.
1. With the engine running, release the parking 3. Place the program/reset switch in the OFF
brake. (center) position.
2. Press the program/reset switch to program. 4. The Information Center will read 00.
1. Press the program/reset switch to program. 5. Press the program/reset switch to reset. If there
are diagnostic codes in field number locations
2. Press the up/down count switch to up count until 071 through 090 they will be removed, unless the
the display reads 051. condition still exists.
3. Place the program/reset switch in the OFF
(center) position.
4. Read the number (2, 3, or 4) shown on the
Information Center. If this is the desired gear
selection, press the program/reset switch to
either program or reset.
Do the following to display the second part of the 1. Press the program/reset switch to program.
transmission ECM ZF part number. 2. Press the up/down count switch to up count until
1. Press the program/reset switch to program. the display reads 096.
2. Press the up/down count switch to up count until 3. Place the program/reset switch in the OFF
the display reads 092. (center) position.
3. Place the program/reset switch in the OFF 4. The Information Centers internal temperature
(center) position. will be displayed in degrees Celsius.
4. The Information Center will display the second Display Location Number 097 Reserved
part of the ZF Transmission ECM part number
for Future Use
(#####, # is a digit from 0 to 9).
Information Center Software Revision Entry Code for Accessing Test Mode
Number Locations 100 to 199
Do the following to access test mode locations 100 to
Do the following to display the Information Center
199.
software revision number.
1. Press the program/reset switch to program.
1. Press the program/reset switch to program.
2. Press the up/down count switch to down count
2. Press the up/down count switch to up count until
until the display reads 098.
the display reads 093.
3. Place the program/reset switch in the OFF
3. Place the program/reset switch in the OFF
(center) position.
(center) position.
4. Press the up/down count switch to up count until
4. The Information Center will display the software
the display reads 21.
revision number.
5. Press the program/reset switch to program.
LED Duty Cycle 6. Press the up/down count switch one time so that
Do the following to display the LED duty cycle. the display reads 099.
4. Place the program/reset switch in the OFF 21. Place the program/reset switch in the OFF
(center) position. (center) position. When the TECM has been
reprogrammed, 110 will be displayed. If 110 is
5. Use the up/down count switch to change the not displayed, press program/reset switch to
display to read 001. This allows changes to reset and turn ignition switch OFF. Wait 15
locations 100 and 101. seconds and repeat procedure (from Step 1) until
6. Press the program/reset switch to program. 110 is displayed. If 110 is displayed continue with
Step 22.
7. Press the up/down count switch to down count
until the display reads 101. 22. Press the reset button momentarily.
8. Place the program/reset switch in the OFF 23. Turn off and restart the machine.
(center) position.
Display Location Numbers 104 - 113
9. Use the up/down count switch to change the
vehicle identification number: if a 521D machine Reserved for Future Use
enter 52101; if a 621D machine enter 62101.
Instrument Cluster (Information Center)
10. Place the program/reset switch in the OFF
Part Number (1st part)
(center) position.
D o th e fo llo win g t o e nt er t he firs t p a r t o f th e
11. Press the up/down count switch to down count
instrument cluster (Information Center) part number.
until the display reads 100.
1. Press the program/reset switch to program.
12. Place the program/reset switch in the OFF
(center) position. 2. Press the up/down count switch to down count
until the display reads 114. The service indicator
13. Use the up/down count switch to change the
flashes intermittently.
vehicle identification number: if a 521D machine
enter 52101; if a 621D machine enter 62101. 3. Place the program/reset switch in the OFF
(center) position.
14. Press the program/reset switch to program.
4. Use the up/down count switch to enter the first
15. Press the up/down count switch to up count until
part of the instrument cluster part number from
the display reads 102.
the parts catalog.
Bur 6-42351 Revised 11-01 Printed in U.S.A.
Copyright
4005-27
Instrument Cluster (Information Center) 1. If your tire and calibration number are listed in
Part Number (2nd part) the table below go to step 3. Do the following to
calculate a calibration number:
Do the following to enter the second part of the
instrument cluster (Information Center) part number. A. Obtain the tire revolution/km (obtainable from
most manufacturers).
1. Press the program/reset switch to program.
B. If the tire revolution/km is not available,
2. Press the up/down count switch to down count measure the distance the tire travels (in
until the display reads 115. The service indicator meters) in 10 revolutions. Divide that number
flashes intermittently. into 1000. Multiply the answer by 10. This is
3. Place the program/reset switch in the OFF how many revolutions your tire makes in a km.
(center) position. 2. Multiply the tire revolution/km by the axle ratio.
4. Use the up/down count switch to enter the Th e a n sw e r will b e t he n ew sp e ed o me te r
sec ond pa rt o f th e ins trume nt cluste r p art calibration number.
number from the parts catalog.
CALIBRATION NUMBER
NOTE: The part number may contain the letter A
followed by a number, to show revision level. Using
the up/down count switch, enter the A as 0 (zero)
followed by the number, (A1 = 01, A2 = 02).
TIRE REV/KM
MACHINE/TIRE
AXLE RATIO
Instrument Cluster (Information Center)
Date Code
Do the following to display the instrument cluster
date code.
521D w/15.5 x 25 L2, L3, 19.20 260 4992
1. Press the program/reset switch to program. XTLA, XHA
2. Press the up/down count switch to down count 521D w/17.5 x 25 L2, L3,
until the display reads 116. The service indicator 19.20 246 4723
XTLA, XHA
flashes intermittently.
621D w/17.5 x 25 L2, L3,
3. Place the program/reset switch in the OFF 20.36 246 5009
XTLA, XHA or 20.5 x 25
(center) position.
XLD 70
4. The Information center will display the date code.
621D w/20.5 x 25 L2, L3,
Read the date code as follows: the first two 20.36 222 4520
XTLA, XHA
numbers = year, next three numbers = day.
3. Press the program/reset switch to program.
Display Location Numbers 117 - 120
Reserved for Supplier Information 4. Press the up/down count switch to up count until
the display reads 130.
Display Location Numbers 121 -129 5. Place the program/reset switch in the OFF
Reserved for Future Use (center) position.
6. Use the up/down count switch to enter the
Speedometer Calibration calibration number from the table.
Do the following to reset the speed ometer
calibration.
NOTE: If a dealer or customer changes tire sizes,
the speedometer calibration will have to be changed
to match the Information Center and transmission
ECM to the new tire size.
NOTE: A calibration number is required to perform
this function.
DISPLAY
LOCATION DEFINITION STATUS
NUMBER
000 Engine Hours
001 Engine Tachometer
002 Speedometer in Miles Per Hour
003 Speedometer in Kilometers Per Hour
004 Engine Coolant Temperature in Degrees Celsius
005 Engine Oil Pressure in Kilopascals
006 Fuel Level in Percent of Fuel in Tank
007 Transmission Oil Temperature in Degrees Celsius
008 Hydraulic Oil Temperature in Degrees Celsius
009 Voltmeter Reading (Continuous)
010 Gauge Display Selection
011 Parking Brake Test / Clutch Calibration
012 Information Center Light Setting - Work Lights Off
013 Information Center Light Setting - Work Lights On
014 Voltmeter Reading at Key-on
015 Alarm Status 00 = Off, 01 = On
00 = Normal Level
016 Coolant Level Status
01 = Low Level
00 = Switch Closed
017 Brake Pressure Switch Status 01 = Switch Opened
(Open = Normal Pressure)
00 = Switch Closed
018 Steering Pressure Switch Status 01 = Switch Opened
(Open = Normal Pressure)
019 Parking Brake Status 00 = Off, 01 = On
020 Pilot Lockout Status 00 = Off, 01 = On
00 = Switch Closed
021 Hydraulic Filter Restriction Switch Status 01 = Switch Opened
(Open = Filter is OK)
00 = Switch Closed
022 Air Filter Restriction Switch Status 01 = Switch Opened
(Open = Filter is OK)
023 Present Work Lights Status 00 = Off, 01 = On
024 Present Fog Lights Status 00 = Off, 01 = On
DISPLAY
LOCATION DEFINITION STATUS
NUMBER
00 = Switch Open
025 Air Conditioning High/Low Pressure Switch Status 01 = Switch Closed
(Open = Normal Pressure)
00 = Filter Acceptable
01 = Filter Restricted
026 Transmission Filter Restriction Indicator Status 02 = Filter Fault
03 = Not Available
(Open - Filter is OK)
027 High Beam Lights Status 00 = Off, 01 = On
101 = F1, 102 = F2, 103 = F3,
104 = F4, 201 = N1, 202 = N2,
203 = N3, 204 = N4, 301 = R1,
028 Requested Gear and FNR Status
302 = R2, 303 = R3, 304 = R4
401 = Request to move shifter
to N
DISPLAY
LOCATION DEFINITION STATUS
NUMBER
039 Current Status Master Indicator (Red) 00 = Off, 01 = On
Current Status of Diagnostic Indicator (Book without the
040 00 - Always
wrench - Operators Manual)
041 Current Status Master Indicator (Yellow) 00 = Off, 01 = On
042 Master Reset - Reset Information Center to Factory Setting
00 = Switch Open
043 01 = Switch Closed
Park Brake Switch Status
(Closed = engaged Parking
Brake)
00 = Switch Closed
044 Redundant Brake Pressure Switch Status 01 = Switch Open
(Closed = Normal Operation)
00 = Switch Open
045 Service Brake Foot Switch Status 01 = Switch Closed
(Closed = Actuated)
00 = Switch Open
01 = Switch Closed
046 Pilot Lockout Switch Status
(Closed = Loader Controls
Locked)
00 = Switch Closed
047 Seat Switch Status 01 = Switch Open
(open = unoccupied)
050 Minimum Gear Selection Range - 1st and 2nd gear
051 Maximum Gear Selection Range - 2nd, 3rd and 4th gear
052 Minimum Gear Read Only
053 Maximum Gear Read Only
Range = 0 to 99
Default = 0
055 Reset Diagnostic Stack, 071 to 090 to zero Set to 21 and then exit this
location 055 to reset diagnostic
stack 071 -099 to zero
061 - 070 Service Hour interval Selection #1 - 10
071,073,
075,077,
079,081, Fault Code #1 Through Fault Code #10
083,085,
087, 089
072, 074, Hour Code #1 Through Hour Code #10. Hour Codes Follow
076, 078, Fault Codes Respectively.
080, 082,
084, 086, I.e.: Hour Code #1 (072) Corresponds with Fault Code #1
088, 090 (071)
DISPLAY
LOCATION DEFINITION STATUS
NUMBER
FAULT CODES
Short circuit to battery voltage or open circuit 1. Check the cables from TCU to the sensor.
46058
at output speed sensor 2. Check the connectors.
46059 3. Check the speed sensor.
Short circuit to ground at output speed sensor
1. Check the cables from TCU to the sensor.
2. Check the connectors.
46060 Logical error at output speed sensor 3. Check the speed sensor.
NOTE: This fault code is reset after power up of the
TCU.
1. Check the sensor signal of the output speed
sensor.
2. Check the connector connected to the output
Output speed zero, does not match other speed.
46062
speeds. 3. Check the cable from the TCU to the sensor.
NOTE: This fault code is reset after power up of the
TCU.
1. Check the cluster controller.
46064 Invalid gear range restriction (CAN) 2. Check wire of CAN-Bus.
3. Check the cable to the cluster controller.
46065 Invalid declutch modulation selection (CAN)
46089 Invalid test mode signal (CAN) 1. Check the cluster controller.
2. Check wire of CAN-Bus.
46090 Invalid park brake status (CAN) 3. Check the cable to the cluster controller.
46091 Invalid shift quality selection (CAN)
INDEX
A 056 through 060 ................................................ 24
Actual Gear Check ................................................20 071 through 090 ................................................ 23
Air Conditioning Indicator ........................................7 097 .................................................................... 25
Air Conditioning Switch Check ..............................19 100 through 199 ................................................ 25
Air Filter Indicator ....................................................7 104 through 113 ................................................ 26
Air Filter Restriction Switch Check ........................18 117 through 120 ................................................ 27
Alarm Check ..........................................................17 121 through 129 ................................................ 27
Automatic Scrolling Gauge Displays .....................15 131 through 139 ................................................ 28
140 through 170 ................................................ 28
B 191 through 196 ................................................ 28
Beacon Indicator ......................................................6 197 .................................................................... 28
Beacon Status .......................................................21 198 .................................................................... 28
Brake 199 .................................................................... 28
Park, Information Center Output Check ............18 Display Location Numbers and Descriptions ......... 29
Park, Testing .....................................................15 Displays
Parking Brake Indicator .......................................7 Gauge, Automatic Scrolling ............................... 15
Brake Pressure ......................................................17 Gauge, Manual Scrolling ................................... 15
Brake Pressure Indicator .........................................6 Individual Function ............................................ 15
Drive Line Shift Status ........................................... 20
C Duty Cycle, LCD .................................................... 25
Calibration Duty Cycle, LED .................................................... 25
Transmission Clutch ..........................................16
Caution and Warning Master Indicator Lights .......21 E
Caution Master Indicator (Yellow) ...........................6 Engine
Check Coolant Temperature ...........................................8
Actual Gear .......................................................20 Oil Pressure Gauge .............................................8
Air Conditioning Switch .....................................19 Engine Coolant Temperature ............................8, 12
Alarm .................................................................17 Engine Oil Pressure ..............................................12
Coolant Level ....................................................17 Engine Oil Pressure Gauge .....................................8
High Beam ........................................................19 Entry Code
Park Brake Switch .............................................22 Test Mode Locations 100 to 199 ....................... 25
Requested Gear ................................................19
Switch, Pilot Lockout .........................................22 F
Switch, Redundant Brake Pressure ..................22 Fault Code Status .................................................. 24
Switch, Service Brake Foot ...............................22 Fault Codes ........................................................... 33
Work Lights .......................................................18 Filter
Clutch Indicator, Air Filter ...............................................7
Calibration, Transmission ..................................16 Indicator, Hydraulic Oil ........................................7
Control Indicator, Transmission Oil ..................................7
Pilot .....................................................................6 Restriction Switch, Air
Coolant Restriction Switch, Air Filter .......................... 18
Engine Temperature ............................................8 Restriction Switch, Hydraulic ............................. 18
Indicator, Low ......................................................6 Restriction Switch, Transmission ...................... 19
Coolant Level Check .............................................17 Fuel
Critical Warning Displays .......................................10 Gauge, Level .......................................................8
Fuel Level Gauge ....................................................8
D Fuel Lever ............................................................. 12
Diagnostic Center ....................................................5
Diagnostic Indicator Status ....................................21 G
Display Center Gauge
Lighting, Setting ................................................17 Engine Oil Pressure ............................................8
Display Location Fuel Level ...........................................................8
047 ....................................................................22 Hydraulic Oil Temperature ...................................7
048 and 049 ......................................................23 Transmission Oil Temperature ............................7
Voltmeter .............................................................8
Bur 6-42351 Revised 11-01 Printed in U.S.A.
Copyright
4005-44
Gauges and Indicators ............................................6 L
Gear LCD Duty Cycle ..................................................... 25
Check, Actual ....................................................20 LED Duty Cycle ..................................................... 25
Check, Requested .............................................19 Left Turn Indicator Status ...................................... 21
Gear Range Read Only .........................................23 Level
Gear Selection Coolant, Check ................................................. 17
Maximum ...........................................................23 Lighting, Setting Display Center ............................ 17
Minimum ............................................................23 Lights
Work ..................................................................18
H Low Coolant Indicator .............................................. 6
High Beam Check ..................................................19
Hourmeter ..............................................................12 M
Hourmeter Indicator Status ....................................20 Manual Scrolling Gauge Displays ......................... 15
Hours Master Reset ......................................................... 22
Service Interval .................................................24 Maximum Gear Selection ...................................... 23
Hydraulic Filter Restriction Switch Check ..............18 Minimum Gear Selection ....................................... 23
Hydraulic Oil Filter Indicator ....................................7 Movement Indicator Status .................................... 21
Hydraulic Oil Temperature .....................................13
Hydraulic Oil Temperature Gauge ...........................7 N
Non-Critical Warning Displays ............................... 11
I
Indicator O
Air Conditioning ...................................................7 Oil
Air Filter ...............................................................7 Pressure Gauge, Engine ..................................... 8
Beacon ................................................................6 Operational Indicator Status .................................. 20
Brake Pressure ...................................................6
Caution and Warning Master, Status Lights ......21 P
Caution Master (Yellow) ......................................6 Park Brake
Diagnostic, Status .............................................21 Information Center Output Check .....................18
Hourmeter, Status .............................................20 Testing ............................................................... 15
Hydraulic Oil Filter ...............................................7 Park Brake Switch Check ...................................... 22
Icon, Service .......................................................9 Parking Brake Indicator ........................................... 7
Left Turn, Status ................................................21 Pilot Control .............................................................6
Low Coolant ........................................................6 Pilot Lockout
Movement, Status .............................................21 Information Output Check .................................18
Operational, Status ...........................................20 Pilot Lockout Switch Check ................................... 22
Parking Brake ......................................................7 Power Circuit Test ................................................... 6
Right Turn, Status .............................................21 Pressure
Secondary Steering .............................................7 Brake Indicator .................................................... 6
Service, Status ..................................................21 Pressure, Brake ..................................................... 17
Stop Master (Red) ...............................................6 Programming Information Center ..........................14
Tachometer, Status ...........................................20 Programming, Information Center ......................... 14
Transmission Oil Filter .........................................7
Work Light ...........................................................6 R
Indicators and Gauges ............................................6 Redundant Brake Pressure Switch Check ............ 22
Individual Function Display ....................................15 Requested Gear Check ......................................... 19
Information and Diagnostic Center ....................5, 12 Reset Diagnostic Stack for Display Locations .......23
Information Center ...................................................5 Reset, Master ........................................................ 22
Internal Temperature .........................................25 Right Turn Indicator Status .................................... 21
Software Revision Number ...............................25
Instrument Cluster S
Date Code .........................................................27
Secondary Steering Indicator .................................. 7
Part Number (1st part) ......................................26
Secondary Steering Pressure Switch .................... 18
Part Number 2nd part) ......................................27
Self-Test .................................................................. 5
Internal Information Center Temperature ..............25
Service Brake Foot Switch Check ......................... 22
Service Indicator Icon .............................................. 9
Service Indicator Status ........................................21
Bur 6-42351 Revised 11-01 Printed in U.S.A.
Copyright
4005-45
Service Interval Hours ...........................................24 V
Setting Display Center Lighting .............................17 Vehicle Idenification Numbers (VINS) ................... 26
Settings, Diagnostics, and Fault Codes .................14 VINS ...................................................................... 26
Software Voltmeter ............................................................... 13
Revision Number, Information Center ...............25 Voltmeter Gauge .....................................................8
Speedometer .........................................................12 Voltmeter, Key ON ................................................ 17
Speedometer Calibration .......................................27
Status W
Beacon ..............................................................21 Work Light Indicator ................................................6
Caution and Warning Master Indicator Lights ...21 Work Lights Check ................................................ 18
Diagnostic Indicator ...........................................21
Drive Line Shift ..................................................20 Z
Fault Code .........................................................24 ZF Transmission
Fault Code, Temporary ......................................28 See Transmission ............................................. 25
Hourmeter Indicator ..........................................20
Left Turn Indicator .............................................21
Movement Indicator ...........................................21
Right Turn Indicator ...........................................21
Service Indicator ...............................................21
Tachometer Indicator .........................................20
Steering
Secondary Indicator ............................................7
Secondary Pressure Switch ..............................18
Stop Master Indicator (Red) ....................................6
Switch
Park Brake, Check ............................................22
Pilot Lockout ......................................................22
Pressure, Secondary Steering ..........................18
Redundant Brake Pressure ...............................22
Restriction, Hydraulic Filter ...............................18
Restriction,Transmission Filter ..........................19
Service Brake Foot ............................................22
T
Tachometer ...........................................................12
Tachometer Indicator Status .................................20
Temperature
Engine Coolant ....................................................8
Internal Information Center ...............................25
Temporary Fault Code Status ...............................28
Test
Power Circuit .......................................................6
Self-Test ..............................................................5
Test Mode Locations 100 to 199 ...........................25
Testing Park Brake ................................................15
Transmission
ZF Transmission
ECM Part Number (1st part) .........................25
ECM Part Number (2nd part) ........................25
Transmission Clutch Calibration ............................16
Transmission Display ............................................13
Transmission Filter Restriction Switch Check .......19
Transmission Oil Filter Indicator ..............................7
Transmission Oil Temperature ..............................13
Transmission Oil Temperature Gauge ....................7
Section
4007
ALTERNATOR
4007
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
TABLE OF CONTENTS
SPECIFICATIONS ....................................................................................................................................................... 2
SPECIFICATIONS
Case part number .............................................................................................................................................................1964860C1
Manufacturer ................................................................................................................................................................ Robert Bosch
Robert Bosch part number .......................................................................................................................................... 0 120 468 054
Output ....................................................................................................................................... 28 volts at 65 amperes at full throttle
Resistance of rotor winding .............................................................................................................................................. 8 to 9 ohms
Resistance of stator winding ...................................................................................................................................0.18 to 0.21 ohms
Minimum brush length, outside housing ................................................................................................................... 7 mm (0.27 inch)
SPECIAL TORQUES
Alternator mounting nuts and bolts ................................................................................................................ 100 Nm (74 pound-feet)
Pulley retaining nut ........................................................................................................................ 60 to 70 Nm (44 to 52 pound-feet)
Alternator housing screw........................................................................................................................4 to 5 Nm (3 to 4 pound-feet)
SPECIAL TOOLS
51L7
11. Connect the tester to the batteries (1), refer to 12. Start the engine and run the engine at full
Figure 1, as follows: throttle.
A. Connect the negative load lead of the NOTE: Do not apply a load to the battery for more than
tester (2) to the negative battery post (3) of 15 seconds at one time. After 15 seconds, turn the load
the 12 volt battery (1) that is connected to control to the OFF position for 60 seconds before
the master disconnect switch (5). applying the load again.
B. Connect the negative voltmeter lead of the 13. Adjust the load control of the tester to get the
tester (6) to the same negative battery post maximum amm eter indication. Read the
(3). ammeter and voltmeter. Make a record of the
ammeter and the voltmeter indications.
C. Connect the positive load lead of the tester
(7) to the positive battery post (8) of the 14. Turn the load control to the OFF position.
same battery.
15. Decrease the engine speed and stop the engine.
16. The ammeter indication in step 13 must not be B. If the ammeter and voltmeter indications
l e s s th a n 6 5 a m p e r e s a n d t h e v o l t m e t e r were n ot co rrect, the p roblem is in th e
indication must be 25 to 29 volts. alternator or voltage regulator. If a new
voltage regulator and brush assembly are
A. If the ammeter and voltmeter indications available, replace the voltage regulator
were correct, the alternator and voltage and brush assembly and repeat the test.
regulator are good.
C. If the alternator still does not operate
correctly, disassemble the alternator and
repair as necessary.
2. Use the pulley nut tool (1), wrench (2), and 5. Remove the nuts (5), washers (6), nuts (7),
socket (3), and remove the retaining nut (4) and washers (8), and plastic washers (9) that hold
washer (5) from the alternator drive pulley (6), the housings together.
refer to Figure 2.
6. Remove the two screws (10) and washers (11)
3 that hold the brush holder and voltage regulator
2 5 (12) to the alternator. Remove the brush holder
and voltage regulator (12).
4
20 1
22
23
2
3
27
28
19
24
25
36
37
44 39
26
38
34 42
32 43
33
31
30 41
40
29
16 35
14 9 21
18 7
13 8
15 5
17 6
10
11 12
45L7
1. RETAINING NUT 13. SPRING 25. REAR BEARING 37. RECTIFIER BRIDGE
2. WASHER 14. BRUSH 26. SNAP RING 38. INSULATOR
3. PULLEY 15. DUST SEAL 27. FRONT BEARING 39. D+ TERMINAL
4. FAN 16. SCREW 28. BEARING RETAINING PLATE 40. B+ TERMINAL
5. NUT 17. WASHER 29. NUT 41. DUST SEAL
6. WASHER 18. CAPACITOR 30. WASHER 42. TERMINAL
7. NUT 19. HOUSING SCREW 31. NUT 43. BUSHING
8. WASHER 20. FRONT HOUSING 32. WASHER 44. STATOR COIL
9. PLASTIC WASHER 21. REAR HOUSING 33. FIBER WASHER
10. SCREW 22. SCREW 34. FIBER SPACER
11. WASHER 23. SPACER 35. INSULATOR
12. BRUSH HOLDER AND 24. ROTOR 36. RECTIFIER SCREW
VOLTAGE REGULATOR
16. Connect an ohmmeter between the two slip 27. Remove the rectifier screws (36) that hold the
rings. The reading on the ohmmeter must be 8 to rectifier bridge (37) to the rear housing (21).
9 ohms. If the reading on the ohmmeter is high, Remove the rectifier bridge (37) from the rear
there is a break in the rotor coil and the rotor housing (21).
assembly will have to be replaced.
28. Remove the insulator (35) from the B+ terminal
17. Remove the rear bearing (25) from the rotor (24) (40).
using a bearing puller.
29. Remove the insulator (38) from the D+ terminal
18. Remove the front bearing (27) and spacer (23) (39).
by using a bearing puller and hydraulic press.
30. Unsolder the stator coil (44) at the connections to
19. Remove the bearing retaining plate (28). the rectifier bridge (37). Remove the stator coil
(44).
20. Check the capacitor (18) for continuity between
th e mo u ntin g ta b an d th e lea d . If the r e is NOTE: Bend phase lead-out wires as little as possible.
continuity, the capacitor (18) is bad. Check the
capacitor (18) by connecting an ohmmeter 31. Test the positive diodes in the rectifier bridge
b e t w e e n t h e mo u n ti n g ta b a n d l e a d . T h e (37). Connect the negative lead of the ohmmeter
ohmmeter will initially show movement and then to the output B+ terminal (40). Connect the
return to indicating no continuity as the capacitor positive lead of the ohmmeter to one of the leads
(18) is charged. Discharge the capacitor (18) by for the positive diodes. The positive diodes are
grounding the lead to the tab before installation. the seven diodes closest to the B+ terminal (40).
21. Check for continuity between each brush (14) 32. Reverse the ohmmeter leads. Read the
and the brush terminal. If there is no continuity, ohmmeter. There must be a high reading and a
replace the brushes (14). low rea ding . If the read ings are the same,
replace the rectifier bridge (37). Repeat this step
22. Measure the length of the brush (14) projecting for the other six diodes.
from the brush holder and voltage regulator (12).
Replace the brushes if the length is 7 mm (0.27 NOTE: D+ terminal (39) must be installed on a new
inch) or less. rectifier bridge (37).
23. Use a soldering iron to disconnect the brush 33. Check the negative diodes in the rectifier bridge
lead. Remove the brush (14) and the spring (13) (37). Connect the negative lead of the ohmmeter
from the brush holder and voltage regulator (12). to the surface of the diode plate that is not
p a in te d . C o n n e ct t h e p o sit ive lea d o f t h e
NOTE: When soldering leads to the terminals, the ohmmeter to one of the leads for the negative
solder must not flow into copper leads. diodes. The negative diodes are the seven
diodes on the side of the rectifier bridge (37)
opposite the B+ terminal (40).
Assembly 15. Install the capacitor (18). Install and tighten the
sc re w ( 1 6 ) a nd w as h e r (1 7 ) th a t ho ld th e
1. Solder the stator coil (44), at the connections, to capacitor (18) to the rear housing (21).
the rectifier bridge (37), refer to Figure 3.
16. Connect the capacitor terminal to the alternator.
2. Install the insulator (38) on the D+ terminal (39).
17. Check the dust seal (15) on the brush holder and
3. Install the insulator (35) on the B+ terminal (40). v o l t a g e r e g u l a t o r ( 1 2 ) t o m a k e s u r e i t is
Check the dust seal (41) and make sure it is in positioned correctly.
place.
18. Install the brush holder and voltage regulator
4. Align the rectifier bridge (37) in the rear housing (12). Make sure the rectifier bridge contact spring
(21) and install the rectifier screws (36) that hold is in contact with the brush holder and voltage
the rectifier bridge (37) to the housing. regulator (12). Make sure the dust seal (15) is in
contact with the housing.
5. Install the insulator (35) on the B+ terminal (40).
19. Install and tighten the two screws (10) and
6. Install the fiber washers (33), washers (32), nuts washers (11) that hold the brush holder and
(31), washers (30), and nuts (29) on the rectifier voltage regulator (12) to the alternator.
bridge terminals.
20. Install plastic washers (9), washers (8), nuts (7),
7. Install the bearing retaining plate (28). washers (6) and nuts (5).
8. Install a new front bearing (27) on the rotor shaft 21. Install the fan (4).
if it has been removed. Install the front bearing
(27) and spacer (23) with a hydraulic press. 22. Install the pulley (3).
9. Install a new rear bearing (25) on the rotor shaft 23. Install the retaining nut (1) and washer (2) on the
if it has been has been removed. Install the rear front of the alternator.
bearing (25) using a hydraulic press.
24. Use the pulley nut tool (1), wrench (2), and
socket (3) to tighten the retaining nut (4) and
washer (5), refer to Figure 2. Tighten retaining
nut (4) to a torque of 60-70 Nm (44 to 52 pound-
feet).
Section
4008
ALTERNATOR - 45 AMPERE
4008
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright 2001 Case Corporation
3350 South Service Road Printed in U.S.A.
Burlington, ON L7N 3M6 CANADA Bur 6-42360 August, 2001
Copyright
4008-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
45 Ampere Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection of the Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inspection and Testing of the Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Inspection and Testing of the Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Testing the Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Testing the Rectifier Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Inspection and Replacement of the Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SPECIFICATIONS
45 Ampere Alternator
Rated output ........................................................................................................................... 28 volts at 45 amperes
Resistance of rotor ............................................................................................................................. 8.1 to 9.9 ohms
Maximum runout for slip rings ....................................................................................................0.05mm (0.002 inch)
Minimum diameter of slip rings.................................................................................................. 26.8 mm (1.055 inch)
Resistance of stator........................................................................................................................ 0.20 to 0.24 ohms
Minimum length of brushes ...............................................................................................................7mm (0.27 inch)
Torque nut for pulley ..............................................................................................60 to 73 Nm (45 to 54 pound-feet)
ALTERNATOR
Disassembly STEP 3
STEP 1
B523411M
STEP 2
B523413M
B523405M STEP 5
Hit the face of the pulley softly with a hammer to
loosen the retainer in the pulley.
B8971201M
B8971204M B8971213M
Remove the voltage regulator and brush holder. Loosen and remove the nut, flat washer, and fiber
washers from the D+ terminal.
STEP 7
STEP 10
B8971207M
STEP 11
B8971210M
B8971222M B8971301M
Loosen and remove the screws that fasten the cover, Remove the rotor from the cover.
stator, and housing together.
STEP 16
STEP 13
B8971304M
B8971231M 1. SCREWS
Remove the cover and rotor from the stator and
Loosen and remove the screws that fasten the
housing. The cover can be difficult to remove. Use a
rectifier bridge to the housing.
soft hammer as required to remove the cover.
STEP 17
STEP 14
B8971307M
B8971508M
Remove the housing.
Loosen and remove the screws that fasten the
bearing retainer to the cover. The rotor now can be
removed.
B8971310M B8971319M
Remove the insulator from the B+ terminal. Remove the shield from the housing.
STEP 19
B8971313M
STEP 21
B9064418M
STEP 22
B9064421M
STEP 25
B9064414M
STEP 26
B9064433M
STEP 27
B9064436M
STEP 31
B9064502M
B9064319M
STEP 32
B9064424M
STEP 35
B9064322M
Touch the terminal to the bracket to discharge the
Touch the leads of the ohmmeter to each lead from condenser.
th e s ta t o r a n d t he fr a me . If a re a d in g sh o w s
continuity, a new stator must be installed.
B9064402M
STEP 37
B8971426M
B8971429M
B8971432M B8971504M
3. Use a suitable support between the rear bearing 6. Press the spacer onto the rotor shaft until the
and the slip ring on the other end of the rotor spacer stops moving.
shaft and press the rotor shaft out of the rear
bearing.
B8971505M
B8971435M
18
20
21
23 22
24 22
23
16
24 22
17
23 19
9
21 10
11
23
26 12
27 13
7
7 15 14
1
2
3
5
6
8
4
BS01B125
Assembly STEP 42
STEP 39
B8971601M
STEP 40
B8971304M
1. SCREWS
B8971313M
Install and tighten the screws that fasten the rectifier
Install the insulator on the D+ terminal.
bridge to the housing.
STEP 41 STEP 44
B8971310M
B8971604M
Install the insulator on the B+ terminal.
Install the fiber washers, flat washer, and nut on the
B+ terminal.
B8971607M B8971301M
Check for a short circuit between the terminal and Install the rotor in the cover.
the housing. If there is continuity, the insulator is bad.
STEP 49
STEP 46
B8971508M
B8971610M Install and tighten the screws that fasten the bearing
Install the fiber washers, flat washer, and nut on the retainer and rotor to the cover.
D+ terminal.
STEP 50
STEP 47
B8971231M
B8971613M Make sure the marks are in alignment and install the
Check for a short circuit between the terminal and cover and rotor in the stator and housing.
the housing. If there is continuity, the insulator is bad.
B8971222M B8971622M
Install and tighten the screws evenly that fasten the Install the voltage regulator and the brush holder. Be
housing, stator, and cover. careful not to damage the brushes.
STEP 52 STEP 55
B8971616M B8971625M
Install the capacitor and tighten the screw. Install the screws and flat washers and tighten the
screws.
STEP 53
STEP 56
B8971619M
B523418M B518009M
Install the pulley and the retainer. Fasten the pulley in a vise with soft jaws. Tighten the
nut to a torque of 60 to 73 Nm (45 to 54 pound-feet).
STEP 58
B523407M
Install the washer and start the nut onto the shaft.
SECTION INDEX
STEERING
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright 2001 Case Corporation
3350 South Service Road Printed in U.S.A.
Hamilton, ON L7N 3M6 CANADA Bur 6-42370 August, 2001
Copyright
Copyright
5001
Section
5001
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright 2001 Case Corporation
3350 South Service Road Printed in U.S.A.
Burlington, ON L7N 3M6 CANADA Bur 6-42380 August, 2001
Copyright
5001-2
TABLE OF CONTENTS
STEERING CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
AUXILIARY STEERING PUMP AND MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removal Installation
1. Remove the left, right, and front cab skirts, 1. Put the seals (8) and base plate (11) in position
located under the cab or canopy. on the steering control valve (5). Install the bolts
(9) and lock washers (10) that fasten the base
2. Remove all dirt and grease from the steering
plate (11) to the steering control valve (5). Refer
co ntr ol v alve ( 5) a nd th e ar ea a ro un d th e
to the illustration on page 5.
steering control valve (5), refer to the illustration
on page 5. 2. Put the base plate (11) and steering control valve
(5) assembly in position on the bottom of the
3. Remove the fill cap for the hydraulic reservoir.
pedestal (12). Make sure that the notch in the
4. Fasten identification tags to the hoses at the steering column shaft (6) on the steering control
steering control valve (5). valve (5) is aligned with the hole in the coupling
(2).
5. Disconnect the hoses from the fittings in the
steering control valve (5). 3. Install the bolts (7), washers (3), and steering
isolator mounts (4) that fasten the base plate (10)
6. Cap or plug the fittings and hoses.
and steering control valve (5) assembly to the
7. Turn the steering wheel as required for access to bottom of the pedestal (12).
the cap screw (1) that holds the steering column
4. Turn the steering wheel as required for access to
shaft (6) of the steering control valve (5) in the
the hole for the cap screw (1) that holds the
coupling (2).
steering column shaft (6) of the steering control
8. Remove the cap screw (1) that holds the steering valve (5) in the coupling (2).
column shaft (6) of the steering control valve (5)
5. Install the cap screw (1) that holds the steering
in the coupling (2).
column shaft (6) of the steering control valve (5)
9. Hold the steering control valve (5) in position and in the coupling (2).
remove the bolts (7), washers (3), and steering
6. Connect the hoses to the fitting in the steering
isolator mounts (4) that fasten the base plate (11)
control valve (5).
and steering control valve (5) to the bottom of the
pedestal (12). 7. Install the fill cap on the hydraulic reservoir.
10. Remove the steering control valve (5) and base 8. Start the engine and turn the machine all the way
plate (11) from the machine. to the left and right several times to remove any
air in the circuits.
11. Remove the bolts (9) and lock washers (10) that
fasten the base plate (11) to the steering control 9. Stop the engine and check for leaks.
valve (5).
10. Check the fluid level in the hydraulic reservoir.
12. Remove the base plate (11) and seals (8) from Add oil as re qu ir ed. S ee Section 10 02 for
the steering control valve (5). specifications.
12
2
10
8
4
4
4
11
3
8
4
3
7
7 6
BS01C107
PRIORITY VALVE
Removal Installation
1. Remove all dirt and grease from the priority valve 1. Start the vacuum pump.
(3) and the area around the priority valve (3),
2. Install the bolt (8), washer (6), and lock nut (7), to
refer to the illustration on page 7.
fasten the priority valve (3) to the bracket (4).
2. Remove the fill cap for the hydraulic reservoir. Refer to the illustration on page 7.
3. Connect a vacuum pump to the hydraulic 3. Connect the hose (1) to the elbow in the side of
reservoir. the priority valve (3).
4. Start the vacuum pump. 4. Connect the hose (10) to the elbow in the side of
the priority valve (3).
5. Tag and disconnect the hose (9) from the priority
valve (3). 5. Connect the hose (5) to the top of the priority
valve (3).
6. Plug the hose (9).
6. Connect the hose (2) to the top of the priority
7. Tag and disconnect the hose (2) from the priority
valve (3).
valve (3).
7. Connect the hose (9) to the bottom of the priority
8. Plug the hose (2).
valve (3).
9. Tag and disconnect the hose (5) from the priority
8. Stop the vacuum pump.
valve (3).
9. Disconnect the vacuum pump from the hydraulic
10. Plug the hose (5).
reservoir.
11. Tag and disconnect the hose (10) from the
10. Install the fill plug on the hydraulic reservoir.
priority valve (3).
11. Start the engine and run at low idle for 30
12. Plug the hose (10).
seconds. Stop the engine and check for leaks.
13. Tag and disconnect the hose (1) from the priority
12. Check to make sure the priority valve works
valve (3).
correctly. See Section 5002.
14. Plug the hose (1).
13. Check the fluid level in the hydraulic reservoir.
15. Loosen and remove the locknut (7), washer (6) Add oil as re qu ir ed. S ee Section 10 02 for
and bolt (8) which fasten the priority valve (3) to specifications.
the bracket (4).
16. Stop the vacuum pump.
1
8 10
7
6
4
3
9 4
11
13
14
12
17
15 16 18
BS01C105
Removal Installation
1. Remove the fill cap for the hydraulic reservoir. 1. Install the auxiliary steering pump and motor (2).
Install the nuts (4), bolts (5) and flat washers.
2. Connect a vacuum pump to the hydraulic
Tighten the bolts. Refer to the illustration on page
reservoir.
9.
3. Start the vacuum pump.
2. Start the vacuum pump.
4. Tag and disconnect the hose (1) from the fitting
3. Connect the hose (1) to the fitting (9) on the
(9) on the auxiliary steering pump and motor (2)
auxiliary steering pump and motor (2).
and in sta ll a plu g in the h ose, refer to th e
illustration on page 9. 4. Connect the hose (3) to the elbow (8) on the
auxiliary steering pump and motor (2).
5. Tag and disconnect the hose (3) from the elbow
(8) on the auxiliary steering pump and motor (2) 5. Stop the vacuum pump. Install the fill cap in the
and install a plug in the hose (3). hydraulic reservoir.
6. Stop the vacuum pump. 6. Connect the ground wire to the rear chassis (7).
7. Turn the master disconnect switch to the OFF 7. Connect the electrical wires to the auxiliary
position. steering pump and motor (2).
8. Tag and disconnect the electrical wires from the 8. Place the master disconnect switch in the ON
auxiliary steering pump and motor (2). position.
9. Tag and disconnect the ground wire from the rear 9. Start and run the engine at low idle, loosen the
chassis (7). hose at the pressure switch to bleed out air in the
line.
10. Remove the nuts (4), bolts (5) and washers (6)
that hold the auxiliary steering pump and motor 10. Stop the engine.
(2).
11. Disconnect the wire from the fuel shutoff
11. Remove the auxiliary steering pump and motor solenoid on the fuel injection pump.
(2).
12. Actuate the starter for 3 to 5 seconds to actuate
the auxiliary steering pump and motor.
13. Turn the steering wheel all the way to the left and
to the right to make su re that the auxiliary
steering pump and motor works correctly. Turn
the key switch to OFF.
14. Connect the wire to the fuel shutoff solenoid.
5
6 7
4
5
6
1
4
2
8
3
BS01C106
STEERING CYLINDER
Removal Installation
1. Loosen the fill cap for the hydraulic reservoir to 1. Put the steering cylinder (1) into position in the
release pressure in the reservoir, then tighten the machine. Make sure that the washer (15) is
fill cap. installed between the steering cylinder (1) and
the rear frame. Refer to the illustration on page
2. Disconnect the hoses (13,14,16 and 17) for the
11.
steering cylinder (1), refer to the illustration on
page 11. NOTE: Use a washer (15) on top and bottm of the
steering cylinder (1) if possible. If only one washer
3. Install plugs in hoses 16 abd 17.
(15) is used, place the washer (15) on the bottom of
4. Remove the grease hose (11) from the tube end the steering cylinder (1).
of the steering cylinder (1).
2. Make sure the washers (6) are in position
5. Loosen and remove the locknut (4) that holds the between the steering cylinder (1) and the front
pin (2) to the steering cylinder (1). frame of the machine.
6. Remove the bolt (3). 3. Install the pivot pin (7) to fasten the rear of the
steering cylinder (1) to the machine frame. Install
7. Remove the pin (2).
the spacer (10), washer (9) and bolt (8) to fasten
8. Remove the washers (6). the pivot pin (7).
9. Remove the bolt (8), washer (9) and spacer (10) 4. Tighten the bolt (8).
that hold the pivot pin (7) at the rear of the
5. Install the pin (2) in the front of the steering
steering cylinder (1).
cylinder (1). Make sure that the washers (6) are
10. Use an acceptable driver and drive the pivot pin in the correct position.
(7) out of the steering cylinder (1)
6. Install the bolt (3) and locknut (4) in the steering
11. Remove the washer(s) (15) from between the cylinder (1) and pin (2). Tighten the locknut (4).
steering cylinder (1) and the rear frame of the
NOTE: The bolt (3) should turn freely in the hole
machine.
after tightening.
12. Remove the steering cylinder (1).
7. Connect the hoses (13,14,16 and 17) to the
hydraulic cylinders.
8. Connect the grease hose (11) to the base end of
the steering cylinder (1).
9. Tighten the fill cap for the hydraulic reservoir.
10. Start the engine.
11. Turn the steering wheel all the way to the right
and then to the left several times.
12. Stop the engine. Check the hydraulic oil level.
See Section 1002 for specifications.
9
16
10
7
13
15
17 1 2
14
8 3
9 15
10 4
12
7 11 14
12
5
15 13 6
2
4
15 6
1
5
BS01C108
5002
Section
5002
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright 2001 Case Corporation
3350 South Service Road Printed in U.S.A.
Burlington, ON L7N 3M6 CANADA Bur 6-40790 March,2001
Copyright
5002-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TROUBLESHOOTING THE STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
AUXILIARY STEERING SYSTEM PUMP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
AUXILIARY STEERING SYSTEM MOTOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
UNDERSTANDING THE RESULTS OF THE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
STEERING RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Pressure Setting Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Pressure Setting Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
STEERING CYLINDER LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SPECIFICATIONS
Auxiliary steering motor
Maximum amperes...............................................................................................................................30 amperes
Minimum armature speed ............................................................................................................ 6950 r/min (rpm)
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)
Steering relief valve
Pressure setting .................................................................................................239 to 243 bar (3465 to 3523 psi)
Location of steering relief valve...................................................................................... in the loader control valve
SPECIAL TOOLS
B785789 B009638
B797157
Equipment Required
1. CAS- 10280 Flowmeter
2. CAS-1808 Flowmeter fitting kit
Test Procedure
1
BB830300
1. AMMETER CLAMP
6. Connect the ammeter clamp (1) to the cable as
1 in illustration above.
7. Make sure that the parking brake is applied and
the bucket is on the floor.
BD00M030
8. Make sure that the oil is at operating
1. ARTICULATION LOCK temperature.
1. Install articulation lock. 9. Make sure that the load valve for the flowmeter is
open (zero pressure).
NOTE: When performing this pressure check,
always be sure the articulation lock is in place, 10. Start and run the engine.
especially when working in the articulation joint 11. Stop the engine and turn the key back to the On
areas. position.
2. Loosen and remove the outlet hose of the 12. Turn the steering wheel, this will activate the
Auxiliar y Steering Pump from the Steering auxiliary steering pump.
Priority Valve.
13. Turn the load valve on the flowmeter towards
3. Install a plug into the hose. CLOSED until the pressure is 104 bar (1500 psi).
4. Connect the inlet of the flowmeter to the outlet 14. Read the flowmeter and ammeter gauges and
fitting on the Steering Priority Valve. record the readings.
5. Install the outlet hose of the flowmeter in the 15. The flowmeter reading must not be less than
hydraulic reservoir and hold in place with wire. 24.6 L/min, (6.5 U.S. gpm). The ammeter reading
must be 315 amps.
16. Turn the key switch to the OFF position. If the
flow was less than the specification, or if the
amperage was more than 315 amperes, remove
the auxiliary steering motor and pump. Test the
auxiliary steering motor. If the motor is good,
make repairs to the pump.
Test Equipment
1. A 24 volt battery that is fully charged. 2
1
NOTE: A 24 volt battery system (two 12 volt
batteries in a series) is used for this test. A 12 volt
battery system will cause damage to the auxiliary 4
steering motor. 3
2. A remote starter switch.
3. A tachometer to check the armature speed.
4. A Sun Electric VAT-33 Starting and Charging
5
System Tester.
B790852
Test Procedure 1. REMOTE STARTER SWITCH
1. Remove the connector that is between the 2. TESTER
3. AUXILIARY STEERING MOTOR
ter minals on the magnetic switch and the
4. AMMETER CLAMP
auxiliary steering motor.
5. 24 VOLT BATTERY SYSTEM
2. Remove the auxiliary steering motor from the
auxiliary steering pump.
3. Remove the drive coupling from the auxiliary
steering motor (3).
4. Connect the auxiliary steering motor (3), remote
starter switch (1) and tester (2) to the 24 volt 8
6 7
battery system (5) as illustrated in Figure 3.
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. Refer to figure 4. Look at the
ammeter (6) in the tester. Make a record of the
ammeter indication. B795328
1
1
BD00M048
1. SAFETY LINK
BD00M048
1. SAFETY LINK
3. Remove the safety link (1) and lower the loader
arms to the ground.
1. Install the safety link (1) and lower the loader
arms slowly, until the safety link is supporting the 4. Stop the engine.
loader arms.
1
BD00M030
10. Hold the bucket control lever in the rollback 1. LOADER CONTROL VALVE
position. 2. PUMP PRESSURE TEST PORT
11. Hold the lift lever in the FLOAT position. 15. Remove the dust cap from the test port (2).
12. Continue holding until the specified temperature 16. Connect a 345 bar (5000 psi) pressure gauge to
of the oil is reached. the test port (2) on the front of the loader control
valve (1).
13. Stop the engine.
NOTE: Make sure when you connect the pressure
14. Remove the cap on the hydraulic reservoir to gauge that you do so in a manner that you can read
release any pressure in the hydraulic system. the pressure gauge while sitting in the operators
seat.
17. Start the engine and operate the machine at full
throttle.
18. With the articulation lock still in place, turn and
hold the steering wheel for a hard right turn.
19. Continue holding the steering wheel, and read
the pressure gauge.
20. The pressure gauge must indicate 239 to 243
bar (3465 to 3523 psi). If the pressure is not
correct, adjust the steering relief valve.
1
1
BD00M048
1. SAFETY LINK
BD00M048
1. SAFETY LINK
3. Remove the safety link (1), and lower the loader
arms to the ground.
1. Install the safety link (1) before adjusting the
steering relief valve. 4. If the pressure gauge is still connected, repeat
steps 17 through 20 in the Pressure Setting Test
P r o c e d u r e. I f t h e p r e s s u r e g a u g e i s n o t
connected, do the entire Pressure Setting Test
Procedure.
5. If necessary, adjust the relief valve again until the
relief valve is within the specified range.
6. Stop the engine before removing the pressure
gauge.
BS01A046
Section
5003
5003
STEERING CONTROL VALVE
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright 2001 Case Corporation
3350 South Service Road Printed in U.S.A.
Burlington, ON L7N 3M6 CANADA Bur 6-42390 August, 2001
Copyright
5003-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 3
STEERING CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 6
SPECIFICATIONS
Manufacturer ..................................................................................................................................................... Eaton
Special Torques
Cap screws for end cap ............................................................................................ 33.9 NM (300 pound-inches)
SPECIAL TOOLS
Retaining ring pliers.......................................................................................................... Eaton part number 600610
Splined shaft end tool, #600604 ........................................................................................... Eaton part number 8063
Disassembly
1. Clean the port area of the steering control valve 7. Hold the gerotor star and drive shaft (6), with
housing before disconnecting the hydraulic lines. your hand. Protect both the gerotor star and
hand with a shop towel while turning.
2. Drain the oil, and plug the ports. Clean the
exterior of the steering control valve housing. 8. Turn the tool clockwise or counter-clockwise to
Protect the machines surfaces during repair. compress the centering spring (12).
3. Put the steering control valve in a vise so that the 9. Hold the drive shaft (6) stationary.
end cap (2) is up, refer to Figure 1.
10. Remove the centering spring (12), spool (9) and
sleeve (8), ball checks (10), pin (11), drive shaft
(6), bearing race (14), retaining ring (18) and
needle thrust bearing (13). Use retaining ring
3 pliers. (See Special Tools).
11. Remove the back-up washer (15), seal ring (16),
2 and O-ring (17).
12. Carefully pry the dust seal (19) from the steering
control valve housing (7), using a small blade
screwdriver. Do not damage the dust seal (19).
NOTE: If the steering control valve housing (7) has
anti-cavitation valves, find the anti-cavitation valves
1 in the steering control valve housing (7).
14
18 13
14
16 7
17
15
19
6
8 10
11
1
2 9
10
12
3
4
21
3
5
20 3
GS98K502
3
4
5
2
3
GS98K530
Inspection 3. If the spool (9) and sleeve (8) or the bore in the
housing of the steering control valve (7) is
1. Clean all parts in cleaning solvent and air dry on damaged or worn, use a new steering control
paper towels. Do not use cloths to wipe parts dry, valve.
as it may leave lint on the parts.
4. Inspect the cap screws (1), pin (11), ball check
2. Check all machined surfaces for wear or (10), backup washer (15), seal ring (16), O-ring
damage. If there are rough places on the ends of (17), needle thrust bearing (13) and bearing race
the gerotor star or gerotor (4), steering control (14). Use new parts as required.
valve housing (7), end cap (2), or spacer plate
(5), use 600 grit emery cloth to smooth the 5. If your steering control valve has anti-cavitation
surfaces, refer to Figure 2. Place the emery cloth valves, inspect the ball checks (20) and roll pins
on a flat surface. If the emery cloth is new, rub a (21) for damage or wear. Use new parts as
piece of steel across the emery cloth six times to required.
remove the sharp pieces of grit. Make sure that
the part is held flat on the emery cloth. Rub each
part across the cloth six times. Check to see if
the rough places are removed. Use this method
until all rough places are removed. Clean the
parts in cleaning solvent to remove any grit.
5
1
5 3
2
1
6 6
8
7
2 6 8
1 7
4 3
5
GS98K505
Section
5004
5004
STEERING PRIORITY VALVE
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright 2001 Case Corporation
3350 South Service Road Printed in U.S.A.
Burlington, ON L7N 3M6 CANADA Bur 6-42400 August, 2001
Copyright
5004-2
TABLE OF CONTENTS
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... ....... 2
STEERING PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... ...... 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... ...... 3
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... ...... 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... ...... 4
SPECIAL TORQUES
Spool Orifice Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3 to 9.6 Nm (65 to 85 lb-inch).
Plugs and Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.9 to 54.2 Nm (25 to 40 lb-ft).
Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1 to 9.5 Nm (72 to 84 lb-inch).
Disassembly STEP 4
Remove plug (5). Remove and discard O-ring (6)
STEP 1 from plug.
Put the steering priority valve in a soft jawed vise.
STEP 5
STEP 2 Remove spring (7).
Remove adapter (1). Remove and discard O-ring (2)
from adapter. STEP 6
Remove spool (8).
STEP 3
Remove relief valve (3). Remove and discard O-ring STEP 7
(4) from relief valve. Remove plug (9). Remove and discard O-ring (10)
from plug.
3 4 11
1 2
10 9
7 8
BS01E129
1. ADAPTER 7. SPRING
2. O-RING 8. SPOOL
3. RELIEF VALVE 9. PLUG
4. O-RING 10. O-RING
5. PLUG 11. HOUSING
6. O-RING
STEP 9 STEP 14
Insp ect spo ol (8) a nd ho using b ore s for d ee p Install new O-ring (6) on plug (5). Install plug and
scratches, gouges, and other damage. Replace O-ring. Tighten plug to a torque of 33.9 to 54.2 Nm
steering priority valve if any of these conditions are (25 to 40 lb-ft).
seen.
STEP 15
STEP 10
Install new O-ring (4) on relief valve (3). Install relief
Check that orifice screws in each end of spool (8) are valve and O-ring. Tighten relief valve to a torque of
fr e e a n d c le a r o f fo r e ig n m a tt e r. W E AR EY E 33.9 to 54.2 Nm (25 to 40 lb-ft).
PROTECTION WHEN USING COMPRESSED AIR.
If n e c e ss a r y, r e m o ve o ri fic e s c re w s a n d u s e
STEP 16
compressed air to remove foreign matter from interior
of spool (8) and orifice screws. Install orifice screws Install new O-ring (2) on adapter (1). Install adapter
in spool (8) ends. Tighten screws to a torque of 7.3 to and O-ring. Tighten adapter to a torque of 8.1 to 9.5
9.6 Nm (65 to 85 lb-inch). Nm (72 to 84 lb-inch).
STEP 11
Check spring (7) for cracks, breaks, or signs of
permanent set. Replace if any of these conditions are
seen.
3 4 11
1 2
10 9
7 8
BS01E129
Section
5005
STEERING CYLINDERS
5005
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright 2001 Case Corporation
3350 South Service Road Printed in U.S.A.
Burlington, ON L7N 3M6 CANADA Bur 6-42410 August, 2001
Copyright
5005-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... ...... 3
STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... ...... 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... ...... 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... ...... 3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... ...... 5
SPECIFICATIONS
Torque for piston cap screw...........................................................................585 to 720 Nm (431 to 531 pound-feet)
Torque for gland.............................................................................................339 to 475 Nm (250 to 350 pound-feet)
Weight ..........................................................................................................................................18kg (39.7 pounds)
STEERING CYLINDER
Disassembly
1. Fasten the tube (1) in a vise. Be careful not to Inspection
damage the tube (1). Refer to the illustration on
page 4. 1. Discard the O-ring (6), backup ring (7), seal (4),
seal (5), wiper (9), and guide (8) from the gland
2. Loosen and remove the gland (3) from the tube (3). Refer to the illustration on page 4.
(1).
2. Discard the seal (12), backup ring (13), and wear
3. Pull the piston (11) straight out of the tube (1). ring (14) that were removed from the piston (11).
4. Fasten the yoke on the piston rod (10) in the vise 3. Clean all parts in cleaning solvent.
and put a support below the piston rod (10) near
the piston (11). Use a shop cloth between the 4. Check to be sure that the piston rod (10) is
suppo rt and the pisto n rod (10) to prevent straight. If the piston rod (10) is bent, install a
damage to the piston rod (10). new piston rod (10).
5. Loosen and remove the bolt (15) and hardened 5. Inspect the inside of the tube (1) for deep
washer (16) that hold the piston (11). grooves and other damage . If there is any
damage to the tube (1), a new tube (1) must be
6. Remove the piston (11) from the piston rod (10). used.
7. Remove the seal (12), backup ring (13), and 6. Remove small scratches on the piston rod (10) or
wear ring (14) from the piston (11). inside the tube (1) with emery cloth of medium
8. Remove the gland (3) from the piston rod (10). grit. Use the emery cloth with a rotary motion.
9. Remove the O-ring (6), backup ring (7), seal (4), 7. Inspect the bushings (2) and replace as required.
seal (5), wiper (9), and guide (8) from the gland
(3).
10
9
4
5
3
7
6
8
14
11
12
13
16
15
1
17
BS01B202
Assembly 12. Install a new backup ring (13) on the piston (11).
1. Install the seal (4) in the gland (3). The seal (4) 13. Install a new seal (12) over the backup ring (13).
must be installed so that the lips of the seal (4) 14. Clean the threads on the end of the piston rod
are toward the small end of the gland (3). The (10) and the threads of the bolt (15) using Loctite
seal (4) can be difficult to install. Use tools that cleaning solvent. Allow to dry. Apply Loctite 242
will n o t da ma ge th e s ea l (4 ). R efe r to th e to the piston rod threads 1/4 inch from the open
illustration on page 4. end of the piston rod so that there is 1/2 inch of
2. Install the seal (5) in the gland (3). Loctite 242 on the piston rod threads. DO NOT
apply Loctite to the first 1/4 inch of the piston rod
3. Install the guide (8) in the gland (3). threads.
4. Install the wiper (9) in the gland (3). 15. Install the bolt (15) and hardened washer (16) in
5. Install the O-ring (6) on the gland (3). The O-ring the piston (11).
(6) must be toward the small end of the gland (3). 16. Install the piston (11) on the piston rod (10) and
6. Install the backup ring (7) on the gland (3). The start the bolt (15) into the piston rod (10).
backup ring (7) must be toward the large end of 17. Tighten the bolt (15) according to torque
the gland (3). If the backup ring (7) is not flat on specifications listed on page 2.
both sides, the side that is not flat must be
toward the O-ring (6). 18. Fasten the tube (1) in the vise. Be careful not to
damage the tube (1).
7. Fasten the yoke on the piston rod (10) in the vise.
19. Apply petroleum jelly to the O-ring (6) and
8. Lubricate the piston rod (10) and the bore in the backup ring (7) on the gland (3) and to the
gland (3) with clean hydraulic oil. sealing surface in the tube (1).
NOTE: If a new gland (3) is being installed, write the 20. Lubricate the piston (11) and the inside of the
part number of the cylinder on the gland (3). tube (1) with clean hydraulic oil.
9. Push the gland (3) onto the piston rod (10). If 21. Push the piston (11) straight into the tube (1). Be
necessary, use a soft hammer to drive the gland careful not to damage the wear ring (14) and seal
(3) onto the piston rod (10). (12) on the piston (11).
10. Put the support below and near the end of the 22. When the piston (11) is in the smooth part of the
piston rod (10). Put a cloth between the support tube (1), start the gland (3) into the tube (1).
and the piston rod (10) to prevent damage to the
piston rod (10). 23. Tighten the gland (3) to 339 to 475 Nm (250 to
350 pound-feet).
11. Install a new wear ring (14) on the piston (11).
Section
5006
CENTER PIVOT
5006
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright 2001 Case Corporation
3350 South Service Road Printed in U.S.A.
Burlington, ON L7N 3M6 CANADA Bur 6-42420 August, 2001
Copyright
5006-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CENTER PIVOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CONNECTING THE FRONT FRAME TO THE REAR FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SPECIFICATIONS
SPECIAL TORQUES
M16 bolt for upper pivot pin.......................................................................220 to 250 Nm (162 to 184 pound-feet)
M12 bolts for the lower pin plate .......................................................................................124 Nm (91 pound-feet)
M12 bolts screws for the lower pin plate .....................................................128 to 136 Nm (94 to 100 pound-feet)
Ferry head screws for the drive shaft ................................................................61 to 81 Nm (45 to 60 pound-feet)
LUBRICANT
Pivot bearings and seals .......................................................................................... Case IH molydisulfide grease
Steering cylinder rod eyes........................................................................................ Case IH molydisulfide grease
FLUIDS
Hydraulic system reservoir ..............................................................................................MS-1209, Hy-Tran Ultra
SPECIAL TOOLS
CAS-10219 ...................................................................................................................... Hand pump (hydraulic ram)
CAS-10600 ............................................................................... Bearing cup and seal puller, includes 24850 adapter
CAS-1960 .................................................................................. *Top bearing driver, bottom bearing driver and plate
* (Requires screw, two nuts, and two washers from CAS-10592)
CENTER PIVOT
1. Remove all dirt and grease from the area of the 20. Install a cap on the hose and a plug in the fitting.
center pivot. Park the machine on a level surface. 21. Stop the vacuum pump.
2. Lower the bucket until the bucket is flat on the 22. Loosen and remove the self-locking nut and bolt
floor. that hold the pivot pin for the steering cylinder
3. Stop the engine and apply the parking brake. rod eye.
4. Remove the covers from both sides of the 23. Remove the pivot pin from the rear frame and the
machine. steering cylinder rod eye.
5. Disconnect the front wiring harness from the cab 24. Remove the washer from the rear frame. Move
floor. the steering cylinder out of the way.
6. Remove any tie straps that fasten the front wiring 25. Repeat steps 22, 23 and 24 for the other steering
harness to the chassis near the center pivot. cylinder.
7. Loosen and remove the nut and washer that 26. Loosen and remove the Ferry head screws and
fasten the chassis ground wire and cab ground retainers that fasten the drive shaft to the front
wire to the studs. yoke. Move the drive shaft out of the way.
8. Loosen and remove the bolt, lock washer, and 27. Place two stands below and in contact with the
nut that fasten the clamp on the front wiring front frame.
harness to the bracket on the rear frame. Move 28. Install blocks between the rear axle and the rear
the front wiring harness out of the way. frame on both sides of the machine to prevent
9. Loosen and remove the fill plug for the hydraulic the rear frame from tipping.
reservoir. 29. Put a jack in contact with both sides of the rear
10. Connect a vacuum pump to the hydraulic frame near the center pivot area. Use another
reservoir. Start the vacuum pump. jack at the rear of the machine to prevent the rear
frame from tipping.
11. Disconnect the brake hose from the backside of
front brake line bracket. 30. Loosen and remove the bolt (1), washer (2), and
spacer (3) that fasten the upper pivot pin (4) to
12. Install a plug in the tube and a cap on the fitting. the rear chassis (5), refer to Figure 1.
13. Disconnect the hoses for the steering cylinder. 31. Use a prybar to remove the upper pivot pin (4).
14. Install caps on the fittings and plugs in the hoses. 32. Loosen and remove the bolts (1) and hardened
15. Loosen and remove the bolts, lock washers, and washers (2) that fasten the lower pin plate (15) to
self-locking nuts that fasten the mounting bracket the lower pivot pin (10).
for the hoses to the bracket on the front frame. 33. Loosen and remove the cap screws (1) and
16. Loosen and remove the bolts, flat washers, and washers (2) that fasten the lower pin plate (15) to
self-locking nuts that fasten the bracket for the the bottom of the rear chassis (5).
hoses to the rear frame. 34. Use the ram and hand pump to remove the lower
17. Disconnect the return hose. pivot pin (10).
18. Install the cap on the hose and a plug in the 35. Install the puller on the bottom spacer (14), see
fitting. Special Tools in this section.
1
2 3
4
5
1
6 2
7
5 9
10
6
5
5 A
16 11
12
6
8
8
13
6 2
15
14 1
2 2
1 A
1
BS01B225
47. Use an acceptable driver, the hydraulic ram, and 5. Tighten a nut on the screw until the bearing cup
the h an d pu mp to r emo ve th e u pp e r p iv ot is seated in the bore of the top pivot. Remove the
bearing (9) from the top pivot. See Special Tools bearing driver and plate from the top pivot.
in this section. 6. Install a bearing cone, spacer, the other bearing
NOTE: The spacers are matched to the bearing cone, and the remaining bearing cup in the top
sets. Do not mix the spacers. Do not use the old pivot, refer to Figure 3.
spacers if new bearing sets are being installed. 7. Install the bearing driver and plate.
48. Use an acceptable driver, the hydraulic ram, and 8. Tighten a nut on the screw until the bearing cup
the hand pump to remove the lower pivot bearing is sea ted a ga in st the spa ce r. R emo ve th e
(12) from the bottom pivot. See Special Tools in bearing driver and plate from the top pivot.
this section.
NOTE: The spacers are matched to the bearing
sets. Do not mix the spacers. Do not use the old
spacers if new bearing sets are being installed.
49. Use an acceptable driver to press the seal (6) out
of each bearing retainer (7 and 13).
B1424A88J
FIGURE 3.
B1425A88J B1430A88J
FIGURE 4. FIGURE 6.
12. Measure the gap between the bearing retainer 20. Apply grease to the upper pivot pin (4).
(7) and the top pivot. Make a record of the
21. Install the upper pivot pin (4) in the top pivot.
measurement. Subtract 0.0762 to 0.1016 mm
(0.003 to 0.004 inch) from the measurement, 22. Lubricate the top pivot until grease is forced out
refer to Figure 4. Select shims (8) equal to that of the seal (6). See Specifications in this section.
value.
23. Rotate the upper pivot pin (4) to check the
13. Remove the bearing driver, plate, and bearing bearing assembly. The upper pivot pin (4) must
retainer (7) from the top pivot. rotate smoothly, but not easily. Leave the upper
pivot pin (4) in place to keep dirt out of the upper
14. Install the shims (8) and the bearing retainer (7).
pivot bearing (9).
15. Install the washers (2) and bolts (1). Tighten the
24. Lubricate the bore for the bottom pivot with
bolts (1) to 124 Nm (92 pound-feet).
grease. Install a bearing cup in the bottom pivot.
16. Install the seal (6) in the bearing retainer (7). The
25. Install the bearing driver and plate, refer to
top of the seal (6) must be even with the top of
Figure 7.
the bearing retainer (7), refer to Figure 5.
B1426A88J
B1427A88J
FIGURE 5.
FIGURE 7.
B1428A88J
FIGURE 8.
30. Tighten a nut on the screw until the bottom
bearing cup is seated against the spacer.
31. Remove the bearing driver and plate from the
bottom pivot.
32. Put the bearing retainer (13) in place on the
B1430A88J
lower pivot bearing (12).
FIGURE 10.
33. Install the bearing driver and plate, refer to
41. Install the other seal (6) in the bottom pivot, refer
Figure 9.
to Figure 11. The top of the seal (6) must be even
with the top of the bottom pivot.
B1429A88J
FIGURE 9.
B1426A88J
34. Tighten a nut on the screw until the bearing FIGURE 11.
retainer (13) is tight against the lower pivot 42. Install the lower bearing spacer (11) and the
bearing (12). bottom spacer (14).
Section
5008
5008
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright 2001 Case Corporation
3350 South Service Road Printed in U.S.A.
Burlington, ON L7N 3M6 CANADA Bur 6-42430 August, 2001
Copyright
5008-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
AUXILIARY STEERING MOTOR AND PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SPECIFICATIONS
Auxiliary steering motor
Maximum amperes...............................................................................................................................30 amperes
Minimum armature speed ............................................................................................................ 6950 r/min (rpm)
Motor .......................................................................................................................................................... 24 volts
Auxiliary steering pump
Minimum flow ..............................................................................................24.6 L/min at 104 bar at 315 amperes
(6.5 U.S. gpm at 1500 psi at 315 amperes)
Disassembly Assembly
NOTE: Refer to Section 5001 for removal and 1. Lubricate all parts with clean hydraulic oil before
installation of the auxiliary steering motor and pump. assembly.
NOTE: The pump is the only component that is 2. Lubricate and install a new seal (4) and retaining
disassembled. The switch (8) and motor (1) are ring (3) on the plate (17). Refer to the illustration
replaced as units and are not serviced. Refer to the on page 5.
illustration on page 5.
3. Lubricate and install a new backup ring (5) and a
1. Make an alignment mark on the pump assembly new seal (6) on the plate (17).
and motor (1).
4. Lubricate and install new O-rings (7) on the body
2. Loosen and remove the two screws (15) and lock (18).
washers (14) that hold the pump assembly to the
5. Lubricate and install the pins (22), drive gear
motor (1).
(20), driven gear (19) and wear plates (23) on the
3. Remove and discard the mounting gasket (13), body (18).
retaining ring (3) and seal (4) from the pump
6. Lubricate and install a new backup ring (5) and a
assembly.
new seal (6) on the end plate (21).
4. Loosen and remove the four bolts (2) that hold
7. Align the marks, made during disassembly, on
the pump assembly together.
the end plate (21), body (18) and plate (17) and
5. Remove the end plate (21) from the body (18). install the four bolts (2). Tighten the four bolts (2).
6. Remove and discard the seal (6) and backup ring 8. Install a new gasket (13) on the pump assembly.
(5) from the end plate (21).
9. Align the marks, made during disassembly, on
7. Remove the wear plate (23), drive gear (20) and the pump assembly and the motor (1).
driven gear (19) from the body (18).
10. Install the lock washer (14) and screw (15).
8. Remove the body (18) from the plate (17). Torque the screw (15) to 35 to 39 Nm (312 to 348
pound-inches).
9. Remove and discard the O-rings (7) from the
body (18).
10. Remove the pins (22) and wear plate (23) from
the body (18).
11. Remove and discard the seal (6) and backup ring
(5) from the plate (17).
NOTE: The only serviceable items on the pump
assembly are the seals (6), backup rings (5), O-rings
(7), seal (4), retaining ring (3) and gasket (13). If any
of the other items are damaged, replace the pump
assembly.
Inspection
1. Inspect the wear plates (23) for grooves, scoring
and pitting. If damage is found replace the pump
assembly. Refer to the illustration on page 5.
2. Inspect the drive gear (20) and driven gear (19).
If the shafts are worn or damaged, replace the
pump assembly.
3. Clean all parts in cleaning solvent and air dry.
4. Inspect the plate (17), end plate (21) and body
(18). Replace the pump assembly as necessary.
10 8
9
11
12 16
13
3 17
4 14
15
5
6
23
19
7
22
18
22
7
20
23
6
5
21
2
BS01C121
SECTION INDEX
POWER TRAIN
((Re
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright 2003 Case Corporation
3350 South Service Road Printed in U.S.A.
Hamilton, ON L7N 3M6 CANADA Bur 6-42442 August, 2001 (Revised February, 2003)
Copyright
Copyright
6001
Section
6001
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright 2003 Case Corporation
3350 South Service Road Printed in U.S.A.
Burlington, ON L7N 3M6 CANADA Bur 6-42451 August, 2001 (Revised 2-03)
Copyright
6001-2
TABLE OF CONTENTS
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . ....... ...... ...... ....... ...... .................... 2
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . ....... ...... ...... ....... ...... ................... 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... ...... ...... ....... ...... ................... 3
Transmission Mounting . . . . . . . . . . . . . . . . ....... ...... ...... ....... ...... . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . ....... ...... ...... ....... ...... . . . . . . . . . . . . . . . . . . 11
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . ....... ...... ...... ....... ...... . . . . . . . . . . . . . . . . . . 18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... ...... ...... ....... ...... . . . . . . . . . . . . . . . . . . 18
Front Axle Mounting . . . . . . . . . . . . . . . . . . ....... ...... ...... ....... ...... . . . . . . . . . . . . . . . . . . 20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . ....... ...... ...... ....... ...... . . . . . . . . . . . . . . . . . . 21
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . ....... ...... ...... ....... ...... . . . . . . . . . . . . . . . . . . 23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... ...... ...... ....... ...... . . . . . . . . . . . . . . . . . . 23
Rear Axle Mounting . . . . . . . . . . . . . . . . . . . ....... ...... ...... ....... ...... . . . . . . . . . . . . . . . . . . 25
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . ....... ...... ...... ....... ...... . . . . . . . . . . . . . . . . . . 26
SPECIAL TORQUES
RH and LH Mounting Brackets to Transmission Mounting Bolts . . . . . . . . . . . . . . 481 to 590 Nm (355 to 435 lb-ft)
Top Mounting Bracket to Transmission Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . 251 to 319 Nm (185 to 235 lb-ft)
Transmission Mounting Brackets to Chassis Mounting Bolts . . . . . . . . . . . . . . . . 890 to 1000 Nm (655 to 735 lb-ft)
Engine Drive Shaft to Transmission Mounting Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 to 41 Nm (25 to 30 lb-ft)
Fuel Supply Hose Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 Nm (30 lb-inch)
Fuel Return Hose Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 Nm (30 lb-inch)
Transmission Fill Tube Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 to 33 Nm (12 to 24 lb-ft)
Rear Drive Shaft to Transmission Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 to 81 Nm (45 to 60 lb-ft)
Center Drive Shaft to Transmission Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 to 81 Nm (45 to 60 lb-ft)
Front Axle Mounting Bolts
P.I.N. JEE0135500 and Below . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .845 to 950 Nm (625 to 700 lb-ft)
P.I.N. JEE0135501 and Above . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .955 to 1075 Nm (705 to 790 lb-ft)
Wheel Bolts
Preliminary Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298 Nm (220 lb-ft)
Final Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 640 to 720 Nm (475 to 530 lb-ft)
Center Bearing Mounting Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 to 128 Nm (73 to 94 lb-ft)
Front Drive Shaft Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 to 81 Nm (45 to 60 lb-ft).
Pivot Pin Caps Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251 to 280 Nm (185 to 205 lb-ft)
Rear Drive Shaft to Rear Axle Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61 to 81 Nm (45 to 60 lb-ft)
TRANSMISSION
Removal STEP 4
STEP 1
Note amount of fuel in fuel tank then refer to Section 9
9007 and remove ROPS cab or ROPS canopy. 8
6
STEP 2
BD01D304
1
Loosen clamp (8). Disconnect suction hose (5) from
hydraulic reservoir and remove with tube assembly
(4) attached from machine. Disconnect case drain
hose (6) from fitting (9); remove hose (6). Remove
and discard O-ring face seal from fitting. Plug hoses
and cap fittings to prevent entry of foreign matter into
BD01D321
hydraulic system.
P u t a 3 7 . 8 l it e r ( 1 0 g a l lo n ) c o n t a in e r u n d e r
transmission drain plug (1). Remove drain plug and
STEP 5
drain transmission oil. Install drain plug after oil has
drained.
11
STEP 3 13
4 14
2 10
5
7
12
BD01D308
17 15
22
18
23
16
BD01D306 BD01D310
Identify, tag, and disconnect brake pump pressure Remove two socket head bolts securing transmission
hose (15) and brake to hydraulic reservoir hose (16). wiring harness clamps (22 and 23).
Position hoses away from transmission. Remove and
discard O-ring face seals from fittings (17 and 18). STEP 10
STEP 7
24
25
26
19
20
BD01D312
27
21
BD01D316
34
28 37
36 35
29
38
BD01D314 BD01D296
Identify, tag, and disconnect transmission wiring At front of transmission, identify, tag, and disconnect
harness connectors from filter maintenance switch parking brake hose (34) from parking brake (35).
(28 ) a nd ou tp ut sp eed se nso r (2 9). Mo ve Move hose away from transmission. Remove four
transmission wiring harness away from transmission. bolts (36) and two straps (37) securing center drive
shaft (38) to transmission output flange. Disconnect
STEP 13 center drive shaft from transmission.
STEP 16
30
39
31 32 41
BD01D333
40
Connect lifting equipment to hydraulic pump (30);
take care not to damage pump tube assembly (31). BD01D323
Take up all slack in lifting equipment. Remove two Remove four bolts (39) and two straps (40) securing
bolts (32) and washers securing pump to rear drive shaft (41) to transmission output flange.
transmission. Disconnect rear drive shaft from transmission.
STEP 14 STEP 17
43
42
33
44
BD01D335 BD01D324
Pull hydraulic pump from transmission and remove Remove two bolts (42) securing hose bracket (43) to
from loader. Remove and discard O-ring (33). transmission. Remove bracket from transmission
and lay on rear axle brake hose (44).
46
45 50
BD01D322 BD01D339
Remove two bolts (45). Remove fill tube (46), with Remove fitting (50). Remove and discard O-ring from
cap and oil gauge assembled, two seals, and metal fitting.
strainer. Discard seals.
STEP 22
STEP 19
51
52
47
48 BD01D340
STEP 20
50
49
BD01D318
57
63
62
56 53 64
53
BD01D338 BD01D326
STEP 26
65
55 55
54 66
54
BD01D341
61 58
BD01D335
73 72
74
75
70 75
A 76
BD01D332 BD01D342
69 69 69 STEP 31
69
BD01D327
BD01D343
82 81
78
76
77
BD01D344 BD01D361
Raise transmission just enough to enable removal of If top mounting bracket (76) requires removal,
RH and LH mounting brackets (78). Remove two remove bolt (81) and washer (82) then remove
b o lt s ( 7 7 ) a n d w a s h e r s s e cu ri n g R H a n d L H bracket.
mounting brackets (78) to transmission. Remove RH
and LH mounting brackets.
STEP 33
BD01D345
Transmission Mounting
79 81 79
80 82
C
B 80
83
83
ISOLATOR 77
INSTALLATION
81
77
82
78
83
79
76
80
75
77
75 83
77
78
BS01E012
Installation STEP 38
STEP 35
C he c k is ola t o rs ( 8 3 ) fo r d e te r io ra tio n , te a r s,
deformation, or other damage. Replace as
necessary: refer to Page 10.
STEP 36 78
82 81 77
BD01D344
76 STEP 39
BD01D361
78
BD01D337
BD01D345
73 72 71
71
81
74
75
BD01D343
69
69
79
69 69 69
69
BD01D337
BD01D327
Tighten bolts (79) securing RH and LH mounting
brackets to a torque of 890 to 1000 Nm (655 to 735 Put fuel tank and plate (70) on hydraulic jack (A) and,
lb-ft). with an assistant, move into position beneath loader.
Make sure vent hose (67, Step 45) with breather
installed is routed up into engine compartment when
fuel tank is raised. Raise fuel tank and plate, align
mounting holes, and secure using six washers and
bolts (69). Lower and remove hydraulic jack (A) from
under fuel tank plate.
59
60
61 58
68
BD01D330 BD01D335
Connect wiring harness wires to fuel level sender Remove plug from fuel return hose (60) and cap from
(68) following tags installed during removal. Remove fitting (61). Put clamp (59) on fuel return hose.
and discard tags. Connect hose to fitting (61) and tighten clamp to a
torque of 3.4 Nm (30 lb-inch). Check that drain valve
STEP 45 (58) is closed.
STEP 48.
65
66
67
55 55
54
BD01D328
54
Route vent hose (67) with breather valve up towards
RH side of fan shroud. Put breather valve in vent BD01D338
63
62 53
56
53
BD01D341
64 Mo v e m o u nt in g b r a ck e ts ( 5 4 ), p a r kin g b ra k e
accumulator (56), and brake accumulators (57) into
position. Secure to rear chassis using four spacers
BD01D326
(55), washers, and bolts (53).
Remove plug from fuel supply hose (63) and cap
from fuel tank fitting (64). Put clamp (62) on hose
(63). Connect fuel supply hose and tighten clamp to
a torque of 3.4 Nm (30 lb-inch).
51
46
52
45
BD01D340 BD01D322
Install new O-ring on fitting (52) and install fitting in Position fill tube (46), two new seals, and metal
transmission. Install new O-ring face seal in fitting strainer on transmission; metal strainer is installed
then connect cooler hose (51) to fitting following tag between seals. Secure using two bolts (45). Tighten
installed during removal. Remove and discard tag. bolts to a torque of 17 to 33 Nm (12 to 24 lb-ft).
STEP 50 STEP 53
50 43
49
42
44
BD01D318 BD01D324
Install new O-ring on fitting (50) and install fitting in Position hose bracket (43) with rear axle brake hose
transmission. Install new O-ring face seal in fitting (44) on transmission. Install two bolts (42) to secure
then connect cooler hose (49) to fitting following tag hose bracket to transmission.
installed during removal. Remove and discard tag.
STEP 54
STEP 51
39
41
40
47
48 BD01D323
34
37 28
36 35
29
38
BD01D296 BD01D314
Connect center drive shaft (38) to transmission and Connect transmission wiring harness connectors to
install two straps (37) and four bolts (36). Tighten output speed sensor (29) and filter maintenance
bolts to a torque of 61 to 81 Nm (45 to 60 lb-ft). switch (28) following tags installed during removal.
Connect parking brake hose (34) to parking brake Remove and discard tags.
(35) following tag installed during removal. Remove
and discard tag. STEP 59
STEP 56
27
31
30 33
BD01D316
STEP 57 24
25
26
BD01D312
17 15
22
18
23
16
BD01D310 BD01D306
Install two socket head bolts to secure transmission At brake valve, install new O-ring face seals in fittings
wiring harness clamps (23 and 22). (18 and 17). Connect brake to hydraulic reservoir
hose (16) and brake pump pressure hose (15)
STEP 62 following tags installed during removal. Remove and
discard tags.
STEP 65
21
11
13
14
10
BD01D317
19
20
BD01D315
8 9
6
1
BD01D304 BD01D321
Remove plugs from hoses and caps from fittings. Check that transmission drain plug (1) is tight.
Install new O-ring face seal in fitting (9). Connect
hydraulic pump case drain hose (6) to fitting (9). STEP 69
Position suction hose (5) between reservoir port and
hydraulic pump inlet port. Connect suction hose (5)
to hydraulic reservoir. Tighten clamp (8).
STEP 67
2
5
7
BS00M474A
FRONT AXLE
Removal STEP 75
STEP 72 2
1 3
1 2 1
BD01D370
STEP 73 4
8
3 5
7
9
5 6
BD01D368
11
10
BD01D371 BD01D412
Disconnect brake hose (10) from fitting (11). Remove Use an acceptable jack to hold front axle.
and discard O-ring face seal from fitting.
STEP 81
STEP 78
12
13
BD01D391
STEP 82
14
BD01D392
14
14
15
15
18
16
16
17
17
BS01E054
Installation STEP 87
STEP 84
Carefully move front axle under machine and raise
against mounting pads on machine.
STEP 85
14
BD01D412
STEP 88
BD01D394
STEP 86
BD01D393
12
13
BD01D391
BD01D392
STEP 89
Repeat Step 88 to remove other jack stand from
under machine.
BS00J104
2
11
1 3
10
1 2 1
BD01D371 BD01D370
Install a new O-ring face seal in fitting (11). Connect Secure drive shaft (3) to front axle using two straps
brake hose (10) to fitting. (2) and four bolts (1). Tighten bolts (1) to a torque of
61 to 81 Nm (45 to 60 lb-ft).
STEP 91
STEP 93
4 If necessary, fill axle with gear lubricant specified in
8 Section 1002.
5 STEP 94
3
Refer to Section 7002 and bleed brakes.
7
STEP 95
9
5 6
BD01D368
STEP 96
Put articulation lock in OPERATING position.
REAR AXLE
STEP 97
Park machine on a level surface; be sure to allow
adequate space at side of machine for removal of 5
rear axle. Stop engine. Actuate brake pedal several
times to discharge brake accumulators. Put key
switch in ON position and move loader control lever
back and forth at least 30 times to release any
pressure from hydraulic circuit. Note amount of fuel
in fuel tank then put key switch in OFF position. 4
STEP 98
BD01D369
STEP 103
BD00M030
STEP 99
Remove fuel tank (Steps 24 through 28). BD01D410
1 2
3
1 2 BD01D414
BD01D362
Use an acceptable jack to hold rear axle.
Remove four bolts (1) and two straps (2). Use a pry
bar to disconnect rear drive shaft (3) from rear axle.
6
8
10
A A
9
10
12
BD01D391 BD01D363
Remove 10 bolts (6) and washers (7) from rear At front of trunnion (9), remove two Allen head bolts
wheels (8). Remove both wheels from rear axle. (10) and washers (11). Remove front cap (12): if
necessary use two M12 by 32 mm (1.25 inches) bolts
in puller holes (A); tighten bolts evenly to pull cap
from axle and trunnion. Remove and discard O-ring
(15) from cap. Repeat this step at rear of trunnion
except remove and retain shim(s) (14) after removal
of rear cap (13). Remove pivot shaft (16) using
acceptable sleeve or rod if necessary.
STEP 107
Carefully lower rear axle and remove through side of
machine.
STEP 108
Remove and discard two seals (17) from rear axle
pivot point.
10
9 11
12
17
15
10
11
7
14
16
11
10 15 18
17
6
11 13
10
BS01E055
STEP 109
10 9 10
9
16
12
13
BD01D482A
A
B
BS01E091A
Install pivot pin (16) and caps (12 and 13) in trunnion
(9) without rear axle or shim(s). Install washers (11)
a n d b o lt s (1 0 ) . Tig h t e n b o l ts se cu re ly. P u s h
assembled pivot pin and caps to rear of machine as
far as possible. Measure and record gap (A) between
rear cap (13) and trunnion. Select shims from the
following:
BD01D499
NOTE: Shims are available in following sizes: 0.50
mm (0.020 inch), 1.0 mm (0.039 inch), and 1.50 mm Clean front (A) and rear (B) pivot area of rear axle
(0.059 inch). where seals (17) will be installed.
STEP 112
Carefully move rear axle under machine. Raise axle
into position in trunnion and align pivot holes in
trunnion with pivot holes in axle.
16 9
9
BS01E091
6 1 2
8 3
1 2
BD01D362
STEP 118
Install fuel tank (Steps 43 through 47). Fill fuel tank
with fuel drained in Step 24.
STEP 119
If necessary, fill axle with gear lubricant specified in
Section 1002.
6002
Section
6002
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright 2001 Case Corporation
3350 South Service Road Printed in U.S.A.
Burlington, ON L7N 3M6 CANADA Bur 6-40800 March, 2001
Copyright
6002-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TRANSMISSION OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Transmission ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Transmission Clutch Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Gear Selections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Automatic/Manual Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Downshift Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Brake Pedal Transmission Declutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
TRANSMISSION PRESSURE TEST POINTS DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CHART FOR RECORDING PRESSURE READINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
PRESSURE TEST RESULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
All or Most Pressures Low and/or Flow Test Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Some Pressures Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Not Enough Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Machine Stops or Hesitates While Shifting - Intermittent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
CONVERTER OUT PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Test Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
LUBRICATION PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Test Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
FLOWMETER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Test Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Flowmeter Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
CONSUMPTION TEST PROCEEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
TRANSMISSION OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
TRANSMISSION SHIFTER LOGIC INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
RELATIONSHIP BETWEEN TRANSMISSION ECM, VALVES, AND CLUTCHES . . . . . . . . . . . . . . . . . . . . . . 20
SPECIAL TOOLS
CAS-1953A Transmission supplemental fitting kit. CAS-1808 Flowmeter kit
Includes: CAS-2324 special 90 degree adapter and
CAS-2702 Flowmeter adapter
CAS-2325 plug and cap set.
CAS-2278 Flow test kit
CAS-1804 Master pressure test kit
SPECIFICATIONS
Main pressure and clutch pressure ................................................................................16 to 18 bar (232 to 261 psi)
Converter in pressure .......................................................................................................8 to 10 bar (116 to 145 psi)
Pressure reduction for solenoids ........................................................................................7 to 9 bar (102 to 131 psi)
Converter out pressure........................................................................................................ 2.5 bar (36 psi) minimum
Lubrication pressure ...........................................................................................................0.2 to 1.2 bar (3 to 18 psi)
Minimum pump output (at 2000 rpm)
521D...................................................................................................................................52 L/min (14 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)
4 1
3 2
5 12
9
6
11
14
13 7
10
BS01A190
1. TRANSMISSION ELECTRONIC CONTROL MODULE 8. INDUCTIVE TRANSMITTER - INTERMEDIATE SPEED SENSOR
2. DOWNSHIFT BUTTON 9. INDUCTIVE TRANSMITTER - TURBINE SPEED SENSOR
3. DECLUTCH ROCKER SWITCH 10. INDUCTIVE TRANSMITTER - ENGINE SPEED SENSOR
4. MANUAL/AUTOMATIC ROCKER SWITCH 11. HALL SENSOR - OUTPUT SPEED SENSOR
5. SHIFTER 12. TRANSMISSION CONTROL VALVE CABLE
6. SUPPLY SYSTEM CONNECTIONS B+ AND RETURN 13. DECLUTCH LIMIT SWITCH
7. TRANSMISSION 14. PLUG
BS01B049
1. CLUTCH SHAFT KR 9. TRANSMISSION PUMP
2. POWER TAKE OFF 10. DRIVE SHAFT
3. CLUTCH SHAFT KV 11. CONVERTER
4. CLUTCH SHAFT K2 12. INDUCTIVE TRANSMITTER FOR ENGINE SPEED
5. CLUTCH SHAFT K3 13. CLUTCH SHAFT K4
6. OUTPUT FLANGE REAR 14. CONVERTER RELIEF VALVE
7. OUTPUT FLANGE CONVERTER SIDE 15. CLUTCH SHAFT K1
8. OUTPUT SHAFT
2 2
2
2
1 3
4
BS01A191
3. OUTPUT FLANGE CONVERTER
1. ATTACHMENT FOR OIL FILLER PIPE WITH OIL DIPSTICK
SIDE
2. TRANSMISSION SUSPENSION BORES 4. OIL DRAIN PLUG
1
2
3
10
6
7
BS01A192
1. CONVERTER BELL HOUSING 6. OUTPUT FLANGE REAR
2. BREATHER 7. OIL DRAIN PLUG
3. TRANSMISSION CASE COVER 8. OUTPUT FLANGE CONVERTER SIDE
4. FILTER HEAD 9. TRANSMISSION CASE
5. FILTER 10. PARKING BRAKE
2
1
1
7 3
4 4
BS01B048
1. LIFTING LUGS 5. OUTPUT FLANGE REAR
2. POWER TAKE OFF 6. FILTER
3. TRANSMISSION CONTROL VALVE 7. FILTER HEAD
4. TRANSMISSION SUSPENSION BORES
TRANSMISSION OPERATION
NOTE: See Figure 10 for Measuring Point, Transmitter, Sensor and Connection locations.
BC01B047
FIGURE 10. MEASURING POINTS AND CONNECTIONS
TEST POINTS
Shift P V R 1 2 3 4 5 6
LP
Speed 65 53 55 56 57 58 60 51 52
1st F
2nd F
3rd F
4th F
1st R
2nd R
3rd R
Neut
P= MAIN PRESSURE 1= FIRST GEAR CLUTCH 4= FOURTH GEAR CLUTCH LP= LUBE PRESSURE
2. Oil type and grade not correct. 2. Engine RPM below Stall Test specified RPM.
(Refer to Section 2002 for specifications.)
3. Oil operating temperature high.
A. Check engine and fuel system for problem.
4. Screen for suction tube plugged.
B. Check that torque converter installation is
5. Suction tube or gaskets leak. correct.
6. Main pressure valve, springs, or valve bore. 3. Engine RPM above Stall Test specified RPM.
7. Reduction valve, springs, or valve bore. (Refer to Section 2002 for specifications.)
8. Charge pump seals or gaskets leak. A. Check converter pressures and flow.
0 to 28 bar (400 psi) gauge with hose long enough to 3. Install the pressure gauge.
take readings in the cab and CAS-2324 Special 4. Heat the oil to an operating temperature of 80 to
Adapter. 100 C (176 to 212 F).
5. While in the cab, put the transmission in
Test Procedure NEUTRAL. Run the engine at full throttle. Record
1. Block the machine tires. the reading in the char t on page 6002.16.
Pressure must be a minimum of 2.5 bar (36 psi).
Test Equipment Required 3. Install the pressure gauge in the cooler return
line at the transmission.
0 to 7 bar (100 psi) gauge.
4. Heat the oil to an operating temperature of 80 to
100 C (176 to 212 F).
Test Procedure
5. While in the cab, run the engine at full throttle.
1. Block the machine tires. Put the transmission in each gear and record the
2. Apply the parking brakes. reading in the chart on page 6002.16. Pressure
must be 0.2 to 1.2 bar (3 to 18 psi).
FLOWMETER TEST
TRANSMISSION OVERHEATING
1. Operate machine in normal operating conditions and observe:
A. Verify actual oil temperature at test point. Normal operating temperature can be 56C (100F) above the
ambient temperatures.
B. Use a stop watch to establish the exact length of time required to reach the overheating condition.
C. Observe engine temperature, does the engine overheat? Which overheats first - engine or transmission?
2. When the transmission reaches overheated condition, shift to Neutral and maintain engine RPM at a fast idle
(1250 to 1450 RPM).
A. Oil temperature returns to Normal - establish length of time.
1. Check oil level, type and grade is correct (See Section 1002).
2. Check operators gear selection is correct for conditions.
3. Make sure brakes are fully released.
4. Check the engine full throttle and stall speeds are correct as specified (See Section 2002).
B. Oil temperature remains overheated.
1. Check for dirty radiator - airflow restricted.
2. Check for engine overheating problem.
3. Check for faulty oil temperature gauge and sender or switch (See Section 4002).
3. Perform all the pressure and flow tests.
4. Compare the pressure and flow test results to the specifications in this section to determine if any circuits are
not within specifications.
5. Refer to Pressure Test Results to determine possible cause of any test results not within specifications.
ERROR CODES
In case of possible errors in the system, a wrench appears on the display, combined with indication of the error
number. See section 4005 for error code retrieval procedures and definitions.
NOTE: Power is supplied through the fuse A to the transmission shifter via 19A wire. This is 24 Volt. Within the
shifter are limit switches to transfer the signal voltages to the outputs. In forward V is high. In reverse R is high. In
neutral N is high. In first gear, B1 is high and B2 is low. In second gear, B1 and B2 are low. In third gear, B1 is low
and B2 is high. In fourth gear, B1 and B2 are high. Downshift, DS, is activated when the end of the shifter is
engaged.
Section
6003
6003
TRANSMISSION
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright 2002 Case Corporation
3350 South Service Road Printed in U.S.A.
Hamilton, ON L7N 3M6 CANADA Bur 6-42460 June, 2002
Copyright
6003-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SPECIAL TOOLS
CAS2802 ALIGNMENT
CAS2799 CLUTCH PACK DOWEL SET
H0LDER AND SPRING
COMPRESSOR TOOLS
CAS2801 TRANSMISSION
CAS2796 NESTING MOUNTING BRACKETS
PLATE
CAS2868 CLUTCH
SPRING COMPRESSOR
(521D AND 621 MODELS
CAS2800 CLUTCH CAS2797 LIFTING ONLY)
ASSEMBLY HOLDING EYEBOLT SET
CAS2798 GEAR KNOB SET
PULLER COLLET SET
BS02C097 THRU 104
CAS40079 TRANSMISSION OVERHAUL KIT
SPECIAL TORQUES
Oil pipes
Studs .............................................................................................................................................. 9 Nm (80 lb-in)
Socket head screw ..................................................................................................................... 23 Nm (204 lb-in)
Screw plug .................................................................................................................................... 51 Nm (38 lb-ft)
Clutch K1, K2, K3, K4 Stud ............................................................................................................ 17 Nm (150 lb-in)
Plugs................................................................................................................................................ 25 Nm (221 lb-in)
Output shaft
Output shaft screws (apply Loctite 243 to threads) .................................................................... 23 Nm (204 lb-in)
Housing cover screws (apply Loctite 574 to threads)................................................................. 46 Nm (407 lb-in)
Output flange screws ................................................................................................................. 34 Nm (301 lb-in)
Oil feed housing and transmission pump
Transmission pump screws ........................................................................................................ 46 Nm (407 lb-in)
Oil feed housing screws ............................................................................................................. 25 Nm (221 lb-in)
Engine connection and converter
Input shaft screws ....................................................................................................................... 115 Nm (85 lb-ft)
Converter housing screws............................................................................................................. 68 Nm (50 lb-ft)
Cover........................................................................................................................................... 23 Nm (204 lb-in)
Converter cover.......................................................................................................................... 46 Nm (407 lb-in)
Input flange ................................................................................................................................. 34 Nm (301 lb-in)
SPECIFICATIONS
Clutch KV and KR plate clearance ......................................................................... 2.5 to 2.7 mm (0.098 to 0.106 in)
Clutch K1, K2,K3 plate clearance........................................................................... 2.1 to 2.3 mm (0.083 to 0.090 in)
Clutch K4 Plate Clearance ..................................................................................... 1.2 to 1.4 mm (0.047 to 0.055 in)
NOTE: The J I Case Company reserves the right to make improvements in design or changes in specifications at
any time without incurring any obligation to install them on units previously sold.
DISASSEMBLY
STEP 1 STEP 4
GD98M833 GD98M837
STEP 5
GD98M835
STEP 3 GD98M838
STEP 6
GD98M836
GD98M844
GD98M847
Be nd loc k p late a wa y fr om he x h e ad sc re ws.
U sin g p r o p er siz e r o d, p r e ss in p u t sh a ft a n d
Remove two hex head screws, lock plate, and
converter from cover.
washer. Remove input flange from shaft.
STEP 11
STEP 8
GD98M845 GD98M848
Pu t alig n me n t ma rk s on co n ve r te r co ve r a n d Remove retaining ring then remove bearing.
housing to aid in assembly. Remove 12 nuts and
hex head screws. STEP 12
STEP 9
GD98M849
GD98M853
GD98M850
Put input shaft and diaphragm in vise as shown. Remove the socket head screws for removal of the
Remove 12 hex head screws to separate transmission pump.
diaphragm and input shaft.
STEP 17
STEP 14
GD98M854
STEP 18
GD98M852
GD98M855
STEP 24
GD98M856
STEP 20 GD98M862
STEP 25
GD98M860
STEP 21
GD98M863
STEP 26
GD98M861
Remove the lock plate, hex head screws, and pry the
converter side output flange from the shaft.
STEP 22 GD98M864
Pry the shaft seal out of the housing bore. Install CAS2802 alignment dowel set.
NOTE: The following steps describe the common
removal of all clutches.
Bur 6-42460 Issued 6-02 Printed in U.S.A.
Copyright
6003-9
STEP 27 STEP 30
Remove CAS2800 clutch assembly holding knob
set and lift cover free.
STEP 31
BK00D029
STEP 32
BK00D028
STEP 33
BK00D026
GD98M877
GD98M874
Remove clutch K3. Remove the bearing outer race and pull output shaft
out of the housing bore.
STEP 35
STEP 38
GD98M875
GD98M878
Remove clutch K4 while lifting input shaft slightly.
Remove the rectangular ring and separate ball
STEP 36 bearing from the shaft.
NOTE: The following steps are for the disassembly
of the clutch KV. The disassembly of the clutch KR is
similar.
STEP 39
GD98M876
GD98M979
GD98M881 BK00D020
Separate the clutch disc carrier from the shaft. Remove snap ring.
STEP 41 STEP 44
GD98M882 BK00D019
Remove the snap ring and remove the clutch disc Remove the compression spring.
pack.
STEP 45
STEP 42
GD98M885
GD98M886 GD98M889
Remove the snap ring. Remove the snap ring and remove the ball bearing.
STEP 49
GD98M887
GD98M890
STEP 50
GD98M888
GD98M892
GD98M893 BK00D018
Remove the idler gear. Preload compression spring using CAS2799 clutch
pack holder and spring compressor tool.
STEP 52
STEP 55
GD98M894
GD98M895
Remove the snap ring and remove the clutch disc BK00D019
BS00G001 GD98M800
Remove the sealing ring. Remove bearing using Remove and discard two sealing rings. Pull two
bearing puller. Tap assembly until piston drops out of bearings from shaft using bearing puller. Remove the
the clutch pack carrier. Then, remove and discard snap ring and separate the clutch disc carrier from
O-rings from piston. the shaft.
STEP 58 STEP 60
BK00D022 GD98M801
Remove the clutch disc carrier from the shaft. Remove the snap ring and remove the clutch disc
pack.
NOTE: The following steps are for the disassembly
of the clutch K4.
STEP 61
BK00D018
STEP 64
BK00D020
STEP 63
GD98M803
STEP 65
Remove bearings from input shaft using a bearing
puller.
BK00D019
ASSEMBLY
NOTE: The following steps are for the reassembly of STEP 69
the oil pipes.
STEP 66
3 GD98M607
GD98M603
STEP 67
Secure suction tube (1) and pressure pipes (2) with
socket head screw and hex nuts. Tighten to a torque
of 23 Nm (204 lb-in)
STEP 68
GD98M608
STEP 71
GD98M605
GD98M610 BK00D019
STEP 73
BK00D018
STEP 76
GD98M612
STEP 74
BK00D020
GD98M613
GD98M617
GD98M616
GD98M619 GD98M621
Use tools to lift the end shim against snap ring Apply Loctite 243 to stud. Tighten stud to a torque of
(upward) until contact is obtained. Measure and 17 Nm (150 lb-in).
record dimension (B) from carrier face to end shim
using depth gauge as s hown. S ubtrac t this STEP 85
measurement from the measurement of Step 80. The
difference is the running clearance.
Example
Dimension A . . . . . . . . . . . . . . . . . 7.25 mm (0.29 in)
Dimension B . . . . . . . . . . . . . . . . . 4.75 mm (0.19 in)
Difference = Running . . . . . . . . . . . 2.50 mm (0.10 in)
Clearance
Required running clearance is 2.5 to 2.7 mm (0.098
to 0.106 in). Use snap ring(s) of different thickness as
necessary to obtain correct running clearance.
STEP 82
GD98M622
Remove clutch disc pack, apply oil to discs, and
install clutch disc pack, end shim, and snap ring as Install ball bearing until contact is obtained. Secure
determined in Step 81. using snap ring.
STEP 83 STEP 86
GD98M620 GD98M623
Install idler gear to align and engage all inner discs, Install needle bearing.
then remove idler gear.
GD98M624 BP00G020
Support the idler gear on the bearing inner race. Install gear and shaft into heated bore.
Press the idler gear against the shoulder.
STEP 91
STEP 88
BK00D024
BK00D023
In st a ll h e at e d b ea r in g o n s ha f t a g a in st sh a ft
shoulder.
STEP 94
GD98M632
STEP 97
GD98M630
STEP 95
GD98M633
STEP 98
GD98M631
GD98M634
BK00D019
BS02C130
1. PLATE CARRIER
2. PISTON
3. OUTER PLATE - ONE-SIDED COATED
4. INNER PLATES
5. OUTER PLATES - COATED ON BOTH SIDES
6. SNAP RING
7. END SHIM
A. RUNNING CLEARANCE 2.1 TO 2.3 MM (0.083 TO 0.090
IN)
STEP 102
BK00D020
GD98M637 GD98M639
Install the end shim and snap ring. Use tools to lift the end shim against snap ring
(upward) until contact is obtained. Measure and
STEP 104 record dimension (B) from carrier face to end shim
using depth gauge as s hown. S ubtrac t this
measurement from the measurement of Step 104.
The difference is the running clearance.
Example
Dimension A . . . . . . . . . . . . . . . . . . .8.2 mm (0.32 in)
Dimension B . . . . . . . . . . . . . . . . . . .6.1 mm (0.24 in)
Difference = Running . . . . . . . . . . . .2.1 mm (0.08 in)
Clearance
Required running clearance is 2.1 to 2.3 mm (0.083
to 0.090 in). Use snap ring(s) of different thickness as
necessary to obtain correct running clearance.
GD98M638
STEP 106
Adjust running clearance for K1, K2, and K3 to 2.1 to Remove clutch disc pack, apply oil to discs, and
2.3 mm (0.083 to 0.090 in). Press down on the end install clutch disc pack, end shim, and snap ring as
shim with approximately 10 kg (20 lb). Measure and determined in Step 105.
record dimension (A) from carrier face to end shim
using depth gauge as shown. STEP 107
Example
Dimension A . . . . . . . . . . . . . . . . . . 8.2 mm (0.32 in)
3
2
1
GD98M640
GD98M641 BK00D024
GD98M642
STEP 110
BK00D025
2 STEP 113
Check operation of the clutch using compressed air.
3
GD98M643
STEP 114
WARNING: Always wear heat protective
gloves to prevent burning your hand when
handling heated parts.
SM121A
GD98M649
STEP 117
GD98M647
STEP 115
GD98M650
STEP 118
GD98M648
GD98M651
BK00D019 BS02C131
1. PLATE CARRIER
2. PISTON
3. OUTER PLATE - ONE-SIDED COATED
4. INNER PLATES
5. OUTER PLATES - COATED ON BOTH SIDES
6. SNAP RING
7. END SHIM
A. RUNNING CLEARANCE 1.2 TO 1.4 MM (0.047 TO 0.055
IN)
STEP 120
GD98M653
GD98M654 GD98M656
Install end shim and snap ring. Use tools to lift the end shim against snap ring
(upward) until contact is obtained. Measure and
STEP 124 record dimension (B) from carrier face to end shim
using depth gauge as s hown. S ubtrac t this
measurement from the measurement of Step 124.
The difference is the running clearance.
Example
Dimension A . . . . . . . . . . . . . . . . . . .7.2 mm (0.28 in)
Dimension B . . . . . . . . . . . . . . . . . . .6.0 mm (0.24 in)
Difference = Running . . . . . . . . . . . .1.2 mm (0.04 in)
Clearance
Required running clearance is 1.2 to 1.4 mm (0.047
to 0.055 in). Use snap ring(s) of different thickness as
necessary to obtain correct running clearance.
GD98M655
STEP 126
Adjust running clearance to 1.2 to 1.4 mm (0.047 to Remove clutch disc pack, apply oil to discs, and
0 . 0 5 5 in ) . P r e s s d o w n o n t h e e n d s h i m w it h install clutch disc pack, end shim, and snap ring as
approximately 10 kg (20 lb). Measure and record determined in Step 125.
dimension (A) from carrier face to end shim using
depth gauge as shown. STEP 127
Example
Dimension A . . . . . . . . . . . . . . . . . . 7.2 mm (0.28 in)
GD98M657
Install the idler gear until all inner discs are engaged,
then remove idler gear.
GD98M658 GD98M661
Assemble two thrust washers and thrust bearing. Assemble thrust washer (3), thrust bearing (2), and
thrust washer (1). Install the thrust washer (1) with
NOTE: Upper and lower thrust washers are the
the chamfer facing the thrust bearing.
same thickness.
STEP 132
STEP 129
GD98M662
GD98M659
Install the assembled clutch disc carrier until all the
Install both needle bearings.
inner discs are engaged.
STEP 130 STEP 133
GD98M660
GD98M663
Install the idler gear.
Install snap ring to secure clutch disc carrier.
BK00D024
Heat bearing.
STEP 135
WARNING: Always wear heat protective GD98M666
gloves to prevent burning your hand when Heat gear to about 120 C (248 F) and install on
handling heated parts. input shaft until contact is obtained.
SM121A
STEP 139
BK00D025
STEP 137
Check operation of the clutch using compressed air.
NOTE: The following steps are for the reassembly of
the input shaft.
GD98M668
GD98M669 GD98M672
Install the turbine shaft until the snap ring snaps into Install output shaft into housing bore until contact is
the recess of the input shaft. made.
STEP 142 NOTE: The following steps are for the installation of
the output shaft and clutches. All clutches have a
WARNING: Always wear heat protective common installation.
gloves to prevent burning your hand when
handling heated parts. STEP 145
SM121A
K1 K4
AN KR
AB
K3 K2
KV
GD98M673
BK00F003
BK00D029 GD98M681
Using CAS2797 lifting eye bolt set and acceptable Install the sealing rings and insert rings in their
lif tin g e q u ip m e n t , in s ta ll h o u s in g c o v e r o n t o respective grooves. Apply grease to the sealing rings
clutches. Install CAS2800 clutch assembly holding and align the rings centrally.
knob set to secure clutch shafts to cover.
STEP 151
STEP 148
KR
KV
K4
K2
K1 K3
GD98M692
GD98M679 Install both the O-rings into the annular groove of the
The above photo shows the position of the single oil pipes and apply grease.
clutches in the housing cover.
STEP 152
STEP 149
Tilt the housing cover 180 degrees.
AN
KV KR
K2 K4
K3 K1
AB
GD98M866
GD98M683 GD98M686
Install output gear and shaft in transmission housing. Install screen sheet on output shaft. Press front and
Install alignment screws. Carefully lower the cover rear bearings on output shaft until contact with
and clutches into the gear box housing. shoulder of output shaft is made.
STEP 155
GD98M688
GD98M689
GD98M690 GD98M697
Apply Loctite 243 to the socket head screws and Heat the output flange to about 90 C (194 F). Apply
install the screws. Tighten the screws to a torque of Loctite 574 to the contact area and assemble the
23 Nm (204 lb-in). flange with the washers and hex head screws.
Tighten the screws to a torque of 34 Nm (301 lb-in).
STEP 160 Bend corner of lock plate over hex head screws.
STEP 163
Repeat Steps 161 and 162 to install shaft seal and
output flange on converter side.
NOTE: The following steps are for the assembly of
the oil feed housing and transmission pump.
STEP 164
GD98M691
STEP 161
GD98M702
GD98M696
GD98M703 GD98M706
Install the oil feed housing with washers and hex Install transmission pump.
head screws. Screw the hex head screws in only
until contact is obtained, do not tighten. STEP 169
STEP 166
GD98M707
STEP 167
GD98M708
GD98M709 GD98M712
Install the oil feed housing with the hex head screws Position converter housing. Secure with hex head
and flat washers. Tighten the screws to a torque of screws. Tighten the screws to a torque of 68 Nm (50
25 Nm (221 lb-in). lb-ft).
GD98M711 GD98M713
GD98M714
GD98M715 GD98M718
STEP 179
GD98M716
STEP 177
GD98M719
GD98M717
STEP 183
GD98M720
STEP 184
Install the screw plug with new O-ring. Tighten the
plug to a torque of 30 Nm (265 lb-in).
STEP 185
GD98M724
STEP 182
GD98M727
GD98M729 GD98M735
Install new O-rings in recesses of oil filter head. Apply grease to the new O-ring and install the speed
Position filter head on transmission and secure using sensor with the socket head screw. Tighten the
two socket head screws. Tighten screws to a torque screw to a torque of 23 Nm (204 lb-in).
of 25 Nm (221 lb-in).
STEP 190
STEP 187
GD98M736
STEP 192
GD98M733
Section
6004
6004
FRONT AND REAR AXLE
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright 2002 Case Corporation
3350 South Service Road Printed in U.S.A.
Burlington, ON L7N 3M6 CANADA Bur 6-42470 June, 2002
Copyright
6004-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
WHEEL END AND BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Brake Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Wheel End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Wheel End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Brake Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
DIFFERENTIAL CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Cleaning, Inspection, and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Rear Axle Pivot Pin Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Determining Pinion Shaft Shim Thickness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Pinion Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Disassembly - Open Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Disassembly - Limited Slip Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Assembly - Open Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Assembly - Limited Slip Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
SPECIFICATIONS
Type of Lubricant ....................................................................................................... Case 135H EP (SAE 85W-140)
Capacity.................................................................................................................................. 20.3 liters (21.5 quarts)
Pinion Shaft Rolling Torque (Without Seal Installed) ................................................................... 2.4 Nm (21.23 lb-in)
Pinion Shaft and Differential Combined Rolling Torque
(Without Seal Installed) ................................................................................... 2.9 to 3.2 Nm (25.66 to 28.32 lb-in)
Ring Gear and Pinion Shaft Backlash .............................................................0.25 to 0.33 mm (0.010 to 0.013 inch)
SPECIAL TORQUES
Bolts Securing Retainer and Flange to Hub (Loctite 270 Applied to Threads) ................................. 114 Nm (84 lb-ft)
Bolts Securing Gears to Planetary Carrier Shafts (Loctite 270 Applied to Threads) ........................ 114 Nm (84 lb-ft)
Socket Head Bolts Securing Wheel End to Axle Housing (Loctite 270 Applied to Threads) ..........226 Nm (167 lb-ft)
Bolt Securing Axle Flange (Loctite 270 Applied to Threads) ....................................................... 139 Nm (102.5 lb-ft)
Bolts Securing Differential Carrier (Loctite 270 Applied to Threads) ............................................. 226 Nm (167 lb-ft)
Ring Gear Mounting Bolts (Loctite 270 Applied to Threads) ..........................................................190 Nm (140 lb-ft)
SPECIAL TOOLS
BD01D644 BDXXXXXXX
PINION NUT REMOVAL TOOL CASXXXX PINION DEPTH GAUGE CASXXXXXX
BD01D646
FALSE PINION TOOL CASXXXXX
Removal STEP 5
IMPORTANT: In this step, brake plates (4) and axle
STEP 1 shaft (5) may stay in axle housing or stay with wheel
Remove drain plugs and drain oil from wheel ends end.
and axle housing. Drain oil into a container having a
capacity large enough to hold 20.3 liters (21.5
quarts). 4
STEP 2
Install axle in an axle stand if available. If axle stand
is not available, secure the axle to a suitable work
bench.
STEP 3 5
BD01D687
STEP 6
4
BD01D506
STEP 4
3 BD01D681
BD01D685
2. HUB 3. FLANGE
Connect suitable lifting equipment to hub (2) and
flange (3). Using a pry bar, separate hub from axle
housing taking care not to damage mating surfaces
of housing and hub.
5 8
7 6
BD01D680 BD01D627
A STEP 10
9
A
8
8 7 6
7 6
BD01D626
10
BD01D622 BD01D520
STEP 12
13
14
11 BD01D522
STEP 13
16
15
12
BD01D523
15. O-RING
16. O-RING
BD01D519
Remove brake piston (13) from brake carrier (14).
12. BLEEDER VALVE
Remove and discard two O-rings (15 and 16).
Remove bleeder valve (12).
20
17
BD01D524 BD01D505
18
18
21
BD01D503
BD01D525
21. RETAINING RING
18. BOLT Remove retaining ring (21).
Loosen, but do not remove, three bolts (18).
STEP 22
STEP 19
22
19
BD01D504
BD01M018
22. WASHER
19. CAP Remove washer (22).
Reposition wheel end to gain access to cap (19).
Using a screwdriver, remove cap. STEP 23
Remove planetary carrier (32) and associated parts
from hub (2).
STEP 24
18
25
BD01D633
STEP 25 27 26
23 BD01D6634
28
24
BD01D635
BD01D632
28. WASHER
24. WASHER
Remove washer (28).
Remove washer (24).
Bur 6-42470 Issued 6-02 Printed in U.S.A.
Copyright
6004-9
STEP 30 STEP 33
Do Steps 24 through 32 to remove remaining two
planetary gears and associated parts from planetary
29 carrier (32). Be sure to keep parts in separate
containers. Mark containers and shafts to ensure
parts are installed on same shaft as removed from.
STEP 34
BD01D638 33
29. SLEEVE
Using slide hammer and puller, remove sleeve (29).
STEP 31
BD01D655
33. BOLT
Remove eight bolts (33).
STEP 35
34
30
BD01D639
STEP 32
BD01D657
34. RETAINER
Remove retainer (34).
31
BD01D640
31. SPACER
Remove spacer (31).
35
BD01D658 BD01D661
STEP 37 STEP 40
36
A
BD01D659 BD01D662
STEP 38 37
38
BD01D663
BD01D660
Remove inner bearing (37) from hub. Remove inner
bearing cup (38) using slide hammer and puller.
2. HUB
Remove hub (2) from flange.
39 STEP 48
Inspect brake friction plate (6) for excessive wear.
discoloration, scoring, and flaking of material over
large areas. Replace if any of these conditions are
seen.
STEP 49
BD01D665
Check separator plates (7) for pitting, scoring, and
other damage. Replace as necessary.
Remove outer bearing cup (39) using suitable puller.
STEP 50
Cleaning and Inspection
Inspect piston (13) and carrier (14) for cracks,
IMPORTANT: Do not use compressed air to dry or breaks, or deformation. Check O-ring grooves in
spin bearings. Allow bearings to air dry. piston and carrier for foreign matter and chipping.
Replace if any of these conditions are seen.
STEP 43
Clean all parts except brake friction plate (6) in STEP 51
cle aning s olve nt. WEAR FACE PROTEC TION Check gears (25) for broken, chipped, or deformed
WH EN U SIN G CO MPRESSED AIR. U se gear teeth. Replace if any of these conditions are
compressed air to clear passages in hub (2). seen.
STEP 44 STEP 52
Check hub (2) and flange (3) for cracks, breaks, Inspect needle bearings (26) for flat spots indicating
deep pitting, erosion, and other damage. Check bolt wear. Replace as necessary.
holes in flange for crossed or stripped threads.
Replace part if any of these conditions are seen. STEP 53
Check planetary carrier (32) for cracks, breaks, or
STEP 45 pitting. Check splines for cracks, breaks, chipping,
Check planetary ring gear in hub (2) for broken, twisting, or deformation. Replace planetary carrier if
chipped, or deformed gear teeth. Replace hub if any any of these conditions are seen.
of these conditions are seen.
STEP 54
STEP 46 Inspect bearings (36 and 37) for rough spots or
Inspect axle shaft (5) splines for breaks, cracks, binding by holding bearing and rotating. If bearing
chipping, twisting, or deformation. Replace axle shaft binds or action is not smooth, replace the bearing.
as necessary. Visually inspect outer race for cracks, bent condition,
and deformation. Check associated bearing cups for
NOTE: If brake friction plate (6) or separator plate
scratches and grooves, If a bearing or bearing cup
(7) is damaged, install a new friction plate and new
requires replacement, the associated bearing or
set of separator plates. Do not mix old and new parts
bearing cup must also be replaced.
in a brake.
26
27
28 18
31 23
24
29 25
26
30
32
38
37
34 33
12
2
39
11
35
3
PLANETARY RING GEAR
(PART OF HUB; NOT SER-
VICED SEPARATELY)
21 1
20
19 36
22
BS01M002
8
10
9
8
7
6
13
17
15
14
16
BS01M001
Assembly STEP 57
Wheel End
STEP 55
38
35
BD01D632
35. SEAL
Position new seal (35), seal lips down, in hub (2).
BD01D664
STEP 58
38. INNER BEARING CUP
Using proper size sleeve, press new inner bearing
cup (38) into hub (2) until flush against shoulder in
hub.
STEP 56
39
BD01D668
Using proper size driver, press seal (35) into hub (2)
until seated against shoulder in hub.
STEP 59
BD01D665
BD01D662
STEP 60
32
31
37
BD01D669
Put hub (2) and flange (3) in a hydraulic press. 31. SPACER 32. PLANETARY CARRIER
Position inner bearing (37) on hub. Using suitable Install spacer (3 1), chamfer down, on shaft of
size driver pushing on inner race of bearing, press planetary carrier (32).
bearing on flange until bearing stops moving.
STEP 64
STEP 61
34
30
BD01D639
BD01D657
30. THRUST WASHER
34. RETAINER
Install thrust washer (30).
Put retainer (34) in position in hub (2) on flange (3).
STEP 65
STEP 62
29
33
BD01D648
BD01D655
29. SLEEVE
33. BOLT
Put planetary carrier in press. Press sleeve (29) on
Apply Loctite 270 to threads of eight bolts (33). Install shaft until sleeve stops moving. Repeat Steps 63
bolts. Tighten bolts to a torque of 114 Nm (84 lb-ft). through 65 to install other sleeves if necessary.
29
26
24
28
BD01D649 BD01D653
25
27
BD01D654
25. GEAR
BD01D650
Install gear (25). Do Steps 66 through 70 to install the
27. WASHER remaining washers, roller bearings, and gears.
Install washer (27).
STEP 71
STEP 68
18
26
23
BD01D631
20
18
18
BD01D630 BD01D505
STEP 74
19
22
BD01M019
19. CAP
Install cap (19).
BD01D504
STEP 78
22. WASHER
Tip wheel end down. Install washer (22).
STEP 75
17
BD01D524
17. O-RING
21 Install a new O-ring (17) in brake piston (13).
BD01D503
13
A 14
16
15
BD01D523 BD01D677
14
12
13
BD01D675
BD01D519
13. BRAKE PISTON 14. BRAKE CARRIER
12. BLEEDER VALVE
Put brake piston (13) and brake carrier (14) in press.
Using a large diameter pusher (A), push brake piston Install bleeder valve (12).
onto brake carrier.
STEP 84
STEP 81
13
14
11
BD01D518
STEP 85
A
9
10
7
BD01D622
BD01D620
10
9 B
A D 7
C BS01M088
BD01D624
BD01D625 5
9 BD01D680
B 5. AXLE SHAFT
8 Install axle shaft (5) in axle housing.
A
STEP 90
4 5
C 7
A
BS01M041
BD01D681
7. SEPARATOR PLATE A. GAP 180 DEGREES APART
4. BRAKE PLATE A. AXLE HOUSING HOLES
8. GRIPPING RING B. 12.5 MM (0.49 INCH)
5. AXLE SHAFT
9. PIN C. GRIPPING RINGS
IMPORTANT: Brake plates must be installed in axle
Using a press and suitable size sleeve, install two
housing with short pin side of brake plates inside axle
gripping rings (8) on each pin (9). Ends of gripping
housing: long pin side of brake plates must be facing
rings must be 180 degrees opposite (A) each other
outward.
when installed. Press gripping rings on pin until 12.5
mm (0.49 inch) (B) is obtained between gripping ring Install brake plates (4) on axle shaft (5). Install pins
and top of pin. Remove brake plates from press. on short pin side of brake plates in holes (A) in axle
Check that pins cannot be rotated in their mounting housing.
holes. If pins can be rotated, gripping rings (C) are
not completely against separator plate (7). Put brake
plates in press and press gripping rings (C) on pin
until rings are completely against separator plate (7).
A A
A
1
BD01D682 BD01D684
STEP 94
BD01D683
planetary gears with axle shaft gear teeth. 1. SOCKET HEAD BOLT
Disconnect lifting equipment from wheel end. Tighten
socket head bolts (1) to a torque of 226 Nm (167
lb-ft).
STEP 95
Remove axle from axle stand or work bench.
STEP 96
Fill axle with amount and type of oil specified in
Section 1002.
DIFFERENTIAL CARRIER
STEP 97
Remove both wheel ends, brakes, and axle shafts
(Steps 1 through 7).
STEP 98
1
BD01D533
1
Disassembly
STEP 99 A
2
A
9
BD01D617
2
A
BD01D531
3
4
BD01D534 BD01D539
3. LOCKING PIN 4. CARRIER 5. DIFFERENTIAL Carefully remove differential from differential carrier.
Position differential carrier on stand so differential (5) Put differential on clean work bench. Go to Step 180
is at top. Using suitable tool, push locking pin (3) up to disassemble open differential or Step 194 to
into collar out of notch in carrier (4). Do the same on disassemble limited slip differential.
other side of differential.
STEP 106
STEP 103
5 A
9 6 7
BD01D540
BD01D538
8
BD01D542
4. CARRIER
8. O-RING
Remove carrier (4). Remove carrier from opposite
side of differential carrier. Remove and discard O-ring (8).
9
A
12
10
BD01D543 BD01D555
11
BD01D544 BD01D556
12
12
BD01D557
BD01D546
12. NUT
13
15
BD01D558 BD01D560
20
16
A
14
BD01D559 BD01D561
14
17
20
BD01D562
17. WASHER
BD01D563
Remove washer (17).
14. OUTER BEARING 20. PINION SHAFT
Remove outer bearing (14) from differential carrier
then remove pinion shaft (20) with washers (15 and
17), spacer (16), inner bearing (18), and shim (19)
installed.
20
18
A
21
BD01D564 BD01D567
18. INNER BEARING 20. PINION SHAFT A. COLLAR 21. OUTER BEARING CUP
Put pinion shaft (20) and inner bearing (18) in If outer bearing cup (21) requires replacement, use a
hydraulic press. Install collar (A). Put a support under slide hammer and suitable puller to remove.
pinion shaft to prevent it from falling on floor. Press
pinion shaft from bearing. STEP 124
STEP 121
19 22
BD01D568
STEP 122
A
10
BD01D673
A A
23 24
23 BD01D495
BD01D482
23 24
24 BD01D499
BD01D491
STEP 134
14
BD01D571
STEP 138
A
BD01D569
STEP 135
Measure differential housing diameter, then calculate
and record its radius.
A STEP 139
18
BD01D570
BD01D614 BD01D600
Install bolt (14) in shaft. Using a lb-in torque wrench, Using inside micro me ter, me asure and re cord
measure rolling torque of pinion shaft. Rolling torque distance (A) between surface of pinion tool and mark
must be 1.6 to 2.4 Nm (14.16 to 21.23 lb-in). If rolling indicating halfway point on differential housing.
torque is too high, loosen nut (12); if too low, tighten
nut then recheck pinion shaft rolling torque. STEP 144
Record the number stamped on pinion shaft. Add the
STEP 141 measurements recorded in Step 134 (pinion tool
head thickness), Step 135 (differential housing
5 radius), and Step 143 (distance between pinion tool
head and differential housing). Subtract the number
4
stamped on the pinion shaft from the sum of the
measurements of Steps 134, 135, and 143. The
remainder is the required shim thickness.
NOTE: Shims are available in the following
thicknesses: 2.5 mm (0.098 inch), 2.6 mm (0.102
inch), 2.7 mm (0.106 inch), 2.8 mm (0.110 inch), 2.9
mm (0.114 inch), 3.0 mm (0.118 inch), 3.1 mm (0.122
2 inch), 3.2 mm (0.126 inch), 3.3 mm (0.130 inch), and
BD01D601 3.4 mm (0.134 inch).
Install differential (5) in differential carrier (2) and
install two carriers (4) to secure differential. Tighten STEP 145
carriers until there is no play and some resistance is Remove differential, pinion tool, and bearings from
felt when differential is rotated. differential carrier. Go to Step 146.
STEP 142
BD01D597
8
7
6
BS01M166
22 21
BD01D568 BD01D567
WARNING: Always wear insulated gloves WARNING: Always wear insulated gloves
or mittens when handling frozen parts. or mittens when handling frozen parts.
If inner bearing cup (22) was removed, freeze new If outer bearing cup (21) was removed, freeze new
bearing cup in dry ice for several hours. Install bearing cup in dry ice for several hours. Install
bearing cup in differential carrier against shoulder in bearing cup in differential carrier against shoulder in
carrier. carrier.
10 17
9
BS01D674 BD01D562
Press axle flange (9) into cover (10) as shown. Install washer (17).
19
16
BD01D561
BD01D565
Install correct thickness shim (19) (as determined in Install new spacer (16).
Steps 133 through 144) on pinion shaft.
STEP 153
STEP 150
18 15
20
BD01D560
13
BD01D612 BD01D558
Install pinion shaft (20) with washers (15 and 17), 13. TAB WASHER
spacer (16), inner bearing (18), and shim (19) in Install tab washer (13).
differ e ntia l ca r rier. Po sitio n a me ta l blo ck o n
differential as shown and secure using two C-clamps. STEP 157
STEP 155
12
BD01D557
12. NUT
BD01D511
Apply Case 135H EP (SAE 85W-140) oil to tab
Apply Case 135H EP (SAE 85W-140) oil to pinion washer face and nut (12) threads. Install nut.
shaft where outer bearing (14) will be installed. Install
outer bearing (14) on pinion shaft in differential STEP 158
carrier. Using suitable size sleeve pushing on outer
bearing inner race press outer bearing on pinion
shaft until threads of pinion shaft are accessible.
Remove C-clamps and metal block installed in Step
154 from differential carrier.
A
12
BD01D555
12. NUT
A. TOOL CASXXXX
Install tool CASXXXX (A) on nut (12).
BD01D556 BD01D538
BD01D614
BD01D671
BD01D539
Tighten carriers (4) evenly and check rolling torque
Move differential into position and carefully position (Step 165).
in differential carrier.
BD01D614
BD01D618
Install bolt (6) in pinion shaft. Using a lb-in torque
wrench, measure rolling torque of pinion shaft and Check that notch in carrier (4) is directly under
differential. Rolling torque must be between 2.9 and locking pin (3). If necessary turn carrier slightly to
3.2 Nm (25.66 to 28.32 lb-in). If rolling torque is too align locking pin and notch. Using hammer, drive
high, loosen carriers (4); if too low, tighten carriers locking pin into notch of carrier. Repeat at opposite
then recheck pinion shaft rolling torque. Remove bolt side of differential.
(6) when correct rolling torque is obtained.
STEP 168
STEP 166
12
BD01D546
BD01D544
11. SEAL
Install seal (11).
9 A
10 9
6 7
BD01D543
BD01D541
9. AXLE FLANGE 10. COVER 6. BOLT 9. AXLE FLANGE
Install cover (10) and axle flange (9). 7. WASHER A. PRYBAR
Reposition differential carrier. Apply Loctite 270 to
STEP 171 threads of bolt (6). Install washer (7) and bolt. Using
prybar (A) to prevent axle flange from turning, tighten
bolt to a torque of 139 Nm (102.5 lb-ft).
8
BD01D542
8. O-RING
Install new O-ring (8).
Installation
1. BOLT
2. DIFFERENTIAL CARRIER
3. LOCKING PIN
FRONT AXLE 3
1
BS01M168
24
3
REAR AXLE 23
BS01M167
BD01D678 BD01D679
Remove all traces of old gasket material from axle Apply Loctite 515 to axle housing differential carrier
housing differential carrier mounting surface. Do the mounting surface.
same on associated mating mounting surface of
differential carrier.
1
BD01D533 BD01D528
STEP 178
Install both axle shafts, brakes, and wheel ends
(Steps 89 through 96).
A
9
BD01D531
DIFFERENTIAL
STEP 179
Refer to Steps 97 through 104 to remove differential
from differential carrier. 7
19
5
BD01D577
STEP 183
BD01D574
5. BOLT 8
Remove 14 bolts (5).
STEP 181
BD01D591
8. COUNTER PLATE
Remove counter plate (8).
STEP 184
6
BD01D576 9
6. RING GEAR
Using a prybar, carefully remove ring gear (6).
BD01D592
9. SIDE GEAR
Remove side gear (9).
13
10
10
11
BD01D584 BD01D587
15
11
BD01D588
16
12
BD01D585 BD01D593
17
4
BD01D594 BD01D578
STEP 192
4
BD01D595
4. BEARING CUP
If bearing cup (4) requires replacement, remove
bearing cup using slide hammer and puller.
BD01D608
3. BEARING
I f i n s p e c t io n i n d i c a t e s b u s h i n g ( 2 ) r e q u ir e s
replacement, remove bushing using proper size
pusher and sleeve. If inspection indicates bearing (3)
re q u ir e s r e p la ce m e n t, r e mo v e b e a r in g u s in g
hydraulic press and collar.
9 10
BD01D579
BD01D574 Remove side gear (11) with separator plates (8) and
5. BOLT friction plates (9 and 10) as an assembly from
housing.
Remove 14 bolts (5).
6
BD01D576 BD01D580
Using a prybar, carefully remove ring gear (6). Remove one separator plate (8).
7
9
8
22
BD01D577 BD01D581
7. HOUSING COVER 22. HOUSING 8. SEPARATOR PLATE 9. FRICTION PLATE
Using two putty knives or other suitable tools inserted Remove three friction plates (9) and three separator
between housing cover (7) and housing (22), pry plates (8).
cover up and remove from housing.
14
11 10
BD01D583 BD01D585
15
12
12
13
BD01D584 BD01D587
17
13
BD01D588
21
21 20
18 19 20
BD01D590 BD01D583
18. SEPARATOR PLATE 20. FRICTION PLATE 20. FRICTION PLATE 21. SIDE GEAR
19. FRICTION PLATE 21. SIDE GEAR
Remove friction plate (20) from side gear (21).
Remove side gear (21) with separator plates (18)
and friction plates (19 and 20) as an assembly from STEP 210
housing.
STEP 207
3
18
BD01D608
3. BEARING
I f i n s p e c t io n in d i c a t e s b u s h i n g ( 2 ) r e q u ir e s
BD01D580
replacement, remove bushing using proper size
18. SEPARATOR PLATE
pusher and sleeve. If inspection indicates bearing (3)
Remove one separator plate (18). re q u ir e s r e p la ce m e n t, r e mo v e b e a r in g u s in g
hydraulic press and collar.
STEP 208
19
18
BD01D581
STEP 213
Check bushing (2) for cracks, grooves, or other
BD01D578 damage. Replace bushing if any of these conditions
are seen.
STEP 214
Inspect bearing (3) for rough spots or binding by
holding bearing and rotating. If bearing binds or
action is not smooth, replace the bearing. Visually
inspect outer race for cracks, bent condition, and
deformation. Check associated bearing cups (4) for
scratches and grooves, If a bearing or bearing cup
requires replacement, the associated bearing or
4 bearing cup must also be replaced.
BD01D595
STEP 215
4. BEARING CUP
Check ring gear (6), side gears, and pinion gears for
If bearing cup (4) requires replacement, remove
broken, chipped, or deformed gear teeth. Check
bearing cup using slide hammer and puller.
internal splines in side gears for cracks, breaks,
chipping, twisting, or deformation. Replace part if any
of the above conditions are seen.
NOTE: If the ring gear (6) is replaced, the pinion
shaft must also be replaced. These parts, ring gear
and pinion shaft, are supplied as a matched set.
STEP 216
Inspect remaining parts for cracks, bent condition, or
damaged or deformed threads. Replace parts as
necessary.
6
1
4
18
15
2
14 12 17 3
14 16
10
15
9
7 8 13 11
5 15
1 12
2 10
10 14
14
4 15
3
BS01M177
1 1
BD01D610 BD01D609
16
BD01D578 BD01D593
14
15
BD01D595
4. BEARING CUP
If bearing cup (4) was removed for replacement,
press new bearing cup into housing or cover until
flush against shoulder. BD01D588
STEP 223
17
13
BD01D594
A
12
BD01D592
BD01D585
Install two short shafts (12) through thrust washer Install side gear (9).
(15), pinion gear (14), and into shaft retainer (13).
Make sure hole (A) in shaft is facing up. STEP 228
STEP 225
8
11
BD01D591
8. COUNTER PLATE
10 18
10 6
BD01D596
5 3
1
BD01D575 BD01D609
BD01D578
1
BD01D610 4
1. CARRIER
If bushing (2) was removed for replacement, press
new bushing into carrier (1) using proper size pusher
and sleeve. Press bushing into carrier until it stops
moving.
BD01D595
4. BEARING CUP
If bearing cup (4) was removed for replacement,
press new bearing cup into housing or cover until
flush against shoulder.
2
1
4
22
18
17 18 6
16 3
16 12
17 14
11
10 19
8 20
21
15
5
12 12 13 16 17
4 14
16
9 17
3 7
2 1
BS01M176
21
19
20
18
A
A
BD01D582 BD01D581
20. FRICTION PLATE 21. SIDE GEAR A. HOLES 18. SEPARATOR PLATE 19. FRICTION PLATE
Install friction plate (20) on side gear (21). Make sure Install three separator plates (18) and three friction
circular cutouts in friction plate are aligned with holes plates (19) alternating between separator plates and
(A) in side gear. friction plates. The first plate installed must be a
separator plate (18); the last plate installed must be a
friction plate (19). Circular cutouts in friction plates
must be aligned.
18
15
BD01D580 BD01D587
21
A
14
18 19 20
BD01D590 BD01D585
18. SEPARATOR PLATE 20. FRICTION PLATE 14. SHORT SHAFT A. HOLE (FOR PIN)
19. FRICTION PLATE 21. SIDE GEAR
Install two short shafts (14) through thrust washer
Install side gear (21) with separator plates (18) and (17), pinion gear (16), and into shaft retainer (15).
friction plates (19 and 20) as an assembly in housing. Make sure hole (A) in shaft is facing up.
16
17
13
BD01D588 BD01D586
16. PINION GEAR 17. THRUST WASHER 13. LONG SHAFT
Install four pinion gears (16) and four thrust washers Install long shaft (13).
(17).
9
12
8
12
13
BD01D584 BD01D581
BD01D582
11
8
5
9 10
BD01D579 BD01D575
22
BD01D596
Section
6004
6004
FRONT AND REAR AXLE
P.I.N. JEE0135501 AND ABOVE
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright 2003 Case Corporation
3350 South Service Road Printed in U.S.A.
Burlington, ON L7N 3M6 CANADA Bur 6-48970 February, 2003
Copyright
6004-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GEAR TOOTH CONTACT PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
WEAR MEASUREMENT ON MULTI-DISC BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
WHEEL END AND BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
BRAKE HYDRAULICS LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
High Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Low Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
DIFFERENTIAL CARRIER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
DIFFERENTIAL DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
DRIVE PINION DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
REAR AXLE PIVOT PIN BUSHINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
BRAKE TUBES REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
BRAKE TUBES INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
DIFFERENTIAL CARRIER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Determine Shim Thickness for Correct Tooth Contact Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Install Drive Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Drive Pinion Bearing Rolling Torque Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
DIFFERENTIAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Open Differential Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Limited Slip Differential Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Adjust Backlash and Bearing Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
SPECIFICATIONS
Lubricant Capacity........................................................................................................22.1 Liters (23.5 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 .........................................................................4.5 to 5.0 mm (0.18 to 0.20 inch)
Sun Gear Shaft End Play ....................................................................................0.5 to 2.0 mm (0.020 to 0.079 inch)
Drive Pinion Rolling Torque ...................................................................................... 1.1 to 4.5 Nm (9.7 to 40 lb-inch)
Differential Carrier Bevel Gear End Play .......................................................... Zero to 0.15 mm (zero to 0.006 inch)
SPECIAL TORQUES
Bolts Securing Wheel End to Axle Housing....................................................................................390 Nm (288 lb-ft)
Locknut Securing Planetary Carrier........................................................................ 700 to 1000 Nm (516 to 737 lb-ft)
Vent Valve Fitting ............................................................................................................................140 Nm (103 lb-ft)
Vent Valve...........................................................................................................................................80 Nm (59 lb-ft)
Axle Housing Connector for Brake Tube ........................................................................................140 Nm (103 lb-ft)
Nut Securing Brake Tube to Connector..........................................................................................140 Nm (103 lb-ft)
Brake Tube Fitting to Wheel End Fitting ............................................................................................. 80 Nm (60 lb-ft)
Breather Plug..................................................................................................................................140 Nm (103 lb-ft)
Nut Securing Input Flange (Apply Loctite 262 to Threads).............................................................600 Nm (442 lb-ft)
Bolts Securing Differential Ring Gear
M12 Bolts ..................................................................................................................................... 120 Nm (88 lb-ft)
M16 Bolts ...................................................................................................................................300 Nm (221 lb-ft)
Bolts Securing Differential Bearing Caps (Apply Loctite 262 to Threads) ......................................185 Nm (136 lb-ft)
Differential Carrier Mounting Bolts (Apply Loctite 262 to Threads) ................................................390 Nm (288 lb-ft)
SPECIAL TOOLS
Brake housing seal installer. . . . . . . . . . . . CAS2880 Step plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8061
Differential bearing cone puller collet set. . CAS2871 Step plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8067
Brake housing inner bearing cup installer . CAS2877 Step plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8073
Brake housing outer bearing cup installer . CAS2878 Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAS2876
Wear ring installer adapter . . . . . . . . . . . . CAS2875 Planetary Gear Puller . . . . . . . . . . . . . . . . . CAS2848
Pinion depth gauge set . . . . . . . . . . . . . . CAS(*TBS) Brake Housing Puller Bridge . . . . . . . . . . . CAS2850
Support bracket . . . . . . . . . . . . . . . . . . . . . CAS2883 Pressure Ring Installer . . . . . . . . . . . . . . . . CAS2860
Slide hammer puller adapter . . . . . . . . . CAS10846-3 Holding Bracket . . . . . . . . . . . . . . . . . . . . CAS2847
Slide hammer . . . . . . . . . . . . . . . . . . . . . . OEM4252 Puller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAS2848
Replacer . . . . . . . . . . . . . . . . . . . . . . . . . . CAS2297 Pulling Attachment . . . . . . . . . . . . . . . . . . .OEM4175
Dial indicator with magnetic base . . . . . CAS10066A Puller Legs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1103
Heat gun . . . . . . . . . . . . . . . . . . . . . . . . . CAS10810 Step Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8065
Engine stand . . . . . . . . . . . . . . . . . . . . . . . OEM4135 Holding Wrench . . . . . . . . . . . . . . . . . . . . CAS1579A
Snap ring pliers . . . . . . . . . . . . . . . . . . . . . OEM6484 Pinion Inner Bearing Cup Installer . . . . . CAS2293-1
Snap ring pliers . . . . . . . . . . . . . . . . . . . . . OEM6177 Pinion Outer Bearing Cup Installer . . . . . .CAS(*TBS)
Snap ring pliers . . . . . . . . . . . . . . . . . . . . . OEM6492 Pinion Seal Installer . . . . . . . . . . . . . . . . .CAS(*TBS)
Alignment Studs . . . . . . . . . . . . . . . . . . . . CAS2861 Pinion Seal Installer . . . . . . . . . . . . . . . . .CAS(*TBS)
Step plate set (includes 8061, 8067, Pulling Attachment . . . . . . . . . . . . . . . . . . .OEM4054
and 8073) . . . . . . . . . . . . . . . . . . . . . . . OEM4288
*TBS: To Be Supplied
BS01D011 BS01D009
COAST SIDE (CONCAVE)
BS01D013
COAST SIDE (CONCAVE)
BS01D012
DRIVE SIDE (CONVEX)
BS01D014
DRIVE SIDE (CONVEX)
BS01D016
BS01D015
COAST SIDE (CONCAVE)
LUBRICATION
6
5
4
2
3
1
2
BS02D084
REAR AXLE SHOWN
BD02D001 BS02D085
NOTE: A wear measurement on the multi-disc brake must be made at least once a year. Wear measurement
should also be made if brake noise is heard, if braking power is reduced, or anytime it is suspected that braking
function is impaired.
Wear measurement must be made on both wheel end sides.
Remove plug, actuate brake and determine dimension (A) using a thickness gauge. If dimension (A) is less than or
equal to 4.0 mm (0.16 inch) the lined discs on both output sides must be replaced. Replace O-ring when installing
the plug. Tighten plug to a torque of 70 Nm (52 lb-ft).
Disassembly STEP 3
NOTE: The following photographs show the rear
axle; dissassembly/assembly procedures are the
same for either axle. Tools and axle shown in the
following photographs may appear slightly different
than the tools and axle you may have. The use of the
tools and disassembly/assembly of axles are the
same regardless of appearance.
STEP 1
BD02D005
STEP 4
BD02D002
STEP 2
BD02D006
STEP 5
BD02D003
BD02D007
BD02D008 BD02D011
Use acceptable lifting equipment to hold wheel end in Remove the shim(s) from the sun gear shaft.
place. Loosen and remove the bolts and washers.
STEP 10
STEP 7
BD02D012
BD02D009 Pull the sun gear shaft out of the planetary gears and
Carefully pull the wheel end from the axle housing. remove.
Remove and discard O-ring from axle housing wheel
end. STEP 11
STEP 8
BD02D013
BD02D014 BD02D017
Remove and discard O-rings from ring gear. Using CAS2848 planetary gear puller and step plate
8061, remove planetary gear and outer bearing from
STEP 13 planetary carrier shaft. Using a suitable puller,
remove the inner bearing from carrier shaft.
STEP 16
Repeat Steps 14 and 15 to remove the remaining
two re ta in ing ring s, pla neta ry gea rs, a nd fo ur
bearings.
STEP 17
BD02D015
STEP 14
BD02D018
BD02D016
BD02D019 BD02D022
STEP 22
BD02D020
STEP 23
BD02D021
BD02D024
BD00M259
Lift and remove the piston from the brake housing.
Put support shim in a press and compress Belleville
washers. Remove retaining ring and pull pin with
Belleville washers and rings installed from support STEP 28
shim. Repeat this step to remove the remaining five
retaining rings and pins from support shim.
STEP 25
BD02D025
BD00M260
STEP 26
BS02D086
BD02D026 BD02D029
Using the CAS2850 brake housing puller bridge and Remove the face seal from the brake housing.
8073 step plate, pull the brake housing from the
wheel end shaft and remove the inner bearing. STEP 33
Using a puller, remove the outer bearing from the
STEP 30 wheel end shaft.
STEP 34
BD02D027
BD02D028
STEP 35
Clean all parts except friction plates in brake disc
p a c k u s i n g c l e a n i n g s o l v e n t . W E A R FA C E
PROTECTION WHEN USING COMPRESSED AIR.
Use compressed air to clear passages in planetary
ring gear and brake housing.
STEP 36
I n s p e c t b e a r i n g r o l l e r s f o r p i t t i n g , s c o r in g ,
deformation, or other damage. Check inner face and
bearing cage for deformation, dents, and other
d a m a g e . C h e c k a s s o c ia te d b e a r in g c u p s f o r BD02D031
scratches, grooves, or cracks. Check bearings for Apply Loctite 574 to inside diameter of a new face
rough spots or binding by holding bearing and seal metal ring. Install face seal metal ring on wheel
rotating. If bearing binds or action is not smooth, end shaft.
replace the bearing.
STEP 41
STEP 37
Inspect bearing cups for pitting, scoring, cracks, or
other damage. Replace if any of these conditions are
seen.
NOTE: If a bearing or bearing cup requires
replacement, the associated part must also be
replaced.
STEP 38
Check planetary ring gear, planetary gears, and
planetary carrier gear teeth for cracks, breaks,
chipping, or other damage. Replace the part if any of BD01F107
these conditions are seen. Check planetary carrier
sh a f t sp lin e s f o r b r ok e n , c ra c ke d , o r t w ist e d
condition. Replace if necessary.
STEP 39
Check wheel end shaft for cracked, broken, or
twisted splines. Replace if any of these conditions
are seen.
BD01F105
BD02D034
A A
BD02D032
A 1
Heat the wheel end shaft outer bearing to 100 C
(212 F) in a bearing oven. Wearing heat resistant
gloves or mittens, install the bearing on the wheel 2
end shaft until the bearing is against the shoulder on
the wheel end shaft.
STEP 43
BS00M073
1. FACE SEAL
2. BRAKE HOUSING
A FILL WITH GREASE
Wet the outer diameter of the face seal with a
solution of 50% water and 50% mineral spirits. Use
CAS2880 seal installer to install the face seal with
the seal lip positioned as shown. Apply grease to
seal as indicated by (A) above.
BD02D033 STEP 46
Using CAS2877 inner bearing cup installer, press the
inner bearing cup into the brake housing until seated
against the shoulder in the brake housing.
STEP 44
Using CAS2878 outer bearing cup installer press the
outer bearing cup into the brake housing until seated
against the shoulder in the brake housing.
BD02D027
BD02D025
BD02D035
BS02D086
GUIDE RING, SUPPORT RINGS AND U-RINGS LOCATION
A B
BD02D036 BD00M282
1. GRIPPING RINGS
Clean the groove of the brake housing with cleaning
solvent. Install the guide ring in the groove. Make Press the four gripping rings on the pins. Ends of
sure the ends (A) of the guide ring are facing up gripping rings must be 180 opposite from each
towards the top (B) of the brake housing and the other.
guide ring is installed completely in its groove in the
brake housing. Apply Loctite 415 to ID of guide ring STEP 52
to secure guide ring in its groove.
STEP 50
BD00M283
5 4
BD02D037
BS00M074
BD00M259 BD02D020
STEP 54
BS02D087
STEP 57
BD02D039
BD02D041
BD02D014
Install the planet carrier into the spline of the wheel Apply grease to new O-rings and install on planetary
end shaft. ring gear.
STEP 59 STEP 62
BD02D042
BD02D044
Apply oil to the clutch discs. Install the outer and
Install two alignment studs in the brake housing.
inner clutch discs alternately starting with an outer
Pos ition the plan eta ry r in g g ea r o n th e b ra ke
clutch disc.
housing. Make sure alignment marks made during
disassembly are aligned. Press planetary ring gear
STEP 60 into brake housing.
BD02D043
BD02D045 BD02D047
Heat the planetary gears inner bearings to 100 C Heat the planetary gears outer bearings to 100 C
(212 F) in a bearing oven. Wearing heat resistant (212 F) in a bearing oven. Wearing heat resistant
gloves or mittens, install the bearings on the shafts gloves or mittens, install the bearings on the shafts
until the bearing is against the bottom of the shaft. until the bearing is against the gear.
STEP 64 STEP 66
BD02D046 BD02D048
Install the planetary gears on the bearings. Install the retaining rings on the planetary gear
shafts.
STEP 67
BD02D051
Install the sun gear shaft in the stub shaft. Make sure
BD02D049 the stub shaft is installed all the way into the sun gear
Using two M18 bolts of suitable length, secure shaft.
p la n e t a r y r in g g e a r to b r a k e h o u s in g . Th e n ,
d e te r min e di me n si on A, f ro m t h e fa c e of t h e STEP 70
planetary carrier stop bolt to the mounting face of the
planetary ring gear.
Example:
Dimension A . . . . . . . . . . . . . 35.60 mm (1.40 inch)
STEP 68
BD02D052
BD02D050 STEP 71
Install the stub shaft in the spline of the axle bevel Subtract dimension B from dimension A. Then
gear. Make sure the stub shaft is installed all the way subtract 1 mm (0.04 inch) from the difference. The
into the axle bevel gear. difference is the required shim size.
Example:
Dimension A + 35.60 mm (1.40 inch)
Dimension B 31.40 mm (1.24 inch)
Difference 4.20 mm (0.16 inch)
Required end play 1.00 mm (0.04 inch)
Difference = shim
3.20 mm (0.12 inch)
size
BD02D012 BD02D154
Install the sun gear shaft in the planet carrier. Install the washers and bolts to secure the wheel end
to the axle housing. Tighten the bolts to a torque of
STEP 73 390 Nm (288 lb-ft).
STEP 76
BD02D011
STEP 77
BD02D009
Install a new slotted pin into the wheel end lock nut.
BD00M303 BD02D153
1. O-RING
Install the cover into the wheel end.
Install a new O-ring on the wheel end cover.
BD02D157
BD02D002 BD02D008
Fasten the axle to a stand. Use acceptable lifting equipment to hold wheel end in
place. Remove the bolts and washers.
STEP 84
STEP 86
BD02D003
BD02D054
BD02D004
BD02D010
BD02D057
Pull the stub shaft out of the sun gear shaft. Be Mount differential carrier in OEM4135 engine stand
careful not to lose shim(s) that may be installed in using one CAS2847 holding bracket.
sun gear shaft.
STEP 92
STEP 88
Do Steps 85 to 87 to remove the other wheel end.
STEP 89
BD02D058
STEP 93
BD02D055
STEP 90
BD02F158
BD02D056
BD02D059 BD02D061
Heat the differential carrier using a hot air blower. Remove both bearing cups.
NOTE: Bolts are installed with Loctite.
STEP 97
STEP 95
IMPORTANT: Do not use an air ratchet or wrench to
remove bolts.
1
BD02D062
BD02D060
1. ALIGNMENT MARK
M a k e a li g n m e n t m a r k s o n b e a r in g c a p s a n d
differential housing to aid in assembly. Remove four
bolts then remove both bearing caps.
DIFFERENTIAL DISASSEMBLY
STEP 98 STEP 101
BD01F059
BD02D064
Remove the bearing from the differential housing
Remove the differential cage half and remove all
using CAS2848 puller, OEM4175 pulling attachment,
parts from the differential housing.
1103 puller legs, and 8065 step plate.
STEP 102
STEP 99
Repeat Step 98 to remove the bearing from the
housing cover.
STEP 100
BD02D065
BD02D063
STEP 104
BD02D067
STEP 107
BD01F091 Put the differential carrier in a press. Press the drive
Install CAS1579A holding wrench on input flange. pinion from the differential carrier. Remove the pinion
Hold flange using holding wrench and remove nut outer bearing.
and washer. Remove holding tool from flange.
STEP 108
STEP 105 Remove the spacer ring and inner bearing from the
drive pinion.
STEP 109
BD02D066
BD02D068
A
A
1 1 2
BD01D482
BD01D495
A
A
2
1 2
BD01D499
BD01D499
1. DIFFERENTIAL CARRIER PIVOT PIN BUSHING
2. AXLE HOUSING PIVOT PIN BUSHING 1. DIFFERENTIAL CARRIER PIVOT PIN BUSHING
A. THRUST SURFACE 2. AXLE HOUSING PIVOT PIN BUSHING
A. GROOVE
Inspect pivot pin bushings in differential carrier and
axle housing for cracks, breaks, deformation, or
other damage. Check oil splash grooves for scoring WARNING: Always wear insulated gloves
or chipping. Check for scoring on thrust surface (A). or mittens when handling frozen parts.
If bushing (1 or 2) requires replacement, do Steps
111 and 112.
Freeze new bushing in dry ice for several hours.
STEP 111 Install bushing in axle housing or differential carrier
with groove (A) on circumference of bushing facing
center of housing or carrier. Install bushing against
shoulder in housing or carrier.
BD01D491
BD02D069 BD02D072
Remove the plug with the breather installed from the Loosen the fitting on the opposite end of the brake
axle housing. tube then remove the brake tube from the axle
housing.
STEP 114
STEP 117
BD02D070
Remove the nut securing the brake tube to the axle BD02D073
BD02D071 BD02D074
Loosen and remove the connector from the axle. Remove the fitting. Remove and discard O-ring and
rectangular ring from fitting.
NOTE: Do Steps 114 to 118 on other wheel end.
1 2
3
4
BD00M340 BD02D116
1. VENT VALVE
Tighten the vent valve to a torque of 80 Nm (59 lb-ft).
2. FITTING
3. O-RING
4. RECTANGULAR RING STEP 122
Install new O-ring and rectangular ring on fitting.
Install and tighten vent valve in fitting.
STEP 120
BD02D117
BD02D115
STEP 123
Install the assembled vent valve and fitting in the
axle. Tighten the fitting to a torque of 140 Nm (103
lb-ft).
BD00M343
1. O-RING
2
1
3
BD02D118 BD02D120
BD00M347
1. O-RING
2. PLUG
BD02D119
3. BREATHER
Install the nut to secure the brake tube fitting. Tighten Remove and discard O-ring (1) from plug (2) and
the nut to a torque of 140 Nm (103 lb-ft). install a new O-ring. Install breather (3) in plug.
STEP 128
BD02D121
STEP 129
Install the CAS(*TBS) pinion depth gauge set on the
differential carrier.
BD02D122
STEP 132
BD01F076
STEP 133
Su btr ac t dime ns io n Y fr om dime ns io n X. Th e
difference is the required shim thickness.
Example C:
Dimension X 172.75 mm (6.801 inch)
Dimension Y 171.65 mm (6.758 inch)
*TBS: To Be Supplied Difference = Shim 1.10 mm (0.043 in)
BD02D124
BD02D125
*TBS: To Be Supplied
BD02D128
STEP 139
WARNING: Always wear heat protective
gloves to prevent burning your hand when
handling heated parts.
SM121A
BD02D129
STEP 142
BD02D127
BD02D130
*TBS: To Be Supplied
Bur 6-48970 Issued 2-03 Printed in U.S.A.
Copyright
6004-36
STEP 143 STEP 146
BD01F091 BD02D132
Install CAS1579A holding wrench on input flange. Using the CAS(*TBS) and CAS(*TBS) pinion seal
Hold flange using holding tool and tighten nut to a installers, install the shaft seal with the seal lip down.
torque of 600 Nm (442 lb-ft). Remove CAS1579A.
NOTE: Just before installation, wet the outer
NOTE: When tightening rotate the pinion shaft in diameter of the shaft seal with a solution of 50%
both directions several times. water and 50% mineral spirits. Fill the space between
the sealing and dust lip with grease.
STEP 144
STEP 147
BD02D131
The rolling torque should be 1.1 to 4.5 Nm (9.7 to 40 Install the input flange. Install CAS1579A holding
lb-inch). If rolling torque is too low, install a thinner wrench on input flange. Apply Loctite No. 262, on the
spacer (Step 138); if rolling torque is too high, install threads of the locknut. Install the washer and locknut
a thicker spacer (Step 138). by hand. Hold flange using holding tool and tighten
nut to a torque of 600 Nm (442 lb-ft). Remove
STEP 145 CAS1579A.
Remove the nut and input yoke from the drive pinion
shaft.
*TBS: To Be Supplied
Bur 6-48970 Issued 2-03 Printed in U.S.A.
Copyright
6004-37
DIFFERENTIAL ASSEMBLY
STEP 148
STEP 149
BD02D133
BD02D134
Install two slotted pins (2 and 3)in each of the four
blind holes in the differential cage half (1). Install Using suitable size sleeve press the ring gear (4)
slotted pins so that slots are 180 from center of onto the slo tted pins until rin g gear is a gainst
differential cage and slots of pins are 180 offset to differential cage half (1).
each other.
8 3
2
7
8 7
6 13
11 10
14
7
5 1
9
4
8
12 7 8
BS01D140
STEP 154 10
7 9
7 11
5
8
1
6
BD02D137
1 A
BD02D138
BD02D142
Carefully assemble the differential cage halves.
Put the bevel gear (8) with installed parts (5 through Make sure the manufacturers markings (A) on both
7) in the differential cage half (1). halves are aligned.
8
1
BD02D139
BD02D136
Put the other bevel gear (8) with installed parts (5 Secure the differential cage halves together using
through 7) in differential cage half (12). two bolts.
13
2
6
10 6
9 8
10
11 3
9 14
8
7 5 4
7 11 7 1
7
5
9 9
10
6 10
12 6
BS01D141
STEP 162
BD02D140
BD02D143 BD02D146
Put the differential in a press to prevent it from Install both bearing cups and adjusting nuts.
turning. Apply Loctite 262 to threads of bolts (13 and
14). Tighten M16 bolts (13), to a torque of 300 Nm STEP 167
(221 lb-ft); tighten M12 bolts (14) to a torque of 120
Nm (88 lb-ft).
STEP 164
BD02D147
BD02D145
BD02D149
STEP 170
Go to the adjusting nut opposite the ring gear and
loosen the nut approximately one turn to release
pressure on the bearing. It should be very noticeable
that pressure is released on the bearing, as the
adjusting nut will turn much easier.
STEP 171
Tighten the bearing adjusting nut slowly until firm
contact is made with the bearing.
NOTE: As the adjusting nut makes firm contact with BD02D150
the bearing, the adjusting nut will immediately begin Install pins to secure both adjusting nuts.
to turn with more effort.
STEP 176
STEP 172 Apply sealing compound (Three Bond Type 1215) to
To adjust the differential bearing preload, note the differential mounting surface on axle housing. Install
position of the adjusting nut. Now tighten the nut two two CAS2861 alignment studs in axle housing to aid
additional notches. installation of differential carrier. Using suitable lifting
equipment, install the differential carrier in the axle
STEP 173 housing then remove alignment studs.
When the bearing preload is adjusted the backlash
may increase slightly. Check pinion backlash to
confirm that it is within specifications as marked on
the ring gear. If within specifications, install the
adjusting nut locking roll pins. If backlash is outside
of specified range, repeat Step 169 through 173
again.
BD02D151 BD02D054
Using new bolts, secure the differential carrier to the Apply grease to a new O-ring and install O-ring in
axle housing. Tighten bolts to a torque of 390 Nm brake port. Position the wheel end on the axle
(288 lb-ft). housing.
BD02D050 BD02D154
Install the stub shaft into the spline of the differential Install the washers and bolts on the wheel end.
bevel gear. Tighten the bolts to a torque of 390 Nm (288 lb-ft)
NOTE: Repeat Steps 178 through 181 for the other
STEP 179 wheel end.
NOTE: Refer to Section 1002 of this service manual
for proper lubricant.
BD02D011
Section
6005
6005
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright 2001 Case Corporation
3350 South Service Road Printed in U.S.A.
Burlington, ON L7N 3M6 CANADA Bur 6-42480 August, 2001
Copyright
6005-2
TABLE OF CONTENTS
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FRONT DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FRONT DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CENTER BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CENTER BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CENTER DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
REAR DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ENGINE DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ENGINE DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
UNIVERSAL JOINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SPECIAL TORQUES
Coupler to Flywheel Bolts ................................................................................................. 53 to 62 Nm (39 to 46 lb ft)
Engine Drive Shaft to Coupler Bolts ................................................................................. 53 to 62 Nm (39 to 46 lb ft)
Engine Drive Shaft to Transmission Bolts ........................................................................ 34 to 41 Nm (25 to 30 lb ft)
Center, Rear and Front Drive Shaft Bolts ......................................................................... 61 to 81 Nm (45 to 60 lb ft)
Carrier Bearing Bolts ...................................................................................................... 99 to 128 Nm (73 to 94 lb ft)
Lock Nut for Yoke on Front Drive Shaft .................................................................... 339 to 375 Nm (250 to 275 lb ft)
Removal STEP 4
Use an acceptable puller and remove the yoke from
STEP 1 the end of the front drive shaft.
STEP 5
Loosen the set screws that secure the center bearing
to the front drive shaft.
STEP 6
Remove any paint or rust from the rear of the front
drive shaft and apply WD40 or similar oil to loosen
any rust between the inner race and the front drive
shaft.
STEP 7
BD01D368
STEP 2
BD01D370
STEP 8
Use a prybar to disengage the front drive shaft from
BD01D715 the front axle and remove the front drive shaft from
Remove the lock nut that fastens the yoke to the front the machine.
drive shaft. NOTE: If necessary, use a brass hammer to drive
the front drive shaft out of the center bearing.
STEP 3
Make an alignment mark on the yoke and the end of
the front drive shaft to make sure that the yoke is
installed correctly.
Installation STEP 14
STEP 9
Apply antiseize compound to the bearing area of the
front drive shaft.
STEP 10
Place the front drive shaft into position in the center
bearing of the machine.
STEP 11
BD01D715
Install the lock nut that fastens the yoke to the front
drive shaft. Tighten the lock nut to a torque of 339 to
375 Nm (250 to 275 lb ft).
STEP 15
Tighten the set screws, that secures the center
bearing to the front drive shaft, alternately until they
stop turning and the hex head socket wrench starts
to spring.
BD01D370
STEP 16
Install the bolts and straps that fasten the front drive
shaft to the front axle. Tighten the bolts to a torque of
61 to 81 Nm (45 to 60 lb ft).
STEP 12
Apply antiseize compound to the splines on the front
drive shaft.
STEP 13
Install the yoke to the front drive shaft, making sure
the alignment marks made during removal are
aligned.
NOTE: If a new front drive shaft has been installed, BD01D368
make sure the yoke being installed is 90 to the yoke Install the bolts and straps that fasten the front drive
on the other end of the front drive shaft. shaft to the center drive shaft. Tighten the bolts to a
torque of 61 to 81 Nm (45 to 60 lb ft).
CENTER BEARING
Removal STEP 20
Make an alignment mark on the yoke and the front
STEP 17 drive shaft to be sure that the yoke is installed
correctly.
STEP 21
Use an acceptable puller and remove the yoke from
the end of the front drive shaft.
STEP 22
Remove any paint or rust from the rear of the front
drive shaft and apply WD40 or similar oil to loosen
any rust between the inner race and the front drive
shaft.
BD01D368
STEP 23
Loosen and remove the bolts and straps that fasten Loosen the set screws that secure the center bearing
the center drive shaft to the front drive shaft. to the front drive shaft.
STEP 18 STEP 24
BD01D715 BD01D715
Loosen and remove the lubrication hose from the Loosen and remove the bolts, washers and nuts that
center bearing fasten the bearing housing to the front frame.
STEP 19 STEP 25
Install two longer bolts, at least 3 inches, to hold the
bearing housing during removal. Use an acceptable
puller to remove the bearing housing from the front
drive shaft.
BD01D715
Loosen and remove the lock nut that fastens the yoke
to the front drive shaft.
Bur 6-42480 Issued 8-01 Printed in U.S.A.
Copyright
6005-7
CENTER BEARING
Installation STEP 31
NOTE: The center bearing and the bearing housing
are not serviced separately. If the center bearing is
worn or damaged or if the bearing housing is
cracked, a new center bearing and bearing housing
must be used.
STEP 26
Apply antiseize compound to the bearing area of the
front drive shaft.
STEP 27
Install the bearing housing so that the lubrication
BD01D715
fitting is at the top.
Install the washer and lock nut that fasten the yoke to
the front drive shaft. Tighten the lock nut to a torque
STEP 28
of 339 to 375 Nm (250 to 275 lb ft).
STEP 32
BD01D715
Removal Installation
STEP 35 STEP 39
BD01D368 BD01D331
Loosen and remove the bolts and straps that fasten Hold the center drive shaft in position and install the
the center drive shaft to the yoke of the front drive bolts and straps that fasten the center drive shaft to
shaft. the transmission. Tighten the bolts to a torque of 61
to 81 Nm (45 to 60 lb ft).
STEP 36
Use a prybar to disengage the center drive shaft from STEP 40
the yoke of the front drive shaft.
STEP 37
BD01D368
STEP 38
Hold the center drive shaft and remove from the
machine.
Removal Installation
STEP 41 STEP 45
BD01D323 BD01D362
Loosen and remove the bolts and straps that fasten Hold the rear drive shaft into position and install the
the rear drive shaft to the transmission. bolts and straps that fasten the rear drive shaft to the
rear axle. Tighten the bolts to a torque of 61 to 81 Nm
STEP 42 (45 to 60 lb ft).
Use a prybar to disengage the rear drive shaft from
the transmission. STEP 46
STEP 43
BD01D323
Install the bolts and straps that fasten the rear drive
BD01D362
shaft to the transmission. Tighten the bolts to a
Loosen and remove the bolts and straps that fasten torque of 61 to 81 Nm (45 to 60 lb ft).
the rear drive shaft to the rear axle.
STEP 44
Hold the rear drive shaft and remove from the
machine.
Removal STEP 50
NOTE: It may be necessary to remove the fuel tank
to gain access to the bolts and straps that fasten the
engine drive shaft to the transmission. Step 47 to
Step 54 show how to remove the fuel tank.
STEP 47
2
BD01D330
Tag and disconnect the two wires from the fuel level
indicator.
1
STEP 51
BD01D325
STEP 48
Loosen the hose clamp and disconnect the return
hose (2) from the fuel tank. Plug the hose and cap
the fitting. Put an identification tag on the hose for
reference during installation. Refer to the above
photo.
BD01D328
Loosen and remove the bolt and nut that fasten the
STEP 49 breather to the machine.
STEP 52
BD01D326
BD01D327 BD01D199
Loosen and remove the six bolts that fasten the fuel Loosen and remove the six bolts that fasten the
tank guard to the machine. engine drive shaft to the engine.
STEP 54 STEP 57
Lower the fuel tank slowly making sure all hoses and Remove the engine drive shaft from the machine.
wires are free and clear.
STEP 55
BD01D342
Installation STEP 60
STEP 58
BD01D332
Place the fuel tank onto a jack and raise into position
BD01D342
making sure all hoses are in place.
Place the engine drive shaft into position on the
transmission and install new straps and bolts. STEP 61
Tighten the bolts to a torque of 34 to 41 Nm (25 to 30
lb ft).
STEP 59
BD01D327
Install the six bolts that fasten the fuel tank and guard
on the machine.
BD01D199 STEP 62
Install the six bolts that fasten the engine drive shaft
to the engine. Tighten the bolts to a torque of 53 to
62 Nm (39 to 46 lb ft)
BD01D328
Install the bolt and nut that fastens the breather to the
machine.
BD01D325 BD01D330
Install the return hose on the fitting and tighten the Install the two wires to the fuel level indicator.
hose clamp. Make sure that the drain valve is in the
closed position.
STEP 64
BD01D326
UNIVERSAL JOINTS
Removal Installation
NOTE: The bearing race and journal that make up
STEP 66 the universal joint are not serviced separately. If the
Remove the drive shaft. bearing race or journal is worn or damaged, a new
universal joint must be used.
STEP 67
STEP 69
Clean the slots in the yoke of the drive shaft.
STEP 70
Install the universal joint and install the bearings (2)
and the rings (1). Refer to the photo in Step 67.
1 STEP 71
2 Install the drive shaft.
BD01D331
1. RING 2. BEARING
Remove the ring (1) and the bearing (2) from the
drive shaft.
NOTE: The above photo shows the drive shaft on
the machine and is for reference of the ring and
bearing only.
STEP 68
Remove the universal joint from the drive shaft.
Section
6006
6006
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright 2001 Case Corporation
3350 South Service Road Printed in U.S.A.
Burlington, ON L7N 3M6 CANADA Bur 6-42490 August, 2001
Copyright
6006-2
TABLE OF CONTENTS
WHEELS AND NUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Torque Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TIRE PRESSURE 521D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHANGING TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSTALLING A WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CHANGING TIRES
1. Have a qualified tire mechanic service the split
The split rim wheels used on this machine rim wheels used on this machine.
can be dangerous. When inflating a tire on
the machine, use a self-locking nozzle and 2. The correct tire equipment, especially a tire
stand at the front or rear of the tire. inflation cage, is required. Using the wrong
procedure for a split rim wheel can result in
death.
! When inflating a tire off the machine, put
th e w he el in a tire inflatio n c ag e. Th e IMPORTANT: When installing a Michelin tire,
retaining ring and rim can come off with lubricate the tire with a tire mounting lubricant and
enough force to result in death to a person inflate the tire to 551 kPa, 5.5 bar (80 psi) to make
in front of the rim. sure that the tire is seated on the rim. Then decrease
48-44 the pressure to the specified pressure.
INSTALLING A WHEEL
1. Make sure the mounting surfaces of the rim and 4. Tighten the wheel nuts to 298 Nm (220
axle flange are clean and free of dirt and grease. pound-feet) in the sequence shown in Figure 1.
Th e n ti g h t e n th e w h e e l n u ts in t h e s a m e
2. Install the wheel, hardened washers and wheel
s e q u e n c e t o 6 4 0 to 7 2 0 N m ( 4 7 5 t o 5 3 0
nuts.
pound-feet).
3. Use a hand wrench (not an impact) to tighten the
w h e e l n u t s t o p u l l t h e w h e e l a g a in s t t h e
planetary housing. DO NOT use an impact
wrench to tighten the wheel nuts.
1
10 8
3 6
5 4
7 9
2
BS00J104
FIGURE 1. WHEEL NUT TORQUE SEQUENCE
Section
6007
6007
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright 2002 Case Corporation
3350 South Service Road Printed in U.S.A.
Burlington, ON L7N 3M6 CANADA Bur 6-42500 June, 2002
Copyright
6007-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SPECIAL TOOLS
SPECIAL TORQUES
Screws Securing End Housings to Valve Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 Nm (48 lb-in)
Screws Securing Pressure Regulator Locating Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 Nm (48 lb-in)
Screws Securing Covers to End Housings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 Nm (48 lb-in)
Valve Housing Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Nm (53 lb-in)
Screws Securing Distribution Plate to Valve Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 Nm (84 lb-in)
DISASSEMBLY
STEP 1 STEP 3
To a i d in a s s e m b ly, p u t a l ig n m e n t m a r k s o n Remove distribution plate (2), housing gasket (3),
transmission control valve (7, figure 1), distribution valve plate (4), and housing gasket (5). Discard
plate (2), and valve plate (4). housing gaskets (3 and 5).
STEP 2 STEP 4
Remove 18 screws (1) securing distribution plate (2) Remove six filter screens (6) from valve plate (4).
to transmission control valve (7).
5
4
3
2
BS98J157
STEP 6
Remove clamp (1) securing wiring harness (8)
connector to cover (3).
STEP 7
Remove 14 screws (2) securing cover (3) to end
housing (14).
STEP 8
Remove cover (3) and gasket (4). Discard gasket (4).
BS02C114
STEP 9 Install CAS2885 transmission valve adjustment tool
Remove 14 screws (5) securing cover (6) to end set in holes where screws (13) were removed.
housing (14). Tighten hex rods of CAS2885 down against end
housing. Remove remaining 16 screws from end
STEP 10 housing (14). Loosen CAS2885 hex rods uniformly to
Remove cover (6) and gasket (7). Discard gasket (7). release spring tension. Remove end housing and
gasket (15). Discard gasket. Remove CAS2885
STEP 11 studs.
STEP 15
BS02C113
STEP 12 STEP 16
Remove three screws (9) and locating plates (10) Repeat Steps 12 through 14 for other side of valve
securing three pressure regulators (11) to end housing (27).
housing (14). Remove pressure regulators (11).
Remove and discard O-ring (12) from pressure
regulators.
NOTE: End housings (14) are under spring pressure.
Use CAS2885 transmission valve adjustment tool set to
hold springs down.
1 4
21
20
18
19
9
23
25
26 22
11
10
12
18
19 15
14
13
14 10 9 7
15
5
16 27
17 13
24 11
17 12
16
6
BS01B099
BS02C1163 BS02C117
Remove three pistons (16 and 18), springs (17 and Remove six orifices (24) from valve housing (27).
19), piston (22), and spring (23) from valve housing
(27). STEP 19
Remove eight plugs (25). Remove and discard O-
ring (26) from plugs.
INSPECTION
STEP 20 STEP 25
Clean all metal parts in cleaning solvent. Check pressure regulators (11) for cracks, breaks, or
o th er d a ma g e . C h e ck c on n e ct or c o nt ac ts fo r
STEP 21 looseness or signs of corrosion. Replace a pressure
Immerse end housings (14,figure 2), valve housing regulator if any of these conditions are seen. Check
(27), valve plate (4, Figure 1), and distribution plate resistance of pressure regulators using a multimeter.
(2) in cleaning solvent and agitate cleaning solvent. Replace a pressure regulator if resistance is not 17
WEAR EYE PROTECTION WHEN USING to 21 ohms.
COMPRESSED AIR. Use compressed air to remove
foreign matter from interior of housings and plates STEP 26
and to ensure that all bores are clear of foreign Check wiring harness (8) connectors for signs of
matter. breaks, cracks, or other damage. Check contacts for
foreign matter or corrosion. Check harness wiring for
STEP 22 signs of broken or cracked insulation and broken or
WEAR EYE PROTECTION WHEN USING frayed wiring at connection to connectors. Replace
COMPRESSED AIR. Use compressed air to ensure wiring harness if any of these conditions are seen.
that orifices (24, figure 2) are clear of foreign matter.
STEP 27
STEP 23 Check springs (17, 19, 20, and 23, figure 2) for
Check filter screens (6, figure 1) for blockage, rips, or cracks, breaks, distortion, or signs of permanent set.
tears. Replace if any of these conditions are seen. Replace a spring if any of these conditions are seen.
STEP 24 STEP 28
Inspect the plates (2 and 4, figure 1), housings (14 Inspect pistons (16, 18, 21 and 22, figure 2) for
and 27, figure 2) and covers (3 and 6) for corrosion, cracks, breaks, chipping, grooves, or other damage.
cracks, breaks, chipping or other damage. Check Replace if any of these conditions are seen.
bores in housings for deep scratches, gouges, and
other damage. Replace a housing or cover if any of
the above conditions are seen.
1 4
21
20
18
19
9
23
25
26 22
11
10
12
18
19 15
14
13
14 10 9 7
15
5
16 27
17 13
24 11
17 12
16
6
BS01B099
ASSEMBLY
NOTE: Apply clean Case No. 1 engine oil (15W-40) STEP 31
to pistons (16, 18, 21, and 22, figure 3) and springs
(17, 19, 20, and 23), orifices (24), new O-rings (12
and 26), and filter screens (6, figure 4) before
assembly.
STEP 29
BS02C118
BS02C117 STEP 32
Install six orifices (24, figure 3) with concave side
facing up. Install orifices until contact with shoulder in
valve housing (27) is made.
STEP 30 15
A
BS02C119
BS02C115
BS02C120
BS02C121 BS02C123
Install a new O-ring (12) lubricated with clean Case Do Step 33 to install remaining pressure regulators
No. 1 engine oil (15W-40) on pressure regulators (11) except make sure pressure regulators are
(11). Install pressure regulators and locating plates positioned as shown above.
(10). Make sure pressure regulators are positioned
as shown above. Locating plates (10) are installed STEP 37
with the nose (bump) down. Install screws (9) and
tighten to a torque of 5.5 Nm (48 lb-in).
4
STEP 34
BS02C125
STEP 35 STEP 38
Install 14 screws (2) to secure cover (3) to end
housing (14). Tighten screws to a torque of 5.5 Nm
(48 lb-in).
STEP 39
A Install gasket (7) and cover (6).
STEP 40
Install 14 screws (5) to secure cover (6). Tighten
screws to a torque of 5.5 Nm (48 lb-in).
BS02C122
BS02C127 BS02C128
Install a new O-ring (26) on eight plugs (25). Install Install two studs in transmission control valve (7,
eight plugs and tighten to a torque of 6 Nm (53 lb-in). Figure 4) then install housing gasket (5).
5
4
3
2
6
BS98J157
BS02C129 BS02C130
Install six filter screens (6) flush in bores of valve Install housing gasket (3) then distribution plate (2).
plate (4). Screens must be facing upward toward Make sure marks made in Step 1 are aligned. Install
distribution plate (2). Make sure marks made in Step 18 screws (1) and tighten evenly to a torque of 9.5
1 are aligned. Nm (84 lb-in).
STEP 45
Refer to Section 6003 and install transmission
control valve.
SECTION INDEX
BRAKES
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright 2001 Case Corporation
3350 South Service Road Printed in U.S.A.
Hamilton, ON L7N 3M6 CANADA Bur 6-42510 August, 2001
Copyright
Copyright
7001
Section
7001
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright 2003 Case Corporation
3350 South Service Road Printed in U.S.A.
Burlington, ON L7N 3M6 CANADA Bur 6-42521 August, 2001 (Revised February, 2003)
Copyright
7001-2
TABLE OF CONTENTS
BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE BRAKE AND PARKING BRAKE ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
P.I.N. JEE0135500 AND BELOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE BRAKE AND PARKING BRAKE ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
P.I.N. JEE0135501 AND ABOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
BRAKE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
BRAKE VALVE
3. Make sure the brake accumulators are 13. Remove the mounting bolts (2), washers (3),
completely discharged. Push down and release brake valve plate (4) and the brake valve (1).
the brake pedals at least 30 times.
4. Turn the master disconnect switch to the OFF
Installation
position. 1. Install the brake valve (1), brake valve plate (4),
5. Remove the cab skirts located under the cab or washers (3) and mounting bolts (2). Refer to the
canopy. illustration below.
6. To release the pressure on the parking brake 2. Connect a vacuum pump to the hydraulic
accumulator, the line at the accumulator must be reservoir. Start the vacuum pump.
SLOWLY cracked open. A pan will be needed to 3. Remove the plugs from the hydraulic lines and
catch the hydraulic oil. connect the hydraulic lines to the brake valve (1).
7. Connect a drain hose to the quick disconnect 4. Stop the vacuum pump and remove.
couplings in each brake circuit to release any 5. Connect all of the electrical connections.
pressure in the brake circuit.
Turn the master disconnect switch to the ON
8. Clean the brake accumulator charging valve (1) position.
and lines, refer to the illustration below.
6. Bleed the brake system. See Section 7002.
9. Put identification tags on all electrical and
hydraulic lines that are connected to the brake 7. Install the cab skirts.
valve (1). 8. Check the hydraulic reservoir oil level and add oil
as required. See Section 1002 for the correct oil.
BS01C126
8
1
10
7
8 6
7 5
6
7 9
8 6
2
5
10
BS01C127
3 9
4 2
6
1
8 1
7
4
10
6
5
BS02K144
BRAKE PUMP
Removal Installation
1. Park the machine on a level surface and lower 1. Install the brake pump (1), mounting bolts (2)
the loader bucket to the floor. Stop the engine. and lock washers (3). Refer to the illustration
below for units P.I.N. JEE0135500 and below or
2. Put blocks on both sides of each tire to prevent
illu stra tion on p age 9 fo r un its P.I.N.
machine movement.
JEE0135501 and above.
3. Raise the engine hood and turn the master
2. Tighten the mounting bolts (2).
disconnect switch to the OFF position.
3. Connect a vacuum pump to the hydraulic
4. Clean the brake pump (1) and lines, refer to the
reservoir. Start the vacuum pump.
illustration below.
4. Remove the plugs or caps and connect the lines
5. Put identification tags on all lines that are
to the brake pump (1).
connected to the brake pump (1).
5. Turn the master disconnect switch to the ON
6. Connect a vacuum pump to the hydraulic
position.
reservoir. Start the vacuum pump.
6. Bleed the brake system. See Section 7002.
7. Disconnect the lines from the brake pump (1)
and put plugs or caps on each line. 7. Check the hydraulic reservoir oil level and add oil
as required. See Section 1002 for the correct oil.
8. Stop the vacuum pump and remove.
9. Remove the mounting bolts (2) and lock washers
(3) from the brake pump (1) and remove the
brake pump (1).
7 4
1
3
2
6
5
9
8
7
9
BS01C125
3
1
4
5
2 4
8
12
11
9
7
11 6
12
10
BS02K143
7002
Section
7002
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright 2003 Case Corporation
3350 South Service Road Printed in U.S.A.
Burlington, ON L7N 3M6 CANADA Bur 6-40811 March, 2001 (Revised February, 2003)
Copyright
7002-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TROUBLESHOOTING THE HYDRAULIC BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CHARGING THE ACCUMULATOR WITH DRY NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
BLEEDING THE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
BRAKE MODULATION PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Testing the Brake Modulation Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Adjusting the Brake Modulation Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CHECKING THE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
BRAKE PUMP OUTPUT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SPECIFICATIONS
Brake pump output ....................................................................................................................30.8 L/min at 172 bar
(8.14 gpm at 2500 psi at 2200 rpm)
Accumulator nitrogen charge pressure...........................................................................53 to 57 bar (775 to 825 psi)
Accumulator valve cut in pressure......................................................................... 147 to 167 bar (2130 to 2422 psi)
Accumulator valve cut out pressure ...................................................................... 190 to 196 bar (2756 to 2843 psi)
Brake warning pressure switch............................................................................................ 117 bar (1697 psi) falling
141 bar (2045 psi) rising
Brake redundant pressure switch .......................................................................................................62 bar (900 psi)
Brake light pressure switch..................................................................................................................4.1 bar (60 psi)
Modulation pressure front brake cylinders.........................................................................60 + 6 bar (870 to 987 psi)
Modulation pressure rear brake cylinders .........................................................................57 + 6 bar (825 to 943 psi)
SPECIAL TOOL
94L95
CAS-10899 NITROGEN CHARGING KIT USED TO CHECK AND
CHARGE THE ACCUMULATOR WITH NITROGEN.
25 20 14
18 15
17 24
6
3
5 21
15
19
14
20
16
10
13 11
23 12
7
8
9 22
BC00N001
1. FRONT BRAKES 10. OIL COOLER (OPTIONAL) 19. BRAKE LIGHT PRESSURE SWITCH
2. REAR BRAKES 11. HYDRAULIC FILTER 20. REDUNDANT BRAKE PRESSURE SWITCH
3. PARKING BRAKE 12. BY-PASS WARNING SWITCH 21. FROM COUPLER LOCKING VALVE (OPTIONAL)
4. FRONT AXLE TEST PORT 13. FILTER BY-PASS 22. NOT USED WITH OPTIONAL FAN REVERSER
5. REAR AXLE TEST PORT 14. BRAKE ACCUMULATOR 23. REVERSE FLOW CHECK VALVE (USED WITH RIDE
6. PARKING BRAKE SOLENOID 15. BRAKE ACCUMULATOR TEST PORT CONTROL ONLY)
7. BRAKE PUMP 16. FAN REVERSER (OPTIONAL) 24. BRAKE AND ACCUMULATOR CHARGING VALVE
8. BREATHER 17. BRAKE WARNING PRESSURE SWITCH 25. PARKING BRAKE ACCUMULATOR
9. RESERVOIR 18. PARKING BRAKE ACCUMULATOR DIAGNOSTIC FITTING (NOT USED IN UNITS P.I.N. JEE0135501 AND
ABOVE)
521D BRAKE ILLUSTRATION
2
1
1 2
BD00N012
4. Pump the brake pedal (8) until there is no 12. If the pressures are not within the required
hydraul ic pressu re in the brake system specifications, then the brake system must be
(approximately 20 pumps). bled.
5. Connect two 207 bar (3000 psi) pressure gauges 13. After bleeding the brake system, perform the
to the test ports (3 and 4). brake system check again.
8 6
5
3
2 1
4
7
BC01B050
BS02M025
11
9
NOTE
10
6 7
12
5
4
3
12
2 1
BS02M027
11
9
NOTE
8
10
5 6 7
1
2 12
3 4
BS02M026
Section
7004
7004
BRAKE ACCUMULATORS
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright 2003 Case Corporation
3350 South Service Road Printed in U.S.A.
Burlington, ON L7N 3M6 CANADA Bur 6-42531 August, 2001 (Revised February, 2003)
Copyright
7004-2
TABLE OF CONTENTS
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 3
DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 3
BRAKE ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 4
PARKING BRAKE ACCUMULATOR P.I.N. JEE0135500 AND BELOW . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 6
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 6
SPECIAL TOOL
94L95
C E
D B A
94L95
NITROGEN CHARGING KIT
NOTE: The parking brake accumulator used on 6. Connect valve F to the valve stem on the
P.I.N. JEE0135501 and above is not rechargeable accumulator.
nor repairable.
7. Turn the T-handle inward on valve F to engage
1. Use the CAS-10899 nitrogen charging kit to the pin in the valve stem.
discharge the accumulator, refer to illustration
8. Open valve D and check the charge pressure on
above. The tool must be disconnected from the
gauge E.
nitrogen tank.
9. To discharge the accumulator, partially open
2. Close valves B, C and D.
valve B. The accumulator charge will bleed down
3. Adjust the regulator A to the minimum pressure through the regulator.
setting by turning the knob counterclockwise.
10. Once the accumulator is fully discharged,
4. Turn the T-handle on valve F fully out. disconnect valve F from the valve stem.
5. Remove the guard (2) and valve assembly cap 11. The accumulator can now be disassembled.
(9) from the accumulator, refer to Figure 2.
BRAKE ACCUMULATORS
Disassembly Assembly
NOTE: See Section 7001 for the proper procedure 1. Fasten the body (1) in a vise. Be careful not to
to remove the accumulator. damage the body (1). Refer to the illustration on
page 5.
WA R N I N G : D O N O T a t t e m p t t o
disassemble any accumulator until the 2. Install a new wear ring (9), O-ring (11) and
nitrogen charge is properly discharged. backup ring (10) on the piston (5).
SM386 3. Lubricate the bore of the body (1) and the piston
(5) with clean oil.
1. Fasten the body (1) in a vise. Be careful not to 4. Start the piston (5) into the body (1), round
damage the body (1), refer to the illustration on surface first. Then push the piston (5) farther into
page 5. the body (1).
2. Remove the screws (3) and guard (2) from the
NOTE: The piston (5) must be installed squarely and
body (1).
slowly into the body (1). Once the piston (5) is started
3. Remove the pressure valve (4) and the elbow (8) straight into the bore of the body (1), use a hammer
from the body (1). and wood block to gently tap the piston into the
4. Remove and discard the O-ring (7) from the polished area of the bore. Keep force on the piston
elbow (8). (5) while tapping into the bore or damage may occur
to the O-ring.
5. Loosen and remove the gland (6) from the body
(1). 5. Install new seals (12) on the gland (6).
6. Remove the piston (5) from the body (1). 6. Lubricate the seals (12) with clean oil and start
7. Remove and discard the wear ring (9), O-ring the gland (6) into the body (1).
(11) and the backup ring (10) from the piston (5). 7. Tighten the gland (6).
8. Remove the seals (12) from the gland (6).
8. Install a new O-ring (7) on the elbow(8).
1. Clean body (1), gland (6) and piston (5) in 10. Install the pressure valve (4) in the elbow (8).
cleaning solvent, refer to the illustration on page 11. Install the guard (2), screws (3) in the body (1).
5.
12. Charge the accumulator with dry nitrogen
2. Inspect the piston (5) for cracks, burrs or other according to instructions in Section 7002.
damage.
3. Inspect the bore of the body (1) for scratches or
scoring using a light.
NOTE: Minor scratches or scoring in the bore of the
body (1) can be removed using crocus cloth.
4. Inspect the pressure valve (4) and replace as
needed.
12 6 9 10 11 4
5
3
7
1 8
BS01B223
1. Fasten the body (1) in a vise. Be careful not to NOTE: The piston (5) must be installed squarely and
damage the body (1), refer to the illustration on slowly into the body (1). Once the piston (5) is started
page 7. straight into the bore of the body (1), use a hammer
and wood block to gently tap the piston into the
2. Remove the screws (3) and guard (2) from the
polished area of the bore. Keep force on the piston
body (1).
(5) while tapping into the bore or damage may occur
3. Remove the pressure valve (4) from the to the O-ring.
body (1).
5. Install new seals (11) on the gland (6).
4. Remove and discard the O-ring (7) from the
pressure valve (4). 6. Lubricate the seals (11) with clean oil and start
the gland (6) into the body (1).
5. Loosen and remove the gland (6) from the body
(1). 7. Tighten the gland (6).
6. Remove the piston (5) from the body (1). 8. Install a new O-ring (7) on the pressure valve (4).
7. Remove and discard the wear ring (8), O-ring 9. Install the pressure valve (4) on the body (1).
(10) and the backup ring (9) from the piston (5).
10. Install the guard (2), screws (3) in the body (1).
8. Remove the seals (11) from the gland (6).
11. Charge the accumulator with dry nitrogen
Inspection according to instructions in Section 7002.
11 6 8 9 10 3
5
2
4
3
1
BS01B224
Section
7008
PARKING BRAKE
7008
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright 2001 Case Corporation
3350 South Service Road Printed in U.S.A.
Burlington, ON L7N 3M6 CANADA Bur 6-42540 August, 2001
Copyright
7008-2
TABLE OF CONTENTS
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PARKING BRAKE TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
PARKING BRAKE
STEP 1
Park the machine on a hard level surface and lower
the loader bucket to the ground.
STEP 2
Place wh eel ch ocks on each wheel to prevent
machine movement.
STEP 3
BD01D296
STEP 7
BDOOM030
STEP 4
BD01D346
STEP 8
BD01D136
STEP 5
With the engine in the OFF position, pump the brake
pedal at least 20 times to discharge the
accumulators.
BD01D347
BD01D347
STEP 10
BD01D350
STEP 14
Install the parking brake assembly on the brake disc.
BD01D348
STEP 15
Loosen and remove the two bolts holding the parking
brake to the transmission. Remove the parking
brake.
STEP 11
BD01D348
BD01D351
BD01D296 BD01D346
Remove the plugs and caps and install the hose onto Remove the cover from the front of the parking
the parking brake. brake.
STEP 17 STEP 21
Park the machine on a clear level surface with wheel
chocks and the articulation lock in place.
IMPORTANT: It will be necessary to have an
assistant help for this procedure. An operator must
be present in the cab at all times to apply the service
brakes and shut down the machine in the event of
mechanical failure.
STEP 18
1
Start the machine and run the engine at low idle with 2
the bucket resting on the ground.
STEP 19 BD01D347
BD01D347
BD01D347 BD00M030
Tighten the jam nut to secure the center post. Remove the articulation lock.
STEP 24 STEP 28
BD01D346 BD01D140
Install the cover on the parking brake. Place the ma ster d isconn ect switch to the O N
position.
STEP 25
Perform the Pa rking Brake Test Procedu re as
described in this section.
STEP 26
Re fe r to Se ctio n 70 02 fo r Bleed in g th e Bra ke
System.
STEP 31 STEP 39
Place the Transmission-Auto switch to the manual Reduce the engine speed to low idle and return the
position, transmission neutral.
STEP 32 STEP 40
Place the Parking Brake switch in the ON position. Shift the gear selector to third gear reverse and
slowly increase the engine speed to wide open
STEP 33 throttle.
Press the Program switch on the instrument cluster.
STEP 41
STEP 34 Verify that the machine does not move.
Press the Up Count switch until the display reads
011. STEP 42
Reduce the engine speed to low idle and return the
STEP 35 transmission to neutral.
Return the Program switch to the OFF position.
STEP 43
STEP 36 Press the Reset switch on the instrument cluster to
Press the UP Count switch until the display reads 01. exit the test mode.
This mode will allow the transmission to engage
while the parking brake is applied. STEP 44
If any machine movement was detected, the parking
brake must be adjusted.
SECTION INDEX
HYDRAULICS
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright 2001 Case Corporation
3350 South Service Road Printed in U.S.A.
Hamilton, ON L7N 3M6 CANADA Bur 6-42550 August, 2001
Copyright
Copyright
8001
Section
8001
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright 2001 Case Corporation
3350 South Service Road Printed in U.S.A.
Burlington, ON L7N 3M6 CANADA Bur 6-42560 August, 2001
Copyright
8001-2
TABLE OF CONTENTS
REMOVAL AND INSTALLATION OF THE LOADER CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REMOVAL AND INSTALLATION OF THE REMOTE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REMOVAL AND INSTALLATION OF THE HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
REMOVAL AND INSTALLATION OF THE LIFT CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
REMOVAL AND INSTALLATION OF THE BUCKET CYLINDER - Z-BAR LOADER . . . . . . . . . . . . . . . . . . . . . 22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
REMOVAL AND INSTALLATION OF THE BUCKET CYLINDERS - XT LOADER . . . . . . . . . . . . . . . . . . . . . . . 26
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
REMOVAL AND INSTALLATION OF THE OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
REMOVAL AND INSTALLATION OF THE RIDE CONTROL ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . 32
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
REMOVAL AND INSTALLATION OF THE RIDE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
REMOVAL AND INSTALLATION OF THE FAN REVERSING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Removal STEP 6
Loosen the filler cap on the reservoir to release the
STEP 1 air pressure in the reservoir.
Park the machine on a level surface.
STEP 7
STEP 2 Drain the hydraulic reservoir.
STEP 8
BD00M048
Raise the lift arms and install the safety link on the lift
arm cylinder. BD00M041
STEP 4
BD01D138
STEP 5
Release the pressure in the ride control accumulator
with the manual bleeder valve at the rear of the front
chassis.
Bur 6-42560 Issued 8-01 Printed in U.S.A.
Copyright
8001-4
REAR OF MACHINE
BS01D179
STEP 9 STEP 10
Disconnect the hoses from the remo te contro l Install a plug in each hose and a cap on each fitting.
valve(s) at the loader control valve one at a time and
fasten an identification tag to each hose. Refer to the
illustration above.
1
2 2
4
3 1 3
4
5
6
BD01D376 BD01D381
BS01D190
Loosen and remove the three bolts and washers that
hold the loader control valve to the valve mounting
plate.
Bur 6-42560 Issued 8-01 Printed in U.S.A.
Copyright
8001-6
STEP 14 B. Connect the head end lift tube (3) to the
Use proper lifting device to lift and remove the loader loader control valve.
control valve. C. Connect the head end tilt tube (2) to the
loader control valve.
Installation D. Connect the rod end tilt tube (1) to the loader
control valve.
STEP 15
STEP 17
4
3 1
5
6
BD01D376
BD01D381
REAR OF MACHINE
BS01D179
STEP 18 STEP 19
Connect the lines from the remote control valve to Fill the hydraulic reservoir with oil. Refer to Section
th e lo a d e r co n tr o l v a lv e . R e f e r to t h e a b o v e 1002 for the correct oil.
illustration.
STEP 23
Slo w ly a n d co mp le te ly e x te nd an d r et ra ct a ll
cylinders at least 10 times to remove any air from the
circuits.
STEP 24
Stop the engine and check for leaks.
STEP 25
Install the access cover on the front of the machine.
BD01D138
BD00M048
Removal STEP 34
Unlatch and open the window on the right hand side.
STEP 27
Park the machine on a level surface and lower the STEP 35
bucket to the floor. Stop the engine and apply the
parking brake.
IMPORTANT: Pump the brake repeatedly to be sure
the brake accumulators have no hydraulic pressure,
then move the loader control lever back and forth
several times to release any hydraulic pressure in the
pilot control circuit.
STEP 28
BD01D271
STEP 36
Remove the access panel.
STEP 37
BD01D138
STEP 29
Loosen and remove the bolts and washers that
fasten the right skirt panel under the right side of the
ROPS cab or ROPS canopy. Remove the right skirt
panel.
STEP 30
Loosen the filler cap on the reservoir to release any BD01D390
air in the reservoir. Disconnect the wire from the solenoid and loosen
and remove the lock-out solenoid to gain access to
STEP 31 the hydraulic hoses.
Drain the hydraulic reservoir.
STEP 38
STEP 32 Put identification tags on each hose and disconnect
Unlatch and open the right hand side access door. one at a time from the remote control valve. Install
plugs in the hoses and caps on the fittings.
STEP 33
STEP 39
Lift the access door up and remove the access door
from the pins. Tag and disconnect the electrical connectors for the
remote control valve.
STEP 44
BD01D720
STEP 41
BD01D722
STEP 45
Connect the electrical connectors for the remote
control valve.
STEP 46
BD01D722
STEP 42
Remove the remote control valve from the hydraulic
control tower.
BD01D720
STEP 47
Remove the plugs from the hoses and the caps from
the fittings and connect the hydraulic hoses to the
fittings according to the identification tags. (Refer to
illustrations on pages 12 through 14 as necessary._
STEP 48
Fill the hydraulic reservoir. See Section 1002 for the
correct hydraulic oil.
BD01D136 BD01D271
Place the master disco nnect switch in the ON Install the access panel on the ROPS cab or the
position. ROPS canopy
STEP 50 STEP 55
Start the engine and run the engine at low idle. Close the right hand window.
STEP 51 STEP 56
Check to see that the remote control valve works Install the access door on the pins and close the
correctly. access door.
STEP 52 STEP 57
Check for hydraulic oil leakage at the remote control Install the right skirt panel under the ROPS cab or the
valve. ROPS canopy and tighten the bolts.
STEP 53
Check the level of hydraulic oil in the reservoir and
add as required.
2
1
BS01D180
2
2
1 2 2 1
BS01D178
2
2
1 2 2 1
BS01D177
Removal STEP 61
STEP 58
Park the machine on a level surface and lower the
bucket to the floor. Stop the engine and apply the
parking brake.
STEP 59 3 1
1
2 4
BD01D303
STEP 60 STEP 62
Drain the hydraulic reservoir then refer to Section
9007 and remove the ROPS cab or ROPS canopy.
BD01D329
2
4
1
3
BD01D308 BD01D307
1. BOLTS (4) 3. PRESSURE HOSE Loosen and remove the two bolts that fasten the
2. LOAD SENSING HOSE 4. HYDRAULIC PUMP hydraulic pump to the transmission.
A. Loosen and remove the four bolts (1)
conn ecting the p ressure ho se (3) to th e STEP 66
hydraulic pump (4). Remove the hydraulic pump from the machine.
B. Tag and disconnect the load sensing hose (2)
from the hydraulic pump (4). STEP 67
C. Plug all lines and cap all fittings.
STEP 64
BD01D335
BD01D333
Installation STEP 71
STEP 68
BD01D308
1. PRESSURE HOSE
BD01D335 2. HYDRAULIC PUMP
3. LOAD SENSING HOSE
Use proper lifting device to lift and support the
hydraulic pump. Install a new O-ring on the hydraulic A. Install the pressure hose (1) to the hydraulic
pump. pump (2).
B. Install the load sensing hose (3) to the
STEP 69 hydraulic pump (2).
STEP 72
1
2
BD01D334 3
Install the hydraulic pump on the transmission.
BD01D303
STEP 70 1. SUCTION HOSE
2. HYDRAULIC PUMP
3. CASE DRAIN HOSE
A. Install the suction hose (1) to the hydraulic
pump (2).
B. Install the case drain hose (3) to the hydraulic
pump (2).
BD01D307
BD01D329 BD01D136
Install the bracket holding the hydraulic hoses. Place the master d isco nnect switch in the O N
Tighten the bolts. position.
STEP 74 STEP 77
See Section 9007 for installing the ROPS cab or Start the engine and run the engine at low idle for two
ROPS canopy. minutes.
NOTE: If any unusual vibration is heard coming from
STEP 75 the pump, stop the machine immediately and check
Fill the hydraulic reservoir with hydraulic oil. See for obstructions in the pump suction line.
Section 1002 for correct oil type.
STEP 78
Stop the engine and check for hydraulic oil leakage
at the hydraulic pump.
STEP 79
Check the level of the hydraulic oil in the reservoir
and add hydraulic oil as required.
Removal STEP 85
STEP 80
Park the machine on a level surface and lower the
bucket to the floor. Stop the engine and apply the
parking brake.
STEP 81
Pump the brake repeatedly to be sure the brake
accumulators have no hydraulic pressure, then move
the loader control lever back and forth several times
to release any hydraulic pressure in the pilot control
circuit.
BD01D709
STEP 82 Loosen and remove the bolt, washer and spacer that
Relieve the pressure in the ride control accumulator hold the pivot pin for the yoke.
with the manual bleeder valve located at the rear of
the front chassis. STEP 86
STEP 83
Loosen the filler cap on the hydraulic reservoir to
release any pressure.
STEP 84
BD01D711
STEP 87
BD01D708
BD01D712
Remove the pivot pin from the yoke end of the lift
cylinder.
STEP 92
BD01D710
STEP 89
BD01D714
STEP 93
BD01D713
Remove the pivot pin from the closed end of the lift
cylinder.
STEP 90
Remove the lift cylinder from the machine
BD01D713
Align the closed end of the lift cylinder with the front
frame and install the pivot pin.
BD01D710 BD01D712
Align the pivot pin with the front frame and install the Install the pivot pin for the yoke. Stop the engine.
spacer, washer and bolt. Tighten the bolt.
STEP 98
STEP 95
BD01D709
BD01D708 Align the pivot pin with the yoke and install the
Remove the caps and plugs and connect the hoses spacer, washer and bolt. Tighten the bolt.
to the lift cylinder.
STEP 99
STEP 96 SLOWLY extend and retract the piston rod three
If the yoke of the lift cylinder is not aligned with the times to remove any air from the lift cylinders.
loader frame, have another person start and run the
engine at low idle and use the loader control lever to STEP 100
SLOWLY move the yoke into alignment with the Lubricate the pivot pins with molydisulfide grease.
loader frame.
STEP 101
Check the level of hydraulic oil in the reservoir and
ad d as r eq uire d. Tig hte n the filler cap o n th e
hydraulic reservoir.
STEP 102
Park the machine on a level surface and lower the
bucket to the floor. Stop the engine and apply the
parking brake.
STEP 103
With the engine stopped, move the bucket control
lever to release pressure in the bucket circuit.
STEP 104
BD01D695
STEP 107
BD01D694
STEP 105
BD01D697
BD01D696
BD01D699 BD01D701
Disconnect the hoses from each side of the bucket Remove the pivot pin from the rod end of the bucket
cylinder. Install plugs in the hoses and caps on the cylinder.
fittings.
STEP 112
STEP 109
BD01D704
BD01D700 Remove the pivot pin from the head end of the
Use a ccep ta ble eq uip ment to ho ld th e bu cket bucket cylinder.
cylinder.
NOTE: It is not necessary to remove the grease line
from the pivot pin unless the pivot pin is to be
STEP 110 replaced.
STEP 113
BD01D698
STEP 114
Apply antisieze compound to the bores in the front
frame and the bores in the loader arm for the bucket
cylinder.
STEP 115
BD01D699
STEP 119
If the rod end of the bucket cylinder is not aligned
with the bellcrank, have another person start the
BD01D706
engine and run the engine at low idle and use the
Use acceptable lifting equipment to lower the bucket bucket control lever to SLOWLY move the piston rod
cylinder into position. eye into alignment with the bellcrank.
STEP 121
BD01D704
STEP 117 Install the spacer, washer and bolt that fasten the
Install the spacer, washer and bolt that fasten the pivot pin to the bellcrank. Tighten the bolt.
pivot pin to the front frame. Tighten the bolt.
NOTE: If a new pivot pin is being installed, connect
the grease line to the pivot pin.
BD01D697 BD01D694
Install the two bolts that fasten the mounting bracket Connect the proximity switch connector to the wiring
for the switch to the bucket cylinder. harness connector.
STEP 127
Start and run the engine at low idle.
STEP 128
SLOWLY extend and retract the piston rod three
times to remove any air from the bucket cylinder.
STEP 129
Lubricate the pivot pins with molydisulfide grease.
BD01D695
Install the two bolts for the mounting bracket for the STEP 130
target bar.
Check the level of the hydraulic oil in the reservoir
and add as required. Tighten the filler cap on the
STEP 124 hydraulic reservoir.
BD01D696
Install the two bolts that fasten the target bar to the
mounting bracket.
2 STEP 137
3 Remove the inner bellcrank (6) from the pivot pins
(7).
STEP 138
5 Remove the nut (8) and the grease line (9) from the
1 bucket cylinder (10).
4 STEP 139
6 Fasten acceptable lifting equipment to the bucket
BS01C084
cylinder (10) and remove the bucket cylinder (10)
from the machine.
1. BUCKET CYLINDER (LEFT HAND SIDE)
2. PROXIMITY SWITCH MOUNTING BRACKET
3. TARGET MOUNTING BRACKET
4. PROXIMITY SWITCH GUARD
5. PROXIMITY SWITCH
6. TARGET BAR
Disconnect the Return-to-Dig proximity switch (5)
and remove with the mounting bracket (2) as an
assembly.
STEP 133
Remove the Return-to Dig target bar (6) with the
mounting bracket (3) from the yoke of the bucket
cylinder (1).
10 9
3
1
5
10
7
4
7
5
4
BS01C085
STEP 152
Park the machine on a level surface and lower the
bucket to the ground. Stop the engine and apply the
parking brake.
STEP 153
BD01D234
STEP 158
BD01D138
STEP 154
BD01D231
BD01D230
With the hood raised loosen the two bolts holding the
shield in place and remove the shield.
STEP 155
Loosen the filler cap on the hydraulic reservoir to
release the air pressure in the reservoir.
STEP 156
Drain the hydraulic reservoir.
STEP 162
BD01D234
BD01D231
BD01D231
STEP 160
Remove the oil cooler from the machine. BD01D234
Install the bolts and washers that fasten the oil cooler
to the cooling frame
STEP 163
BD01D231
STEP 168
BD01D234
STEP 165
Fill the hydraulic reservoir with hydraulic oil. See
Section 1002 for the correct hydraulic oil. BD01D230
Install the shield and tighten the two bolts holding the
STEP 166 shield.
STEP 169
Check the level of the hydraulic oil in the reservoir
and add hydraulic oil as required.
BD01D136
STEP 170
Park the machine on a level surface and lower the
bucket to the floor. Stop the engine and apply the
parking brake.
STEP 171
With the engine NOT running, pump the brake
repeatedly to be sure the brake accumulators have
no hydraulic pressure, the move the loader control
lever back and forth several times to release any
hydraulic pressure in the pilot control circuit.
BD01D716
STEP 172 Loosen and remove the nuts and washers from the
Relieve the pressure in the ride control accumulator U-bolt. Remove the U-bolt.
with the manual bleeder valve located at the rear of
the front chassis. STEP 176
STEP 173
Loosen the filler cap on the hydraulic reservoir to
release any air in the reservoir.
STEP 174
BD01D717
STEP 177
Remove the ride control accumulato r from the
BD01D717 machine.
Disconnect the hose from the elbow at the bottom of
the ride control accumulator. Install a plug in the hose
and a cap on the fitting.
NOTE: The above photo shows the center drive
shaft removed and was done for photographic
reasons only.
STEP 178
Place the ride control accumulator in position on the
front frame.
STEP 179
BD01D717
STEP 182
BD01D717
Refer to Section 8002 Testing the Ride Control for
Install the two bolts that fasten the accumulator the proper charging of the accumulator to check for
bracket to the front frame. Tighten the bolts. leaks.
BD01D716
STEP 185
BD01D138
BD01D374
BD00M041
Disconnect the electrical connector on top of the ride
Remove the access cover. control valve.
4
3
5 2
14
13
6
12
9
11
7 8
10
BS01D191
STEP 199
Install the ride control valve (3) in position on the
front frame (1). Refer to the illustration on page 35.
STEP 200
Install the washers (13) and bolts (12) through the
ride control bracket (2) and into the ride control valve
(3). Tighten the bolts (12).
STEP 201
Lubricate and install new O-rings to all necessary
fittings. BD01D136
STEP 205
Connect the accumulator bleed hose (4) to the elbow
(5) at the ride control valve (3).
STEP 206
BD00M041
BD01D374
STEP 213
Refer to Section 8002 and perform the Ride Control
Test Procedure.
BD00M048
STEP 214 5
Park the machine on a level surface and lower the
bucket to the ground. Stop the engine and apply the 4
parking brake.
STEP 215
3
With the engine NOT running, pump the brake
repeatedly to be sure the brake accumulators have
no hydraulic pressure, then move the loader control
2
lever back and forth several times to release any 1 5 5
hydraulic pressure in the pilot control circuit.
BD01D360
STEP 219
Remove the fan reversing valve from the machine.
STEP 220
Remove and discard all O-rings from the fittings.
STEP 221
Place the fan reversing valve into position on the
machine.
STEP 222
Lubricate and install new O-rings in the fittings.
STEP 223
5
BD01D359
4
Connect the electrical connector for the fan reversing
valve.
3 STEP 225
Check the level of the hydraulic oil in the reservoir.
2
STEP 226
1 5 5
Start the engine and run the engine at low idle for two
BD01D360
minutes.
1. FAN FORWARD HOSE
2. FAN REVERSE HOSE STEP 227
3. FAN VALVE RETURN HOSE Stop the engine and check for hydraulic oil leakage
4. FAN VALVE SUPPLY HOSE at the fan reversing valve.
5. NUTS
6. WASHERS (NOT SHOWN)
STEP 228
7. BOLTS (NOT SHOWN)
Check the level of the hydraulic oil in the reservoir
A. Install the bolts (7), washers (6) and nuts (5).
and add as required. Tighten the filler cap on the
Tighten the nuts (5).
reservoir.
B. Connect the fan valve supply hose (4) to the
fitting on the fan reversing valve.
C. Connect the fan valve return hose (3) to the
elbow on the fan reversing valve.
D. Connect the fan reverse hose (2) to the fitting
on the fan reversing valve.
E. Connect the fan forward hose (1) to the fitting
on the fan reversing valve.
8002
Section
8002
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright 2001 Case Corporation
3350 South Service Road Printed in U.S.A.
Burlington, ON L7N 3M6 CANADA Bur 6-40820 March, 2001
Copyright
8002-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Problems in All Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Problem in All Loader Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Problem in the Braking Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Problem in a Single Loader Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Problem in the Steering Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Problem in the Ride Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TESTING AND ADJUSTING THE PUMP DIFFERENTIAL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Adjusting the Main Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TESTING THE HYDRAULIC PUMP PERFORMANCE AND TORQUE LIMITER . . . . . . . . . . . . . . . . . . . . . . . . 8
TESTING AND ADJUSTING THE MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
TESTING AND ADJUSTING THE CIRCUIT RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
TESTING THE RIDE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
521D HYDRAULIC COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
521D HYDRAULIC COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SPECIFICATIONS
Pump Output ...............................................................................................135 to 138 L/min at 2000 rpm at 138 bar
(35.5 to 36.5 gpm at 2000 rpm at 2000 psi)
Main relief valve pressure settings
521D (Z-Bar/XT) ................................................................................................248 to 252 bar (3596 to 3654 psi)
Circuit relief valve pressure setting
Auxiliary A and B port (XT and Z-Bar) .......................................................................................290 bar (4206 psi)
Bucket A and B port (Z-Bar) ......................................................................................................290 bar (4206 psi)
Bucket A port (XT) .....................................................................................................................183 bar (2654 psi)
Bucket B port (XT) .....................................................................................................................290 bar (4206 psi)
Steering relief valve pressure setting ............................................................................................. See Section 5002
Accumulator pressure .................................................................................................................... See Section 7002
SPECIAL TOOLS
633L95 B877168V
CAS-1904 PRESSURE FITTING KIT CAS-1808 FLOWMETER FITTING KIT
632L95 B877895M
CAS-1906 PRESSURE FITTING KIT CAS-10090 HAND PUMP
B785789M B877558M
CAS-10280 FLOWMETER CAS-1804 PRESSURE FITTING KIT
TROUBLESHOOTING PROCEDURE
Check the oil level in the hydraulic reservoir. Is Fill the hydraulic reservoir with the hydraulic oil
No specified in Section 1002.
the oil level correct?.
Yes
Problems in All Circuits - See the following pages for other circuits
Replace the return line hydraulic filter.
See Section 2002. Do the stall test to see if
the engine is good.
See Section 8003 and check for contaminated See Page 7. Do the flowmeter tests of the
No hydraulic pump.
oil. Is the oil contaminated?
Yes
Yes
Check the cylinder piston packing. Is the See Section 8006 and repair the cylinder.
No
packing good?
Yes
See Page 10. Check and adjust the circuit See Section 8005. Disassemble the loader
relief valves. Then check the operation of contr ol valve and c heck for wo r n o r
No
the circuit again. Does the circuit work damaged parts.
correctly?
Yes
Yes
Yes
STEP 1
Make sure that the temperature of the hydraulic oil is
at least 52C to 60C (125F to 140F). The following
is the procedure for heating the hydraulic oil.
A. Start the engine and run at high idle.
B. Lower the loader bucket to the ground.
C. Hold the lift control lever in the FLOAT 1
position.
D. Roll the bucket back against the stops and
hold.
BD00N020
E. View the oil temperature by pressing the
program switch, then press the up count
switch to function 008. Return the program
switch to the center (OFF) position.
STEP 2
BD00N017
1
Connect two 69 bar (1000 psi) test gauges to the test
ports (1) and (2) located on the loader control valve.
BD00M041
1. COVER PLATE
STEP 4
Remove the cover plate to gain access to the loader Start the engine and run at low idle.
control valve.
STEP 5
Make sure all of the controls are in the neutral
position and record the readings on the test gauges
(1) and (2).
STEP 6
The pressure on test por t (1) should read
approximately 29 bar (420 psi). The pressure on test
port (2) should read approximately 51 bar (740 psi).
NOTE: These readings may vary from one machine
to another. The important value is the difference
between the two readings.
STEP 9
If this reading is more or less than that specified, it
will be necessary to adjust the pump.
BS01B022
7 NOTE
4
5
2
BS01A308
STEP 1
1
BD00M041
STEP 2
2
1
BD00N017
STEP 6
Start the engine and remove the safety link (refer to
step 2) and lower the loader arms to the ground.
STEP 7
Operate the machine at full throttle. Tilt the bucket to
a full rollback position and hold while observing the 2
pressure gauge.
1
STEP 8
The pressure should read between 248 and 252 bar BS01A046
(3596 to 3654 psi). 1. LOADER CONTROL VALVE
2. RELIEF VALVE ADJUSTMENT
STEP 9 With the engine running and the loader on the
If the pressure is not within the specifications, it will ground, loosen the jam nut and turn the adjustment
be necessary to adjust the main relief valve. s c r e w ( 2 ) c l o c k w i s e fo r h i g h e r p r e s s u r e o r
counterclockwise for lower pressure.
NOTE: 1/4 turn of the adjusting screw changes the
pressure setting approximately 35 bar (500 psi).
STEP 11
Repeat the Pressure Check Procedure.
STEP 12
If the pressure is not within the specifications, repeat
steps 10 and 11 until pressure is within the required
range.
STEP 13
Stop the engine before removing the pressure
gauge.
STEP 5
Operate the handle of the hand pump and read the
highest pressure. Repeat this step several times to
4 4 be sure of the reading.
STEP 6
Compare the reading to the specifications on Page 3.
STEP 7
If the pressure is not correct, adjust the circuit relief
valve.
3 Adjustment
3 1
1 STEP 1
2 Loosen the lock nut. Turn the adjustment screw
clockwis e to increase the pressure or
counterclockwise to decrease the pressure.
BS01A046
6 20
14 3
15
13 2
1 4
9 11
5 10
16
12
4
18
19
7 8
17
BC00N140
1.RIDE CONTROL VALVE (OPTIONAL) 11. STEERING PRESSURE DIAGNOSTIC COUPLER
2.RIDE CONTROL ACCUMULATOR 12. BRAKE ACCUMULATORS
3.RIDE CONTROL ACCUMULATOR BLEEDER VALVE 13. BRAKE AND ACCUMULATOR CHARGING VALVE
4.LIFT CYLINDERS 14. BRAKE WARNING PRESSURE SWITCH
5.BUCKET CYLINDER (TILT CYLINDER) 15. BRAKE LIGHT PRESSURE SWITCH
6.STEERING CONTROL VALVE 16. BRAKE ACCUMULATOR PRESSURE DIAGNOSTIC COUPLER
7.STEERING CYLINDERS 17. REAR BRAKE CYLINDERS
8.AUXILIARY STEERING PUMP AND MOTOR (OPTION - 18. FRONT BRAKE CYLINDERS
NORTH AMERICAN MODELS) 19. PARKING BRAKE CYLINDER
9. AUXILIARY STEERING PRIORITY VALVE (OPTION - 20. FRONT AND REAR AXLE BRAKE PRESSURE DIAGNOSTIC
NORTH AMERICAN MODELS) COUPLERS
10. AUXILIARY STEERING PRESSURE SWITCH
NOTE: The hydraulic schematic is located in the rear pocket. All numbers are coordinated with the hydraulic
schematic for reference.
38
41 30
40 22 39
34 37
24 36
35
25 33
29 32
28
25
21
31
26
27
23
BC00N140
Section
8003
8003
CASE CORPORATION
700 STATE STREET
RACINE, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright 1995 Case Corporation
3350 SOUTH SERVICE ROAD Bur 7-49640 Printed in U.S.A.
BURLINGTON, ON L7N 3M6 CANADA Issued May 1995
Copyright
8003-2
TABLE OF CONTENTS
PORTABLE FILTER ..................................................................................................................................................... 3
NOTE: The Case Corporation reserves the right to make improvements in design or
changes in specifications at any time without incurring any obligation to install them on units
previously sold.
SPECIAL TOOLS
806128
806127
GENERAL INFORMATION
Contamination in the hydraulic system is a major cause of 1. Cylinder rod seals leak.
the malfunction of hydraulic components. Contamination is
any foreign material in the hydraulic oil. Contamination can 2. Control valve spools do not return to neutral.
enter the hydraulic system in several ways.
3. Movement of control valve spools is difficult.
1. When you drain the oil or disconnect any line.
4. Hydraulic oil becomes too hot.
2. When you disassemble a component.
5. Pump gears, housing, and other parts wear rapidly.
3. From normal wear of the hydraulic components.
6. Relief valves or check valves held open by dirt.
4. From damaged or worn seals.
7. Quick failure of components that have been repaired.
5. From a damaged component in the hydraulic system.
8. Cycle times are slow; machine does not have enough
All hydraulic systems operate with some contamination. power.
The design of the components in this hydraulic system
per mits efficient operation with a small amount of If your machine has any of these problems, check the
contamination. An increase in this amount of contamination hydraulic oil for contamination. See Types of Contamination
can cause problems in the hydraulic system. The following list below. If you find contamination, use the Portable Filter to
includes some of these problems. clean the hydraulic system.
TYPES OF CONTAMINATION
There are two types of contamination, microscopic and 3. Visible contamination is foreign material that can be
visible. found by sight, touch, or odor. Visible contamination can
cause a sudden failure of components. Examples of
1. Microscopic contamination occurs when very fine visible contamination:
particles of foreign material are in suspension in the
hydraulic oil. a. Particles of metal or dirt in the oil.
2. These particles are too small to see or feel. Microscopic b. Air in the oil.
contamination can be found by identification of the
following problems or by testing in a laboratory. Examples c. The oil is dark and thick.
of the problems:
d. The oil has the odor of burned oil.
a. Cylinder rod seal leak.
e. Water in the oil. See page 7.
b. Control valve spools do not return to NEUTRAL.
a. Remove all the hydraulic oil from the inlet and outlet 9. Stop the vacuum pump.
hoses for the portable filter.
10. Connect the inlet hose for the portable filter to the valve
b. Remove the filter element from the portable filter. that is installed in the hole for the drain plug.
c. Remove all hydraulic oil from the portable filter. 11. Disconnect the vacuum pump from the filler cap opening
on the hydraulic reservoir.
d. Clean the inside of the housing for the filter
element. 12. Install the outlet hose for the portable filter in the
hydraulic reservoir.
2. You must know whether the contamination is microscopic
or visible. See Types of Contamination on page 4. 13. Open the valve that is installed in the hole for the drain
plug.
3. If the contamination is microscopic:
14. Move the switch for the portable filter to the ON position.
a. Check the maintenance schedule for the machine to Start and run the engine at 1500 rpm (r/min).
lear n if the hydraulic oil must be changed. If
needed, change the hydraulic oil. See Section 1002 15. Run the portable filter for 10 minutes.
for specifications. Change the hydraulic filter.
16. Continue to run the portable filter. Increase the engine
b. Do steps 6 through 38. s p e e d t o f u l l t h r o t t l e. H e a t t h e o i l t o o p e r a t i n g
temperature by doing the following steps:
4. If the contamination is visible:
a. Hold the bucket control lever in the ROLLBACK
a. Change the hydraulic oil and hydraulic filter. See position for 15 seconds.
Section 1002 for oil specifications.
b. Return the bucket control lever to NEUTRAL for 30
b. Do steps 5 through 38. seconds.
5. Check the amount of contamination in the hydraulic c. Repeat steps 17a through 18b until the oil in the
system by doing the following steps: hydraulic system is at operating temperature.
a. Disassemble one cylinder in two different circuits. 17. Continue to run the engine at full throttle. Continue to run
Check for damage to seals, scoring of the cylinder the portable filter.
wall, etc. Repair the cylinders as necessary.
18. Operate each hydraulic circuit to completely extend and
b. If, in your judgment, the damage to the cylinders retract the cylinders. Continue to operate each hydraulic
was caused by severe contamination and is not the circuit two times, one after the other, for 45 minutes.
result of normal wear, it is necessary to remove,
clean and repair valves, pump, lines, cylinders, 19. Decrease the engine speed to low idle.
hydraulic reservoir, etc. in the hydraulic system.
20. Continue to run the portable filter for 10 minutes.
6. Connect a vacuum pump to the hydraulic reservoir air
breather hose. Start the vacuum pump. 21. Stop the portable filter.
7. Loosen and remove the drain plug from the reservoir. 22. Stop the engine.
25. Disconnect the inlet hose for the portable filter from the 31. Remove the hydraulic filter element from the machine.
valve.
32. Install a new hydraulic filter element on the machine.
26. Connect a vacuum pump to the breather hose of the
hydraulic reservoir. 33. Check the oil level in the hydraulic reservoir. Add oil as
required. See Section 1002 for specifications.
27. Start the vacuum pump.
34. Start the engine. Check for oil leakage around the new
28. Remove the valve from the hole for the drain plug. hydraulic filter.
WARNING: If retracting the cylinder rods 11. Be sure all control levers are in the NEUTRAL position.
causes the attachment to be raised, block
! the attachment in place before proceeding to
the next step!
12. Start the engine and run the engine at low idle.
5. Remove the hydraulic oil filter from the machine. 17. Slowly and completely extend all cylinders. As the piston
rod comes out of the cylinder, oil will be pushed out of the
6. Install a new hydraulic oil filter on the machine. rod end of the cylinder.
7. Install the drain plug in the bottom of the reservoir. 18. Support the loader frame so that the loader frame will
stay in the RAISED position.
8. Fill the hydraulic reservoir with 14.4 U.S. gallons (54.5
litres) of Case TCH Fluid. 19. Stop the engine.
21. Check the oil level in the hydraulic reservoir. Add oil as
required. See Section 1002 for specifications.
Section
8006
CYLINDERS
8006
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright 2001 Case Corporation
3350 South Service Road Printed in U.S.A.
Burlington, ON L7N 3M6 CANADA Bur 6-42590 August, 2001
Copyright
8006-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
BUCKET CYLINDERS Z-BAR MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
BUCKET CYLINDERS FOR XT MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REPLACING THE BUSHINGS FOR THE LIFT CYLINDERS
Z-BAR AND XT MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REPLACING BUSHINGS FOR THE BUCKET CYLINDERS XT MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REPLACING BUSHINGS FOR THE BUCKET CYLINDER Z-BAR MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SPECIFICATIONS
Approximate weight
Lift Cylinder - XT and Z-Bar.......................................................................................................75.7 kg (167 pounds)
Bucket Cylinder - Z-Bar Models.................................................................................................75.6 kg (167 pounds)
Bucket Cylinder - XT Models ........................................................................................................73 kg (160 pounds)
SPECIAL TORQUES
Screw in Gland Z-Bar Bucket Cylinder ..........................................................135 to 542 Nm (100 to 400 pound-feet)
Screw in Gland XT Bucket Cylinder ..............................................................135 to 542 Nm (100 to 400 pound-feet)
Screw in Gland for Lift Cylinders XT and Z-Bar Models ................................135 to 542 Nm (100 to 400 pound-feet)
Piston Bolt for Lift Cylinders XT and Z-Bar Models ...............................1780 to 2180 Nm (1312 to 1607 pound-feet)
Piston Bolt for Z-Bar Bucket Cylinder ....................................................3310 to 3850 Nm (2440 to 2838 pound-feet)
Piston Bolt for XT Bucket Cylinder ........................................................1780 to 2180 Nm (1312 to 1607 pound-feet)
Lock Screw for all Cylinders .............................................................................................. 2.3 Nm (20 pound-inches)
SPECIAL TOOLS
Torque Multiplier ......................................................................................................................................... CAS-1039
LIFT CYLINDER
Disassembly Inspection
1. Clean the outside of the cylinder. If the hoses 1. Discard the parts that were removed from the
were removed with the cylinder, remove the piston and the gland.
hoses from the cylinder.
2. Clean all parts in cleaning solvent. Use only lint
2. Fasten the tube (1) in an acceptable repair stand free cloths for cleaning and drying.
or other holding equipment, refer to Figure 1. Do
3. Check to be sure that the piston rod is straight. If
not damage the tube (1).
the piston rod is not straight, replace it with a
3. Loosen and remove the self-tapping screw (12). new piston rod.
4. Use a spanner wrench to loosen and remove the 4. Illuminate the inside of the tube for deep grooves
gland (4) out of the tube (1). and other damage. If there is any damage to the
tube, replace it with a new tube.
5. Pull the piston rod (13) straight out of the tube (1)
to prevent damage to the tube (1). 5. Remove any small scratches on the piston rod or
inside the tube with emery cloth of medium grit.
6. Fasten the piston rod eye or yoke in a vise and
Use the emery cloth with a rotary motion.
put a support under the piston rod (13) near the
piston (15). Put a shop cloth between the support 6. Inspect the bushings in the piston rod eye or
and the piston rod (13) to prevent damage to the yoke and the tube. Replace as required.
piston rod (13).
7. Inspect the gland for rust. Clean and remove rust
7. Use a torque multiplier, CAS-1039, to loosen and as necessary.
remove the bolt (14), washer (19) that fastens
8. Inspect the gland end of the tube for sharp edges
the piston (15) to the piston rod (13).
that will cut the gland O-ring and remove as
8. Remove the piston (15) from the piston rod (13). necessary.
9. Remove the gland (4) from the piston rod (13). 9. Inspect the piston for damage and wear. If the
piston is damaged or worn, replace it with a new
10. Remove the seal (16), ring (17)and the wear ring
piston.
(18) from the piston (15).
11. Remove the O-ring (10), ring (9), O-ring (11),
wiper (5), seal (6), seal (7), and bushing (8) from
the gland (4).
BC01A163
Assembly 16. Install the bolt (14) into the piston rod (13).
Tighten the bolt (14) to a torque of 1780 to 2180
NOTE: If a new gland is being used, put the part N m ( 1 3 1 2 t o 1 6 0 7 p o u n d - f e e t) . A t o r q u e
number of the cylinder on the new gland. multiplier can be used to help torque the bolt
1. Install the bushing (8) in the gland (4), refer to (14).
Figure 1. 17. Install a new wear ring (18) in the wide groove on
2. Install the seal (6) in the gland (4). The seal (6) is the outside of the piston (15), refer to Figure 1.
to be installed so that the lips of the seal (6) are 18. Install a new ring (17) in the other groove on the
toward the bushing (8). The seal (6) can be outside of the piston (15).
difficult to install.
19. Install a new seal (16) on the top of the ring (17).
3. Install the seal (7) in the gland (4). The side of
the seal (7) with the groove must be toward the 20. Fasten the tube (1) in an acceptable repair stand
bushing (8). or other holding equipment. Be careful to prevent
damage to the tube (1).
4. Install a new wiper (5) in the gland (4). The lips of
the wiper (5) must be toward the outside end of 21. Lubricate the inside of the tube (1) and the piston
the gland (4). (15) with clean oil.
5. Install a new O-ring (11) in the groove on the OD 22. Push the piston (15) straight into the tube (1).
of the gland (4). 23. When the piston (15) is in the smooth part of the
6. Install a new ring (9) in the groove on the OD of tube (1), start the gland (4) into the tube (1).
the gland (4). If both sides of the ring (9) are not 24. Lubricate the O-rings (10 and 11) on the gland
flat, the side that is not flat must be toward the (4) with clean oil.
small end of the gland (4).
25. Turn the gland (4) into the tube (1). Tighten the
7. Install a new O-ring (10) next to the ring (9) in the gland (4) to a torque of 135 to 542 Nm (100 to
groove on the outside of the gland (4). The 400 pound-feet).
O-ring (10) must be toward the small end of the
gland. 26. If the original parts are being assembled:
8. Fasten the piston rod eye or yoke in the vise. A. Tighten the gland to a torque of 135 to 542
Nm (100 to 400 pound-feet).
9. Remove any marks and sharp edges on the
chamfer at the end of the piston rod (13). Make B. Install and tighten the lock screw (12) to a
sure that the piston rod (13) is clean. torque of 2.3 Nm (20 inch-pounds).
10. Lubricate the bore of the gland (4) and the piston C. If, after tightening the gland, the lock screw
rod (13) with clean oil. (12) holes are not aligned, a new hole for the
lock screw (12) must be drilled. See Step 27.
11. Push the gland (4) onto the piston rod (13). If
necessary, use a soft hammer to drive the gland 27. If a new gland (4) or a new tube (1) are being
(4) onto the piston rod (13). assembled:
12. Put a support below and near the end of the A. Tighten the gland (4) to 135 to 542 Nm (100 to
piston rod (13). Use a shop cloth between the 400 pound-feet).
suppo rt and the pisto n ro d (13) to prevent B. Use a No. 27 drill bit and drill a hole half in the
damage to the piston rod (13). gland (4) and half in the tube (1). Drill to a
13. Start the piston (15) onto the piston rod (13). depth of 11 mm (7/16 inch). Do not drill within
13 mm (1/2 inch) of a ho le for the gland
14. Put the washer (19) on the bolt (14). wrench.
15. Clean the threads on the end of the piston rod C. Install and tighten the lock screw (12) to a
and the threads of the piston bolt using Loctite torque of 2.3 Nm (20 inch-pounds).
cleaning solvent. Allow to dry. Apply Loctite 242
to the piston rod threads 1/4 inch from the open 28. If the hoses were removed with the cylinder,
end of the piston rod so that there is 1/2 inch of install new O-rings, if equipped, on the hose
Loctite 242 on the piston rod threads. DO NOT fittings. Lubricate O-rings with clean oil. Install
apply Loctite to the first 1/4 inch of the piston rod the hoses.
threads.
Disassembly Inspection
1. Clean the outside of the cylinder. If the hoses 1. Discard the parts that were removed from the
were removed with the cylinder, remove the piston and the gland.
hoses from the cylinder.
2. Clean all parts in cleaning solvent. Use only lint
2. Fasten the tube (1) in an acceptable repair stand free cloths for cleaning and drying.
or other holding equipment, refer to Figure 2. Do
3. Check to be sure that the piston rod is straight. If
not damage the tube (1).
the piston rod is not straight, replace it with a
3. Loosen and remove the locking screw (12) from new piston rod.
the gland (4) and tube (1).
4. Illuminate the inside of the tube for deep grooves
4. Use a spanner wrench to loosen and remove the and other damage. If there is any damage to the
gland (4) out of the tube (1). tube, replace it with a new tube.
5. Pull the piston rod (12) straight out of the tube (1) 5. Remove any small scratches on the piston rod or
to prevent damage to the tube (1). inside the tube with emery cloth of medium grit.
Use the emery cloth with a rotary motion.
6. Fasten the piston rod eye or yoke in a vise and
put a support under the piston rod (12) near the 6. Inspect the bushings in the piston rod eye or
piston (17). Put a shop cloth between the support yoke and the tube. Replace as required.
and the piston rod (12) to prevent damage to the
7. Inspect the gland for rust and clean and remove
piston rod (12).
rust as necessary.
7. Use a torque multiplier, CAS-1039 to loosen and
8. Inspect the gland end of the tube for sharp edges
remove the bolt (15), washer (14) that fastens
that will cut the gland O-ring and remove as
the piston (17) to the piston rod (12).
necessary.
8. Remove the piston (17) from the piston rod (12).
9. Inspect the piston for damage and wear. If the
9. Remove the gland (4) from the piston rod (12). piston is damaged or worn, replace it with a new
piston.
10. Remove the seal (18), backup ring (19) and wear
ring (20) from the piston (17).
11. Remove the O-ring (11), backup ring (10), wiper
(5), seal (6), seal (7) and bushing (8) from the
gland (4).
BS01A174
Assembly 16. Install the bolt (15) into the piston rod (12).
Tighten the bolt (15) to a torque of 3310 to 3850
NOTE: If a new gland is being used, put the part N m ( 2 4 4 0 t o 2 8 3 8 p o u n d - f e e t) . A t o r q u e
number of the cylinder on the new gland. multiplier can be used to help torque the bolt
1. Install the bushing (8) in the gland (4), refer to (15).
Figure 2. 17. Install a new wear ring (20) in the wide groove on
2. Install the seal (6) in the gland (4). The seal (6) is the outside of the piston (17), refer to Figure 2.
to be installed so that the lips of the seal (6) are 18. Install a new backup ring (19) in the other groove
toward the bushing (8). The wide seal (6) can be on the outside of the piston (17).
difficult to install.
19. Install a new seal (18) on the top of the backup
3. Install the seal (7) in the gland (4). The side of ring (19).
the seal (7) with the groove must be toward the
bushing (8). 20. Fasten the tube (1) in an acceptable repair stand
or other holding equipment. Be careful to prevent
4. Install a new wiper (5) in the gland (4). The lips of damage to the tube (1).
the wiper (5) must be toward the outside end of
the gland (4). 21. Lubricate the inside of the tube (1) and the piston
(17) with clean oil.
5. Install a new O-ring (9) in the groove on the
gland (4). 22. Push the piston (17) straight into the tube (1).
6. Install a new backup ring (10) in the groove on 23. When the piston (17) is in the smooth part of the
the OD of the gland (4). If both sides of the tube (1), start the gland (4) into the tube (1).
backup ring (10) are not flat, the side that is not 24. Lubricate the O-rings (9 and 11) on the gland (4)
flat must be toward the small end of the gland with clean oil.
(4).
25. Turn the gland (4) into the tube (1). Tighten the
7. Install a new O-ring (11) next to the backup ring gland (4) to a torque of 407 +/- 68 Nm (300 +/- 50
(10) in the groove on the outside of the gland (4). pound-feet).
The O-ring (11) must be toward the small end of
the gland. 26. If the original parts are being assembled:
8. Fasten the piston rod eye or yoke in the vise. A. Tighten the gland to a torque of 135 to 542
Nm (100 to 400 pound-feet).
9. Remove any marks and sharp edges on the
chamfer at the end of the piston rod (12). Make B. Install and tighten the lock screw (3) to a
sure that the piston rod (12) is clean. torque of 2.3 Nm (20 inch-pounds).
10. Lubricate the bore of the gland (4) and the piston C. If, after tightening the gland, the lock screw (3)
rod (12) with clean oil. holes are not aligned, a new hole for the lock
screw (3) must be drilled. See Step 27.
11. Push the gland (4) onto the piston rod (12). If
necessary, use a soft hammer to drive the gland 27. If a new gland (4) or a new tube (1) are being
(4) onto the piston rod (12). assembled:
12. Put a support below and near the end of the A. Tighten the gland (4) to a torque of 135 to 542
piston rod (12). Use a shop cloth between the Nm (100 to 400 pound-feet).
suppo rt and the pisto n rod (12) to prevent B. Use a No. 27 drill bit and drill a hole half in the
damage to the piston rod (12). gland (4) and half in the tube (1). Drill to a
13. Start the piston (17) onto the piston rod (12). depth of 11 mm (7/16 inch). Do not drill within
13 mm (1/2 inch) of a ho le for the gland
14. Put the washer (16) on the bolt (15). wrench.
15. Clean the threads on the end of the piston rod C. Install and tighten the lock screw (3) to a
and the threads of the piston bolt using Loctite torque of 2.3 Nm (20 inch-pounds).
cleaning solvent. Allow to dry. Apply Loctite 242
to the piston rod threads 1/4 inch from the open 28. If the hoses were removed with the cylinder,
end of the piston rod so that there is 1/2 inch of install new O-rings, if equipped, on the hose
Loctite 242 on the piston rod threads. DO NOT fittings. Lubricate O-rings with clean oil. Install
apply Loctite to the first 1/4 inch of the piston rod the hoses.
threads.
Bur 6-42590 Issued 8-01 Printed in U.S.A.
Copyright
8006-10
Disassembly Inspection
1. Clean the outside of the cylinder. If the hoses 1. Discard the parts that were removed from the
were removed with the cylinder, remove the piston and the gland.
hoses from the cylinder.
2. Clean all parts in cleaning solvent. Use only lint
2. Fasten the cylinder in a vise or other holding free cloths for cleaning and drying.
equipment. Be careful to prevent damage to the
3. Check to be sure that the piston rod is straight. If
tube (1), refer to Figure 3.
the piston rod is not straight, replace it with a
3. Loosen and remove the lock screw (3) from the new piston rod.
gland (4) and tube (1).
4. Illuminate the inside of the tube for deep grooves
4. Use a spanner wrench to loosen and remove the and other damage. If there is any damage to the
gland (4) from the tube (1). tube, replace it with a new tube.
5. Pull the piston rod (12) straight out of the tube (1) 5. Remove any small scratches on the piston rod or
to prevent damage to the tube (1). inside the tube with emery cloth of medium grit.
Use the emery cloth with a rotary motion.
6. Fasten the rod yoke in a vise and put a support
below the piston rod (12) near the piston (13). 6. Inspect the bushings in the piston rod eye or
Use a shop cloth between the support and the yoke and the tube. Replace as required.
piston rod (12) to prevent damage to the piston
7. Inspect the gland for rust and clean and remove
rod (12).
rust as necessary.
7. Use a torque multiplier, CAS-1039, to loosen and
8. Inspect the gland end of the tube for sharp edges
remo ve th e p is to n b olt (1 7) a nd ha rde ne d
that will cut the gland O-ring and remove as
washer (18) that secure the piston (13).
necessary.
8. Remove the piston (13) from the piston rod (12).
9. Inspect the piston for damage and wear. If the
9. Remove the gland (4) from the piston rod (12). piston is damaged or worn, replace it with a new
piston.
10. Remove the backup ring (14), piston seal (15)
and wear ring (16) from the piston (13).
11. Remove the wiper (5), seal (7), seal (8) and the
bushing (6) from the gland (4).
NOTE: Use care not to scratch the ID of gland when
removing seals.
12. Remove the O-ring (10) and backup ring (11)
from the OD of gland (4).
BS01A175
Assembly 16. Install the piston bolt (17). Tighten the piston bolt
(17) to a torque of 1780 ti 2180 Nm (1312 to
NOTE: If a new gland (4) is being installed, put the 1607 pound-feet). A torque multiplier can be
part number of the cylinder on the new gland (4). used to help tighten the piston bolt (17).
1. Install the bushing (6) in the gland (4), refer to 17. Install a new wear ring (16) in the groove on the
Figure 3. outer end of the piston (13).
2. Install the seal (8). The seal (8) must be installed 18. Install the piston backup ring (14) into the
with the seal lips toward the small end of the remaining groove in the piston (13).
gland (4). The seal (8) can be difficult to install.
19. Install a new piston seal (15) on top of the
3. Install the seal (7). The seal (7) must be installed backup ring (14).
with the lips toward the small end of the gland (4)
also. 20. Fasten the tube (1) in a vise or other holding
equipment. Be careful to prevent damage to the
4. Install a new wiper (5) in the gland (4). The lips of tube (1).
the wiper (5) must be toward the large end of the
gland (4). 21. Lubricate the inside of the tube (1) and the piston
(13) with clean oil.
5. Install a new O-ring (9) in the groove of the gland
(4). 22. Push the piston (13) straight into the tube (1).
6. Install a new backup ring (11) in the groove on 23. When the piston (13) is in the smooth part of the
the outside of the gland (4). If both sides of the tube (1), start the gland (4) into the tube (1).
backup ring (11) are not flat, the side that is not 24. Lubricate the O-ring (9 and 10) on the gland (4)
flat must be toward the small end of the gland with clean oil.
(4).
25. Tighten the gland (4) into the tube (1). Tighten
7. Install the O-ring (10) on the gland (4). The the gland to a torque of 135 to 542 Nm (100 to
O-ring (10) must be toward the small end of the 400 pound-feet).
gland (4).
26. If the original parts are being assembled:
8. Fasten the piston rod yoke in the vise.
A. Tighten the gland to a torque of 135 to 542
9. Remove any marks and sharpen edges on the Nm (100 to 400 pound-feet).
chamfer at the end of the piston rod (12).
B. Install and tighten the lock screw (3) to a
10. Lubricate the bore of the gland (4) and the piston torque of 2.3 Nm (20 inch-pounds).
rod (12) with clean oil.
C. If, after tightening the gland, the lock screw (3)
11. Push the gland (4) onto the piston rod (12). If holes are not aligned, a new hole for the lock
necessary, use a soft hammer to drive the gland screw (3) must be drilled. See Step 27.
(4) onto the piston rod (12).
27. If a new gland (4) or a new tube (1) are being
12. Put a support below and near the end of the assembled:
piston rod (12). Use a shop cloth between the
suppo rt and the pisto n ro d (12) to prevent A. Tighten the gland (4) to 135 to 542 Nm (100 to
damage to the rod. 400 pound-feet).
13. Put the piston (13) on the end of the piston rod B. Use a No. 27 drill bit and drill a hole half in the
(12). gland (4) and half in the tube (1). Drill to a
depth of 11 mm (7/16 inch). Do not drill within
14. Put the hardened washer (18) on the piston bolt 13 mm (1/2 inch) of a ho le for the gland
(17). wrench.
15. Clean the threads on the end of the piston rod C. Install and tighten the lock screw (3) to a
and the threads of the piston bolt using Loctite torque of 2.3 Nm (20 inch-pounds).
cleaning solvent. Allow to dry. Apply Loctite 242
to the piston rod threads 1/4 inch from the open 28. If the hoses were removed with the cylinder,
end of the piston rod so that there is 1/2 inch of install new O-rings, if equipped, on the hose
Loctite 242 on the piston rod threads. DO NOT fittings. Lubricate the O-rings with clean oil.
apply Loctite to the first 1/4 inch of the piston rod Install the hoses.
threads.
Disassembly
1. Put the piston tube (4) in a press, refer to Figure
4.
2. Use an acceptable driver to press the wipers (1)
3
and bushings (2) out of the piston tube (4).
3. Clean the bore for the bushings (2) in the tube
1
(4).
4
Assembly
1. Use an acceptable driver to press a new bushing
2
(2) into the tube (4) until the bushing (2) is
centered in the tube (4). 1
2. Use an acceptable driver to install the wipers (1) 2
in the tube (4). The lips of the wipers (1) must be
toward the outside of the bore.
BS01C003
Disassembly
1. Put the piston tube (4) in a press, refer to Figure 3
5.
2. Use an acceptable driver to press the wipers (1)
and bushing (2) out of the piston tube (4).
3. Clean the bore for the bushings (2) in the tube
(4). 1 4
Assembly 2
1. Use an acceptable driver to press new bushings
(2) into the tube (4). Refer to Figure 5.
2. Use an acceptable driver to install the wipers (1)
in the tube (4). The lips of the wipers (1) must be 2
toward the outside of the bore. 1
BS01C002
Disassembly
1
1. Put the piston rod eye (3) in a press, refer to
Figure 6.
2 3
2. Use an acceptable driver to press the wipers (1)
and bushing (2) out of the piston rod eye (3). 2
3. Put the tube (4) in a press.
1
4. Use an acceptable driver to press the bushings
(2) out of the tube (4).
5. Clean the bore for the bushings (2) in the piston
rod eye (3) and the tube (4).
4
Assembly
1. Use an acceptable driver to press new bushings
2
(2) into the piston rod eye (3). Refer to Figure 6.
2. Use an acceptable driver to install the wipers (1)
in the piston rod eye (3). The lips of the wipers
(1) must be towards the outside of the bore.
2
3. Use an acceptable driver to press new bushings
(2) into the tube (4).
BS01C004
Section
8007
8007
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright 2001 Case Corporation
3350 South Service Road Printed in U.S.A.
Burlington, ON L7N 3M6 CANADA Bur 6-42600 August, 2001
Copyright
8007-2
TABLE OF CONTENTS
COUPLER SOLENOID LOCKING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... ...... 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... ...... 3
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... ...... 3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... ...... 3
Disassembly STEP 11
Install solenoid (2) on valve cartridge (3).
STEP 1
Clean exterior of valve. STEP 12
Install nut (1) to secure solenoid (2).
STEP 2
Remove nut (1) and solenoid (2) from valve cartridge
(3). 1
STEP 3
Remove valve cartridge (3) from valve housing (7).
2
STEP 4
Remove and discard all O-rings (4 and 5) and
back-up rings (6).
Assembly GS98J818
1. NUT 5. O-RING
STEP 9
2. SOLENOID 6. BACKUP RING
Install new O-rings (4 and 5) and back-up rings (6) as 3. VALVE CARTRIDGE 7. VALVE HOUSING
shown. 4. O-RING
STEP 10
Lubricate O-rings (4 and 5) using clean oil then install
valve cartridge (3) in valve housing (7).
Bur 6-42600 Issued 8-01 Printed in U.S.A.
Copyright
8007-4
NOTES
Section
8013
8013
PILOT PRESSURE ACCUMULATOR AND RIDE
CONTROL ACCUMULATOR
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright 2003 Case Corporation
3350 South Service Road Printed in U.S.A.
Burlington, ON L7N 3M6 CANADA Bur 6-42621 August, 2001 (Revised February, 2003)
Copyright
8013-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
RIDE CONTROL ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
PILOT PRESSURE ACCUMULATOR P.I.N. JEE0135500 AND BELOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CHARGING THE ACCUMULATOR WITH NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SPECIFICATIONS
Ride Control Accumulator Dry Nitrogen Pressure ............................ 17.2 +/- 1.7 bar (250 +/- 25 psi) at 21 C (70F)
Ride Control Accumulator Fluid Capacity............................................................................. 3.79 liters (231 cu. inch)
Ride Control Accumulator Maximum Operating Pressure
P.I.N. JEE0135500 and Below ...................................................................................................207 bar (3000 psi)
P.I.N. JEE0135501 and Above ................................................................................................. 248 bar (3600 psi)
Pilot Pressure Accumulator Dry Nitrogen Pressure......................... 13.8 +/- 1.7 bar (200 +/- 25 psi) at 21 C (70 F)
Pilot Pressure Accumulator Fluid Capacity ............................................................................ 95 liters (59.5 cu. inch)
Pilot Pressure Accumulator Maximum Operating Pressure ...........................................................207 bar (3000 psi)
SPECIAL TORQUES
Accumulator Gas Charging Valve Cap .................................................................................13.6 Nm (10 pound-feet)
Gas Charging Valve.............................................................................................88 to 102 Nm (65 to 75 pound-feet)
Cap screws for the protection bracket .......................................................... 54 to 61 Nm (480 to 540 pound-inches)
Gland .............................................................................................................163 to 176 Nm (120 to 130 pound-feet)
SPECIAL TOOLS
94L95 B786441M
CAS-10899 NITROGEN ACCUMULATOR CHARGING KIT CAS-1456 GLAND WRENCH
C E
D B A
94L95
CAS-10899 NITROGEN CHARGING KIT
NOTE: The pilot pressure accumulator used on 7. Turn the T-handle inward on valve F to engage
P.I.N. JEE0135501 and above is not repairable nor the pin in the valve stem.
rechargeable.
8. Open valve D and check the charge pressure on
1. Use the CAS-10899 Nitrogen Charging Kit to gauge E.
d i s c h a r g e t h e a c c u m u l a t o r, r e f e r t o t h e
9. To discharge the accumulator, partially open
illustration above. The tool must be disconnected
valve B. The accumulator charge will bleed down
from the nitrogen tank.
through the regulator.
2. Close valves B, C and D.
10. Once the accumulator is fully discharged,
3. Adjust the regulator A to the minimum pressure disconnect valve F from the valve stem.
setting by turning the knob counterclockwise.
11. The accumulator can now be disassembled.
4. Turn the T-handle on valve F fully out.
5. Remove the guard and valve assembly cap from
the accumulator.
6. Connect valve F to the valve stem on the
accumulator.
Disassembly Assembly
NOTE: Refer to Section 8001 for the proper 1. Fasten the body (1) in a vise. Be careful not to
procedure for the removal of the ride control damage the body (1). Refer to the illustration on
accumulator. page 7.
11 8 9 10 3
12
6 5
7 2
4
3
1
BS01B224
1. Fasten the body (1) in a vise. Be careful not to NOTE: The piston (5) must be installed squarely and
damage the body (1), refer to the illustration on slowly into the body (1). Once the piston (5) is started
page 9. straight into the bore of the body (1), use a hammer
and wood block to gently tap the piston into the
2. Remove the screws (3) and guard (2) from the
polished area of the bore. Keep force on the piston
body (1).
(5) while tapping into the bore or damage may occur
3. Remove the pressure valve (4) from the to the O-ring.
body (1).
5. Install the cap (12) in the body (1).
4. Remove and discard the O-ring (7) from the
pressure valve (4). 6. Install new seals (11) on the gland (6).
5. Loosen and remove the cap (12) from the body 7. Lubricate the seals (11) with clean oil and start
(1). the gland (6) into the body (1).
6. Loosen and remove the gland (6) from the body 8. Tighten the gland (6).
(1).
9. Install a new O-ring (7) on the pressure valve (4).
7. Remove the piston (5) from the body (1).
10. Install the pressure valve (4) in the body (1).
8. Remove and discard the wear ring (9), O-ring
(10) and the backup ring (9) from the piston (5). 11. Install the guard (2), screws (3) in the body (1).
9. Remove the seals (11) from the gland (6). 12. Charge the accumulator with dry nitrogen
according to instructions on page 10.
Inspection
WA R N I N G : U s e o n l y n i t r o g e n w h e n
1. Clean body (1), gland (6), cap (12) and piston (5) charging the accumulator. DO NOT use air
in cleaning solvent, refer to the illustration on
or oxygen that will cause an explosion.
page 9. SM115A
11 9 10 3
6 8
5 12
2
7
4
3
1
BS01B224
5 4
3 2
GS98N801
WARNING: Use only nitrogen when charging the accumulator. Do not use air or oxygen that will cause an
explosion.
M253A
WARNING: Do not drop the accumulator. A charged accumulator contains nitrogen compressed to 31 bar
(450 psi). If the charging valve breaks away from the accumulator, the escaping nitrogen will propel the
accumulator at a dangerous rate of speed.
M406
WARNING: Do not expose the accumulator to temperatures above 49 C (120 F). A charged accumulator
contains nitrogen compressed to 31 bar (450 psi). High heat will cause the safety plug to blow out of the
accumulator and the escaping nitrogen will propel the accumulator at a dangerous rate of speed.
M407
IMPORTANT: The four valves must be in the positions noted in the procedure before connecting the Nitrogen
Accumulator Charging Kit to the machine or nitrogen, refer to the above illustration.
IMPORTANT: To help prevent equipment damage, the low pressure gauge valve C MUST BE SHUT OFF during
high pressure (10 bar/150 psi and above) applications.
SECTION INDEX
MOUNTED EQUIPMENT
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright 2001 Case Corporation
3350 South Service Road Printed in U.S.A.
Hamilton, ON L7N 3M6 CANADA Bur 6-42640 August, 2001
Copyright
Copyright
9001
Section
9001
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright 2001 Case Corporation
3350 South Service Road Printed in U.S.A.
Burlington, ON L7N 3M6 CANADA Bur 6-40830 March, 2001
Copyright
9001-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ACCELERATOR PEDAL AND CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Checking the Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Adjusting the Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
BRAKE PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SPECIFICATIONS
Engine speeds
Low idle - 521D Z-Bar and XT......................................................................................... 1020 to 1080 r/min (rpm)
High idle - 521D Z-Bar and XT ........................................................................................ 2220 to 2280 r/min (rpm)
4
10
8 7 6
BS01B023
PARKING BRAKE
Checking the Parking Brake 5. Release the lock nut (2) and turn the adjusting
screw (3) clockwise until the two brake pads (4)
1. Park the machine on a level surface. make contact with the brake disc (5).
2. The transmission must be in manual shift mode 6. Turn the adjusting screw (3) counter clockwise
and the gear select must be in 3rd gear. and set the clearance, this should be 1/2 of one
NOTE: The Transmission Control Module will turn, refer to the table below.
disconnect the transmission if any other gear is used. Adjusting
Type Clearance (mm) Revolutions
Screw
3. Press the program switch. Min. 0.5 1/4
Small M16 (size 8) Rated Clearance 1.0 1/2
4. Press the up count switch until the display reads
Max 1.5 3/4
011. Min. 1.0 2/5
Large M20 (size 10) Rated Clearance 2.0 4/5
5. Press the program switch back to the center
Max 3.0 1 1/5
position.
6. Press the up count switch once. 7. Hold the adjusting screw (3) in position with a
allen head wrench and lock with the lock nut (2).
7. Make sure the transmission selector is in 3rd
neutral and the parking brake switch is on and in 8. Install the end cap (1).
manual mode.
9. Perform the Checking the Parking Brake
8. Shift the transmission selector into 3rd gear procedure again.
FORWARD and slowly increase engine rpm.
10. If the parking brake is still out of adjustment, see
9. The parking brake should hold the machine at section 7008 and replace the brake shoes on the
full throttle. parking brake.
10. If the machine begins to move, decrease the
engine speed and stop the engine. See Adjusting 1
the Parking Brake in this section.
11. Press the reset switch to exit the test mode.
B. With the service brakes applied, put the 1. END CAP 4. BRAKE PADS
machine into gear. 2. LOCK NUT 5. BRAKE DISC
3. ADJUSTING SCREW 6. PARKING BRAKE
C. The parking brake light on the cluster will turn
PARKING BRAKE
off at this time.
D. Put the transmission back into neutral before
proceeding.
4. Remove the end cap (1), refer to the illustration
on this page.
Bur 6-40830 Issued 3-01 Printed in U.S.A.
Copyright
9001-7
BRAKE PEDAL
2
11
3
4
10 1
11
2
11
3
5
7
6
8 4
BS00N109
9002
Section
9002
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright 2001 Case Corporation
3350 South Service Road Printed in U.S.A.
Burlington, ON L7N 3M6 CANADA Bur 6-42650 August, 2001
Copyright
9002-2
TABLE OF CONTENTS
SAFETY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Problem: No Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SYSTEM CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Mechanical Compressor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Blower and Compressor Clutch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cab Temperature Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Visual and Leak Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Evaporator/Heater Core Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Evaporator/Heater Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
PRESSURE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Manifold Gauge Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pressure Test Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
PRESSURE-TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
QUICK REFERENCE TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
A/C RECOVERY AND CHARGING STATION CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
PROBLEM: NO COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Indication of No Refrigerant or Low Refrigerant Charge: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Indication of Large Quantity of Air in System: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Condenser Malfunctioning - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
HFC-134a Stable Saturation Pressure/ Temperature Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Expansion Valve Malfunctioning - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Refrigerant Contamination: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
PROBLEM: NOT ENOUGH COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Air in the System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Not Enough Refrigerant - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
High Side Restriction - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Expansion Valve Not Operating - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Compressor Turning But Not Pumping Properly - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Expansion Valve Stuck Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Condenser Not Operating - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Air in the System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
PROBLEM: INTERMITTENT COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Moisture in the System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
PROBLEM: NOISE IN SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Too Much Refrigerant in System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
TUBE CONNECTIONS TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SAFETY PROCEDURES
THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT
FOLLOWS AND BE ALERT TO THE POSSIBILITY OF
PERSONAL INJURY OR DEATH. M171B
ATTENTION: Only authorized technicians certified 3. Keep refrigerant containers in the correct upright
by an approved training and certification organization position. Always keep refrigerant containers
may service or repair motor vehicle or mobile air away from heat and sunlight. The pressure in a
conditioning systems. It is mandatory that all container will increase with heat.
refrigerant must be RECOVERED and RECYCLED
4. Always reclaim refrigerant from the system, if
when removed from a system during servicing.
you are going to weld or steam clean near the air
Refrigerant HFC-134a is the most stable, and easiest conditioner system.
to work with of the refrigerants now used in air
5. Always check the temperature and pressure of
conditioner systems. Refrigerant HFC-134a does not
the air conditioner system before reclaiming
contain any chlorofluorocarbons (CFCs) which are
refrigerant and when you test the system.
harmful to the earths ozone layer.
6. Dangerous gas can form when refrigerant comes
Safety procedures must be followed when working
in contact with an open flame. Never permit
with Refrigerant HFC-134a to prevent possible
fumes to be inhaled.
personal injury.
7. Never leak test with compressed air or flame
1. Always wear safety goggles when doing any
testers. Tests have indicated that compressed
service work near an air conditioner system.
mixt ur e s o f HFC - 13 4 a a n d a ir c an fo rm a
Liquid refrigerant getting into the eyes can cause
combustible gas.
se rio u s in jur y. D o th e fo llow ing if yo u g et
refrigerant near or in your eyes: 8. Always reclaim refrigerant from the system
before removing any air conditioning component.
A. Flush your eyes with water for 15 minutes.
B. See a physician immediately.
2. A drop of liquid refrigerant on your skin may
cause frostbite. Open the fittings carefully and
slowly when it is necessary to service the air
conditioner system. Your skin must be treated for
frostbite or a physician must be seen if you get
refrigerant on your skin.
299L7C A22094
BELT TENSION TOOL CAS-10808 REFRIGERANT RECOVERY, RECYCLING AND CHARGING
STATION, OEM-1415
A22090
109L7
ELECTRONIC LEAK DETECTOR OEM-1437
SAFETY GOGGLES CAS-10073-3
OPERATION
The refrigerant circuit of the air conditioning system The refrigerant, still in a high pressure liquid form,
con ta in s five major co mp on ents: comp ressor, then flows from the receiver-drier to the expansion
condenser, receiver-drier, expansion valve and valve. The expansion valve then causes a restriction
evaporator. These components are connected by in flow of refrigerant to the evaporator core. The
tubes and hoses and operate as a closed system. e va p o r a t o r me t e r s r e fr ig e ra n t f lo w b a s e d o n
The air conditioner system is charged with HFC-134a evaporator heat load.
refrigerant.
As the refrigerant flows through the evaporator core,
The compressor receives the refrigerant as a low the refrigerant is heated by the air around and
pressure gas. The compressor then compresses the flowing through the evaporator fins. The combination
refrigerant and sends it in the form of a high pressure of increased heat and decreased pressure causes
gas to the condenser. The air flow through the the air flow through the evaporator fins to become
condenser then removes t he heat from the very cool and the liquid refrigerant to become a low
refrigerant. As the heat is removed the refrigerant pressure gas. The cooled air then passes from the
changes to a high pressure liquid. evaporator to the cab for the operators comfort.
The high pressure refrigerant liquid then flows from The electrical circuit of the air conditioning system
t h e c o n d e n s e r t o t h e r e c e i v e r - d r i e r. T h e consists of a fan speed control, temperature control,
receiver-drier is a container filled with moisture one (1) relay, a blower motor, blower resistor, A.C.
removing material, which removes any moisture that compressor clutch, A.C. low pressure switch, A.C.
may have entered the air conditioner system in order high pressure switch, and A.C. warning light.
to prevent corrosion of the internal components of
the air conditioner system.
3
5
4
208L95
TROUBLESHOOTING
Perform a visual inspection of the machine. Check 5. - Are there heavy accumulations of oil, or oily
the following and correct as necessary: dust around the fittings, indicating refrigerant
leakage?
1. - Obtain service history if possible.
6. - Are air ducts undamaged, sealed properly and
2. - Is compressor drive belt in place and tensioned?
in position?
3. - Are grille screens, fan blades, condenser, air filter, and
7. - Condensate drain hoses and check valves
evaporator unobstructed?
present and unobstructed?
4. - Are there any sharp bends or kinks in the
hoses?
Problem: No Cooling
Mechanical - See Mechanical Compressor
No Check Page 8
Compressor Runs
Electrical - See Blower and Compressor
Clutch Check Page 9
Yes
Problem: Problem:
Not Enough Cooling Erratic Cooling
MECHANICAL
ELECTRICAL
See Blower and Compressor Clutch Check on Page 9.
MECHANICAL
SYSTEM CHECKS
Evaporator/Heater Core
1. See Section 9004 for access to the
evaporator/heater core.
2. Inspect the fins on the evaporator/heater
core. All the fin s th at have b end s or
damage must be made straight.
3. Inspect the evaporator/heater core for
r e s t r i c t i o n s . I f t h e c o r e i s d r y, u s e
compressed air or a brush and vacuum
cleaner. If the core is wet or filled with
Evaporator/Heater Core mud, flush the core with water using a
hose without pressure. Make sure the
wate r dra in s freely from th e
evaporator/heater core. DO NOT USE
STEAM.
WARNING: Do not steam clean any air
conditioning systems parts while the system is
charged. The heat will cause the refrigerant to
rise to a pressure that could cause the system
to explode.
PRESSURE TESTING
Manifold Gauge Set During normal operation the low pressure gauge
must always indicate from 10 to 35 psi (0.7 to 2.4
NOTE: The gauge set is not accurate enough to bar) after the system has run 10 to 15 minutes.
optimize an existing charge of HFC-134a. The best
use of the gauge set is to determine whether HIGH PRESSURE GAUGE - The high pressure
undercharge or overcharge exists, and then gauge is used to indicate pressures in the high side
evacuate, reclaim and recharge system with the of the system. The gauge must indicate from 0 to 400
recommended quantity (charge) of HFC-134a. psi (0 to 27.6 bar) minimum.
The manifold gauge set is the most important tool During normal operation, the high pressure gauge
used to service the air conditioning system. The will normally indicate from 120 to 310 psi (8.3 to 21.4
manifold gauge set is used to measure the high and bar). See pressure-temperature chart on page 14.
low pressures of the system, as a tool to troubleshoot
for correct refrigeran t charge quantity, system Pressure Test Connection
diagnosis, and operating efficiency. The manifold
C o n n e c t th e ma n if o l d g a u g e s e t in t o t h e a ir
gauge set can read both the high (discharge) and low
conditioning system as shown. Make sure that both
(suction) sides at the same time, since pressure must
valves in the manifold gauge set are closed.
be compared in order to make a diagnosis of system
operation.
LOW PRESSURE GAUGE - The low pressure gauge
is a compound gauge. It is best used to judge
e va c u a tio n e ff e ct iv e ne s s . A va c u u m r e a d in g
indicates a system malfunction. For this reason, it is
nece ssary to use a compo und gau ge tha t w ill
indicate both pressure and vacuum.
PRESSURE-TEMPERATURE CHART
The pressure-temperature chart is based on the 2. All panels and access doors installed and closed.
following conditions:
3. Cab filters clean and installed.
NOTE: High humidity will cause higher air louver
4. Heater valve at engine closed.
temperatures and dramatic increase in suction
pressure. The table shown represents readings 5. Measurements taken 15 minutes after startup.
taken in low relative humidity. Adjust the chart
according to local conditions.
1. Engine at 1500 RPM, no load, fan speed &
temperature control at max setting, A/C switch
ON, all louvers and doors open
STEP 3
BD01D251
BD01D273
PROBLEM: NO COOLING
476L7
SEE PRESSURE - TEMPERATURE CHART ON PAGE 14
HIGH HIGH
476L7
SEE PRESSURE - TEMPERATURE CHART ON PAGE 14
Refrigerant Contamination:
1. See table below and check stable saturation pressures at
given temperature to determine if contamination exists.
A. Measure pressure from gauge on reclamation unit.
B. Measure temperature from refrigerant in reclamation
tank. If refrigerant has been in reclamation unit for some
time, use ambient temperature. The numbers in the
Refrigerant Contamination
table represent the boiling point for HFC-134a.
C. Pressure readings below range given in chart indicate
contaminated refrigerant.
IMPORTANT: Do not use contaminated refrigerant or mix
with uncontaminated refrigerant. Dispose of in accordance
with all applicable laws and local procedure.
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)
NORMAL TO
SLIGHTLY HIGH NORMAL
476L7
SEE PRESSURE - TEMPERATURE CHART ON PAGE 14
LOW LO W
476L7
SEE PRESSURE - TEMPERATURE CHART ON PAGE 14
HIGH LOW
476L7
SEE THE PRESSURE - TEMPERATURE CHART ON PAGE 14
HIGH HIGH
476L7
SEE PRESSURE - TEMPERATURE CHART ON PAGE 14
NORMAL NORMAL
476L7
SEE PRESSURE - TEMPERATURE CHART ON PAGE 14
NORMAL
HIGH
TO HIGH
476L7
SEE PRESSURE - TEMPERATURE CHART ON PAGE 14
NOTE: When tightening air conditioning hose or pipe fittings, a second wrench serving as support must be used.
IMPORTANT: Special care is required when tightening the fittings on the compressor, condenser and evaporator
since these connections are easily distorted.
Section
9003
9003
AIR CONDITIONER SYSTEM SERVICE
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright 2001 Case Corporation
3350 South Service Road Printed in U.S.A.
Burlington, ON L7N 3M6 CANADA Bur 6-42660 August, 2001
Copyright
9003-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SAFETY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
PRESSURE - TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SPECIFICATIONS
Air conditioning system refrigerant capacity ........................................................................................ 1.6 kg (3.5 lbs)
SPECIAL TOOLS
A22094 109L7
REFRIGERANT RECOVERY, RECYCLING AND RECHARGING SAFETY GOGGLES CAS-10073-3
STATION OEM-1415
SAFETY PROCEDURES
THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT
FOLLOWS AND BE ALERT TO THE POSSIBILITY OF
PERSONAL INJURY OR DEATH. M171B
ATTENTION: Only authorized technicians certified 3. Keep refrigerant containers in the correct upright
by an approved training and certification organization position. Always keep refrigerant containers
may service or repair motor vehicle or mobile air away from heat and sunlight. The pressure in a
conditioning systems. It is mandatory that all container will increase with heat.
refrigerant must be RECOVERED and RECYCLED
4. Always reclaim refrigerant from the system, if
when removed from a system during servicing.
you are going to weld or steam clean near the air
Refrigerant HFC-134a is the most stable and easiest conditioner system.
to work with of the refrigerants now used in air
5. Always check the temperature and pressure of
conditioning systems. Refrigerant HFC-134a does
the air conditioner system before reclaiming
not contain chlorofluorocarbons (CFCs) which are
refrigerant and when you test the system.
harmful to the Earths ozone layer.
6. Dangerous gas can form when refrigerant comes
Safety procedures must be followed when working
in contact with an open flame. Never permit
with refrigerant HFC-134a to prevent possible
fumes to be inhaled.
personal injury.
7. Never leak test with compressed air or flame
1. Always wear safety goggles when doing any
testers. Tests have indicated that compressed
service work near an air conditioner system.
mixt ur e s o f HFC - 13 4 a a n d a ir c an fo rm a
Liquid refrigerant getting into the eyes can cause
combustible gas.
se rio u s in jur y. D o th e fo llo w ing if yo u ge t
refrigerant near or in your eyes: 8. Always reclaim refrigerant from the system
before removing any air conditioning component.
A. Flush your eyes with water for 15 minutes.
B. See a physician immediately.
2. A drop of liquid refrigerant on your skin may
cause frostbite. Open the fittings carefully and
slowly when it is necessary to service the air
conditioner system. Your skin must be treated for
frostbite or a physician must be seen if you get
refrigerant on your skin.
STEP 1
A22114
STEP 4
BD01D251
STEP 2
A22107
BD01D273
A22112 A22110
Connect the main power plug to a 115 volt AC outlet. Slowly open the oil drain valve and drain the oil into
Move the main power switch to the ON position and the reservoir. When the oil stops draining, close the
depress the recovery start switch. oil drain valve completely.
The compressor will shut OFF automatically when
recovery is complete. Wait for 5 minutes and observe STEP 8
the manifold pressure gauges for a pressure rise. If
pressure rises above 0 psi (0 bar), depress the
hold/cont switch. Then wait for the compressor to
automatically shut OFF.
STEP 6
A22111
STEP 9
A22108
BD01D273
STEP 10
A22113
STEP 12
BD01D273
A22113 A22123
Program 3.5 lbs and press the enter key. The display Press the Vacuum key. Automatic will appear on
will flash once indicating the programmed data has the display. Vacuum will appear on the display and
been accepted. after a slight delay, the vacuum pump will start. The
display will show the amount of time programmed
STEP 14 and begin a countdown to zero.
W h e n th e p ro g r a mme d tim e h a s e la p se d , a n
automatic hold occurs. Check the low pressure
gauge to see that the A/C system maintains a 28 to
29-1/2 inches of mercury (Hg). The low pressure
gauge must not increase faster than one inch of
mercury (Hg) in 10 minutes. A previously charged,
le a k - f r e e s y s te m w il l l e a c h r e fr ig e r a n t f r o m
compressor oil and raise system pressure under
vacuum. If the system will not hold vacuum, a leak
exists that must be corrected before recharging can
begin. See Section 9002 in the manual for a leak
test.
A22114 STEP 17
Fully open the low and high pressure valves.
STEP 15
A22113
A22114 A22117
Completely close the high and low pressure manifold Observe the pressure gauge readings to determine
valves. that the correct amount of refrigerant has entered the
system. See chart on Page 9002-9 for temperature
ATTENTION: Check the OEM equipment manual
and pressure variations.
before performing Step 19 to avoid damaging the
recovery unit. The pressure reading should be
obtainable with valves closed. Damage may occur if STEP 21
the machine is started with the valves accidently
open or if either or both valves are opened while the
A/C system is operating.
STEP 19
Start the engine and run at 1500 RPM. Operate the
air conditioner system at maximum cooling setting
and blower speed with the doors and windows open.
NOTE: The compressor will not operate if the
system pressure is too low or too high. The pressure
indicator lamp will illuminate when the relay is
actuated by a low or high pressure and the
compressor clutch will disengage. To restart the BD01D273
compressor, the air conditioner control or blower Stop the engine, close any open valves and carefully
switch must be turned to the OFF position and then remove the manifold gauge hoses.
to the ON position.
STEP 22
BD01D251
Section
9004
9004
REMOVAL AND INSTALLATION OF AIR CONDITIONING
COMPONENTS FOR SYSTEMS WITH HFC-134A
REFRIGERANT
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright 2003 Case Corporation
3350 South Service Road Printed in U.S.A.
Burlington, ON L7N 3M6 CANADA Bur 6-42671 August, 2001 (Revised February, 2003)
Copyright
9004-2
TABLE OF CONTENTS
SAFETY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
COMPRESSOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
P.I.N. JEE0135500 and Below . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
P.I.N. JEE0135501 and Above . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
COMPRESSOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
P.I.N. JEE0135500 and Below . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
P.I.N. JEE0135501 and Above . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
EXPANSION VALVE AND EVAPORATOR/HEATER CORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
SAFETY PROCEDURES
THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT
FOLLOWS AND BE ALERT TO THE POSSIBILITY OF
PERSONAL INJURY OR DEATH. M171B
ATTENTION: Only authorized technicians certified 3. Keep refrigerant containers in the correct upright
by an approved training and certification organization position. Always keep refrigerant containers
may service or repair motor vehicle or mobile air away from heat and sunlight. The pressure in a
conditioning systems. It is mandatory that all container will increase with heat.
refrigerant must be RECOVERED and RECYCLED
4. Always reclaim refrigerant from the system if you
when removed from a system during servicing.
are going to weld or steam clean near the air
Refrigerant HFC-134a is the most stable, and easiest conditioner system.
to work with of the refrigerants now used in air
5. Always check the temperature and pressure of
conditioner systems. Refrigerant HFC-134a does not
the air conditioner system before reclaiming
contain any chlorofluorocarbons (CFCs) which are
refrigerant and when you test the system.
harmful to the earths ozone layer.
6. Dangerous gas can form when refrigerant comes
Safety procedures must be followed when working
in contact with an open flame. Never permit
with Refrigerant HFC-134a to prevent possible
fumes to be inhaled.
personal injury.
7. Never leak test with compressed air or flame
1. Always wear safety goggles when doing any
testers. Tests have indicated that compressed
service work near an air conditioner system.
mixt ur e s o f HFC - 13 4 a a n d a ir c an fo rm a
Liquid refrigerant getting into the eyes can cause
combustible gas.
se rio u s in jur y. D o th e fo llow ing if yo u g et
refrigerant near or in your eyes: 8. Always reclaim refrigerant from the system
before removing any air conditioning component.
A. Flush your eyes with water for 15 minutes.
B. See a physician immediately.
2. A drop of liquid refrigerant on your skin may
cause frostbite. Open the fittings carefully and
slowly when it is necessary to service the air
conditioner system. Your skin must be treated for
frostbite or a physician must be seen if you get
refrigerant on your skin.
SPECIAL TOOLS
A22094 109L7
REFRIGERANT RECOVERY, RECYCLING AND CHARGING SAFETY GOGGLES CAS-10073-3
STATION OEM-1415
COMPRESSOR REMOVAL
STEP 1
BD01D189
STEP 2
Discharge the air conditioning system according to
the instructions in Section 9003.
STEP 3
BD01D184
STEP 6
BD01D165
BD01D191
BD01D193 BD01D165
Loosen and remove the four compressor mounting Remove the four bolts and washers holding the drive
bolts. belt guard. Remove the guard.
STEP 8 STEP 12
Remove the compressor from the machine. Identify, tag, and disconnect the low pressure hose
from the compressor suction port and the high
P.I.N. JEE0135501 and Above pressure hose from the discharge port. Immediately
install plugs and caps in the hoses and on the ports.
STEP 9
STEP 13
Identify, tag, and disconnect the engine harness
connector from the compressor clutch connector.
STEP 14
2 4
1
BD01D138
STEP 10
Discharge the air conditioning system according to 3
the instructions in Section 9003.
BS02J067
1. BOLT 3. BOLT
2. DRIVE BELT 4. AC COMPRESSOR
Loosen bolts (1 and 3). Move compressor (4) to put
slack in drive belt (102) then remove drive belt.
STEP 15
Remove bolt (1), two washers, spacer, and nut.
Support compressor (4) and remove bolt (3), three
washers, and nut securing compressor. Remove
compressor from engine.
Bur 6-42671 Revised 2-03 Printed in U.S.A.
Copyright
9004-7
COMPRESSOR INSTALLATION
STEP 16
Position and support the compressor on the engine.
STEP 17
BD01D184
STEP 18 STEP 20
BD01D191
BD01D184
Connect the compressor clutch wire to the engine Carefully remove the protective cap, install a new
harness assembly. O-ring, and connect the low pressure line to the
suction port on the compressor.
2 4
1
BD01D189
STEP 22 3
BS02J067
1. BOLT 3. BOLT
2. DRIVE BELT 4. AC COMPRESSOR
Position and support compressor (4) on mounting
bracket. Secure using bolt (3), three washers, and
nut. Install bolt (1), two washers, spacer, and nut.
STEP 26
Install drive belt (2). Move compressor (4) to take up
slack in drive belt then tighten bolts (1 and 3).
BD01D165 STEP 27
Install d rive b elt g ua rd a nd secu re u sin g fou r Co nne ct the e ng in e ha rne ss con ne ctor to th e
washers and bolts. compressor clutch connector following tags installed
during removal. Remove and discard tags.
STEP 23
Charge the air conditioning system according to the STEP 28
instructions in Section 9003. IMPORTANT: In this step, use caution when
removing cap as new compressors have internal
STEP 24 pressure when shipped.
Slowly remove protective cap from compressor
discharge port. Following tags installed during
removal, install a new O-ring and connect high
pressure hose to compressor discharge port. Repeat
this step to connect low pressure hose to compressor
suction port. Remove and discard tags.
BD01D136
BD01D165 BD01D136
Install drive b elt g ua rd a nd secu re u sin g fou r Place the master d isco nnect switch in the ON
washers and bolts. position.
STEP 30
Charge the air conditioning system according to the
instructions in Section 9003.
Removal STEP 36
STEP 32
Park the machine on a level surface and lower the
bucket to the floor.
STEP 33
Discharge the air conditioning system according to
the instructions in Section 9003.
STEP 34
BD01D396
STEP 37
BD01D138
STEP 35
BD01D397
STEP 38
BD01D395
BD01D398
BD01D399 BD01D402
Fold the rubber mat over to gain access to the cover Remove the screws holding the valve cover plate
plate and remove the screws holding the cover plate. and remove the plate.
STEP 40 STEP 43
BD01D400 BD01D403
Remove the six screws and remove the back panel. Remove and discard the insulation tape from the
fittings and the expansion valve.
STEP 41
STEP 44
3
1
BD01D401 4
Remove the back screw holding the cover plate and DS01D183
remove the cover plate.
5. LIQUID TUBE 7. FITTINGS
6. SUCTION TUBE 8. EXPANSION VALVE
Disconnect the liquid tube (1), suction tube (2) and
the fittings (3) from the expansion valve (3). Cap and
plug all fittings and tubes.
STEP 47
BD01D265
C o n n e c t t h e h o s e s a n d h o s e c la m p s t o t h e
BD01D265 evaporator/heater core.
Remove the hose clamps and the hoses from the
evaporator/heater core. STEP 51
Lubricate new O-rings for the expansion valve with
STEP 48 clean refrigerant oil.
Re mo v e th e ev a po r at or /h ea te r co r e fro m th e
machine. STEP 52
Install th e new O-rin gs in the ope nin gs of th e
expansion valve.
STEP 53
3
1
4
BS01D183
BD01D403 BD01D398
Install new insulation tape around the fittings and the Fold the rubber mat back into place and install the
expansion valve. metal plate and screws.
STEP 55 STEP 59
BD01D402 BD01D397
STEP 56 STEP 60
Install the cover for the evaporator/heater core.
STEP 57
BD01D396
BD01D395 BD01D136
Connect the wiring connector to the operators seat Place the master d isco nnect switch in the O N
(if equipped with air seat option). position.
STEP 62
Charge the air conditioning system according to the
instructions in Section 9003.
CONTROL VALVE
Removal Installation
STEP 64 STEP 68
Park the machine on a level surface and lower the Make sure the control knob is in the OFF position.
bucket to the ground.
STEP 69
STEP 65
1
2
4 3
BD01D266
STEP 71
4 3
BD01D266
CONDENSER
Removal STEP 77
STEP 72
Park the machine on a level surface and lower the
bucket to the ground.
STEP 73
BS01D181
Fa s t e n i d e n t if ic a ti o n t a g s o n th e h o s e s a n d
disconnect the hoses from the condenser.
STEP 78
Install plugs in the hoses and caps on the fittings.
BD01D136
STEP 74
Discharge the air conditioning system according to
the instructions in Section 9003.
STEP 75
BD01D142
1. COVER 2. CONDENSER
BS01D182
Open the cover (1) to gain access to the condenser
(2). L oo s e n a n d re mo v e th e b o lts th a t fa st en th e
condenser to the brackets.
STEP 76
STEP 80
The condenser is connected to brackets which pivot
on the cooling frame. Pivot the condenser to gain Remove the condenser.
access to the mounting bolts and the hoses.
CONDENSER
Installation STEP 84
STEP 81
Inspect the condition of the seals on the condenser.
If the seals are bad, replace the seals.
STEP 82
Put the condenser in position on the brackets.
STEP 83
BS01D181
STEP 85
Pivot the condenser down and close the cover.
STEP 86
Charge the air conditioning system according to the
instructions in Section 9003.
STEP 87
BS01D182
BD01D136
Section
9006
LOADER
9006
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright 2001 Case Corporation
3350 South Service Road Printed in U.S.A.
Burlington, ON L7N 3M6 CANADA Bur 6-42690 August, 2001
Copyright
9006-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
BUCKET TEETH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Replacement of the Tooth Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Replacement of the Bucket Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Replacement of the Bucket Corner Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
RETURN TO DIG ADJUSTMENT (Z-BAR MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT
(Z-BAR AND XT MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
RETURN TO DIG ADJUSTMENT (XT MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REMOVING THE LOADER FRAME (Z-BAR MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLING THE LOADER FRAME (Z-BAR MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REMOVING THE LOADER FRAME (XT MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLING THE LOADER FRAME ( XT MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SPECIFICATIONS
Special Torques
Bolts for the Bucket Teeth..............................................................................515 to 618 Nm (380 to 456 pound-feet)
BUCKET TEETH
6
1
3
4
5
BS01C083
IMPORTANT: Before adjusting the return-to-dig, 7. Loosen the bolts holding the target bar (3) to the
make sure that the target bar on the bucket linkage is target mounting bracket (1). Slide the target bar
not damaged. Slowly roll back and dump the bucket (3) towards the proximity switch (5) until the face
and make sure that the target bar stays the same of the proximity switch (5) is completely covered.
distance from the switch. The switch mounting 8. Align the target bar (3) parallel to the tilt cylinder
bracket protects the switch. Make sure the target bar (2) and tighten the bolts.
cannot touch the switch when the bucket is dumped.
9. Turn the ignition switch to the ON position. Do
1. Park the machine on a level surface. Raise the NOT start the engine.
lift arms until they are approximately horizontal
and dump the bucket. Lower the bucket until the 10. Place the bucket control lever in the ROLLBACK
bucket edge is on the ground. position.
2. Apply the parking brake and stop the engine. 11. Loosen the bolts holding the target bar (3) to the
target mounting bracket (1).
3. Loosen the bolts holding the target mounting
bracket (1) to the tilt cylinder eye. Align the target 12. Slide the target bar (3) slowly away from the
mounting bracket (1) parallel to the tilt cylinder proximity switch (5), until the control lever returns
(2). Tighten the bolts, refer to the illustration on to the center position. Tighten the bolts holding
this page. the target bar (3).
4. Loosen the bolts holding the proximity switch 13. Check to make sure that the 3.5 to 5.0 mm (1/8
mounting bracket (4) to the tilt cylinder (2). to 3/16 inch) gap is still maintained.
Position the proximity switch (5) parallel to the 14. Start the engine.
target bar (3) and tighten the bolts. 15. Place the detent switch in the ON position and
5. Adjust the proximity switch (5) out towards the place the return to travel/float detent switch to
target bar (3), until an air gap of 3.5 to 5.0 mm the TRAVEL position.
(1/8 to 3/16 inch) is obtained. Torque the jam nut 16. Raise the lift arms approximately horizontal, and
to 6 to 7.5 Nm (4.5 to 5.5 pound-feet). put the bucket in the fully dumped position.
NOTE: The proximity switch (5) must not protrude 17. Place the loader control lever in the ROLLBACK
past the proximity switch guard (6). position, and verify that the electromagnet holds
6. Start the engine, position the bucket to the it in that position until the end of the target bar (3)
correct digging angle and stop the engine. passes in front of the proximity switch (5).
18. Lower the lift arms and verify that the bucket is at
the correct digging angle.
Bur 6-42690 Issued 8-01 Printed in U.S.A.
Copyright
9006-5
5
6
3
2
1
BS01C081
1. Park the machine on a level surface. 5. Position the return to travel target (5) opposite
the proximity switch (3) and tighten it to the target
2. Start the engine and apply the parking brake.
mounting plate (1).
3. Lower the lift arms and place the bucket flat on
6. Adjust the proximity switch (3) out towards the
the ground.
return to travel target (5) until an air gap of 3.5 to
4. Stop the engine. 5.0 mm (1/8 to 3/16 inch) is obtained.
NOTE: To avoid damge to the proximity switch (3), it 7. Lock the proximity switch (3) in this position with
must be adjusted back to clear everything on the lift the jam nut. Torque the jam nut to 6 to 7.5 Nm
arm as it passes. Refer to the illustration on this (4.5 to 5.5 pound-feet).
page.
2
A
B
1
BS01C082
APPROXIMATE APPROXIMATE
RESULTING RETURN TO RESULTING HEIGHT
MACHINE A B
TRAVEL HINGE PIN CONTROL HINGE PIN
HEIGHT HEIGHT
521D Z-BAR 57 mm (2.3 inches) 358 mm (14.1 inches) 54 mm (2.1 inches) 3302 mm (130 inches)
521D XT 47 mm (1.9 inches) 438 mm (17.3 inches) 48 mm (1.9 inches) 3302 mm (130 inches)
HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT ILLUSTRATION Z-BAR AND XT MODELS
8. Refer to the table and the illustration on this 13. Place the detent switch in the ON position, and
page. Position the height control target (1) on the set the return to travel/float detent switch to the
target mounting plate (3) using the table above. return to travel position.
NOTE: The higher the height control target (1) is 14. Place the loader control lever in the raise
positioned in its slot in the target mounting plate (3), position and verify that the electromagnet holds it
the lower the lift arms will stop as they are raised. in that position until the height control target (2)
passes in front of the proximity switch (3). Refer
9. Tighten the height control target (1).
to the illustration on page 5.
10. Position the return to travel target (2) using the
15. With the lift arms still raised, place the loader
table above.
control lever in the lower position and verify that
NOTE: The higher the return to travel target (2) is the electromagnet holds it in that position until
positioned in its slot in the target mounting plate (3), the return to travel target (5) passes in front of
the lower the lift arms will stop as they are lowered. the proximity switch (3). Refer to the illustration
on page 5.
11. Check to make sure the proximity switch (3) and
all of the mounting bolts are tight. Refer to the 16. Repeat steps 8 through 15 until the desired
illustration on page 5. heights are reached.
12. Start the engine. 17. Lower the bucket to the ground and stop the
engine.
2
3
5
1
4
6
BS01C084
1. BUCKET CYLINDER (LEFT HAND SIDE) 3. TARGET MOUNTING BRACKET 5. PROXIMITY SWITCH
2. PROXIMITY SWITCH MOUNTING BRACKET 4. PROXIMITY SWITCH GUARD 6. TARGET BAR
RETURN TO DIG ADJUSTMENT ILLUSTRATION XT MODELS
IMPORTANT: Before adjusting the return-to-dig, 8. Loosen the bolts holding the target bar (6) to the
make sure that the target bar on the bucket linkage is target mounting bracket (3). Slide the target bar
not damaged. Slowly roll back and dump the bucket (6) away from the proximity switch (5) until the
and make sure that the target bar stays the same face of the proximity switch (5) is completely
distance from the switch. The switch mounting uncovered.
bracket protects the switch. Make sure the target bar 9. Align the target bar (6) parallel to the bucket
cannot touch the switch when the bucket is dumped. cylinder (1) and tighten the bolts.
1. Park the machine on a level surface. Raise the 10. Turn the ignition switch to the ON position. Do
lift arms until they are approximately horizontal NOT start the engine.
and dump the bucket. Lower the bucket until the
bucket edge is on the ground. 11. Place the bucket control lever in the ROLLBACK
position.
2. Apply the parking brake and stop the engine.
12. Loosen the bolts holding the target bar (6) to the
3. Loosen the bolts holding the target mounting target mounting bracket (3).
bracket (3) to the bucket cylinder clevis. Align the
target mounting bracket (3) parallel to the bucket 13. Slide the target bar (6) slowly towards the
cylinder (1) and tighten the bolts. Refer to the proximity switch (5), until the bucket control lever
illustration on this page. returns to the center position. Tighten the bolts
holding the targe bar (6).
4. Loosen the bolts holding the target bar (6) to the
target mounting bracket (3). Align the target bar 14. Check to make sure that the 3.5 to 5.0 mm (1/8
(6) parallel to the bucket cylinder (1) and tighten to 3/16 inch) gap is still maintained.
the bolts. 15. Start the engine.
5. Loosen the bolts holding the proximity switch 16. Place the detent switch in the ON position and
mounting bracket (2) to the bucket cylinder (1). set the return to travel/float detent switch to the
Position the proximity switch (5) face parallel to return to travel position.
the target bar (6) and tighten the bolts. 17. Raise the lift arms to approximately the
6. Adjust the proximity switch (5) out towards the horizontal position and put the bucket in the fully
target bar (6) until an air gap of 3.5 to 5.0 mm dumped position.
(1/8 to 3/16 inch) is obtained. Torque the jam nut 18. Place the loader control lever in the ROLLBACK
to 6 to 7.5 Nm (4.5 to 5.5 pound-feet). position and verify that the electromagnet holds it
NOTE: The proximity switch (5) must not protrude in that position until the end of the target bar (6)
past the proximity switch guard (4). passes in front of the proximity switch (5).
7. Start the engine, position the bucket to the 19. Lower the lift arms to the ground and verify that
correct digging angle and stop the engine. the bucket is at the correct digging angle.
10
22 18 8
16 15
17
18 7
9
20
19 2
6
11
5 21 1
5
5
4
14
23
12
3
13
BS01C087
14
15
12 14
13 4
11
13 6
12
11 5
10
2
9
8
BS01C085
BS01C089
BS01C086
B1445A88J
Section
9007
9007
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright 2001 Case Corporation
3350 South Service Road Printed in U.S.A.
Burlington, ON L7N 3M6 CANADA Bur 6-42700 August, 2001
Copyright
9007-2
TABLE OF CONTENTS
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......................... 2
POSSIBLE DAMAGE TO THE ROPS CAB OR ROPS CANOPY . . . . . . . . . . . . ......................... 3
MAINTENANCE AND INSPECTION OF THE ROPS CAB OR ROPS CANOPY ......................... 3
ROPS CAB AND ROPS CANOPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......................... 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......................... 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SPECIAL TORQUES
ROPS Cab and ROPS Canopy Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 773 to 854 Nm (570 to 630 lb-ft)
Operators Seat Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 to 87 Nm (54 to 64 lb-ft)
Top Step Mounting Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 to 61 Nm (40 to 45 lb-ft)
Removal STEP 5
NOTE: Procedures and photos in following steps
cover in detail removal and installation of ROPS cab.
Removal and installation of ROPS canopy is similar
to removal and installation of ROPS cab.
STEP 1
Park machine on a level surface and lower bucket to
floor. Stop engine. Actuate brake pedal several times
to discharge brake accumulators. Put key switch in
ON position and move loader control lever back and
forth at least 30 times to release any pressure from
hydraulic circuit. Put key switch in OFF position. BD01D139
STEP 6
BD00M030
STEP 4 STEP 7
Open hood.
BD00M031
BD01D259 BD01D263
Remove skirting under each side and front of cab. If machine is equipped with windshield washers,
identify, tag, and disconnect front (1) and rear (2)
STEP 9 windshield washer nozzle hoses from supply hoses.
STEP 12
BD01D261
STEP 13
4
3 3
5
6
6
BD01D262
9 11
8
10 15
14
BD01D267 BD01D390
STEP 15 14
BC01D272
BD01D271 STEP 18
Remove access panel.
STEP 16
BD01D275
22 25
23
17
16
18 24
26
BD01D277 BD01D285
Cut, remove, and discard tie strap (16). Disconnect If machine is equipped with two brake pedals,
throttle cable (17) from pedal assembly (18). Move remove retaining ring (22) securing pin (23) to brake
throttle cable away from cab. pedal (24). Remove pin. Remove two bolts (25),
pedal and shaft (26), pivot assembly, and block.
STEP 20 Remove pedal (24) cover pad.
STEP 23
19 27
BD01D279
control valve fittings to prevent entry of foreign matter Remove three screws, washers, and seal channel
into hydraulic system. cover (27).
STEP 21 STEP 24
21
20
BD01D282 BD01D288
Remove LH fender (20) and top step (21). Raise floor mat up and away from brake pedal to
gain access to mounting hardware.
28 29
28
BD01D287 BD01D291
STEP 26
30
29
28
BD01D282
31
29
BD01D293
33
32
BD01D297 BD01D283
Install two lifting eyes in threaded holes at top front of At LH and RH bottom rear of cab, loosen two bolts
cab. (32) and remove cover plate (33) to gain access to
cab rear mounting hardware.
STEP 30
STEP 32
BD01D389
BD01D289
STEP 33
BD01D298
BD01D300
Slowly raise cab from rear chassis. Check that all tie
straps and clamps have been removed and all
hoses, tubes, and wires are disconnected and free.
Check that brake valve with hoses attached is free
and clear of cab. Remove the ROPS cab or ROPS
canopy from the machine. Lower cab or canopy onto
wooden blocks to prevent damaging cab or canopy.
33 39
34
35
38
32
37
36
BS01D195
Installation STEP 36
STEP 34
Check rubber mounts (38) for deterioration, tears,
deforma tion , or oth er d ama ge; replace rub ber
mounts as necessary.
STEP 35
BD01D290
STEP 37
BD01D300
33
41
40
32
BD01D283
BD01D298
BD01D297 BD01D284
Remove two lifting eyes installed in Step 29 in If machine has a ROPS cab and is equipped with air
threaded holes at top front of cab. conditioning, remove plugs from tubes and caps from
hoses at left rear bottom of cab. Install new O-rings in
STEP 40 air conditioning evaporator tubes. Connect two hoses
to evaporator tubes. Refer to Section 9002 and
charge air conditioning system.
STEP 43
31
29
BD01D293
STEP 41 BD01D287
STEP 44
30
29
28
BD01D282
27
19
BD01D286 BD01D279
Install seal channel cover (27) and secure with three Remove plugs from hoses and caps from fittings.
washers and screws. Co n n ec t h o se s t o ste e rin g co nt ro l va lve ( 19 )
following tags installed during removal. Remove and
STEP 46 discard tags.
STEP 49
22 25
23
17
24 16
26
18
BD01D285
pivot assembly, and block; secure with two bolts (25). Connect throttle cable (17) to pedal assembly (18).
Install pin (23) through brake pedal (24) and pedal Install new tie strap (16) to secure front windshield
shaft crank. Install retaining ring (22) to secure shaft. washer hose to throttle cable.
STEP 47 STEP 50
21
20
BD01D282 BD01D275
Install LH fender (20) and top step (21). Tighten step Position hoses as shown and install new tie strap.
(21) mounting bolts to a torque of 54 to 61 Nm (40 to
45 lb-ft).
A D
D
A D
E
C B C
B
F E
F
A BS01D177A
A. ORANGE-BLACK D. GREEN-BLACK
B. YELLOW-BLACK E. PILOT PRESSURE HOSE
C. RED-BLACK F. PILOT TANK HOSE
C
A Remove plugs from hoses and caps from fittings.
B D Connect hoses to two-lever controller and install in
hose mounting grommet halves as shown above. Go
to Step 56.
E F
BS01D177B
A. ORANGE-BLACK D GREEN-BLACK
B. YELLOW-BLACK E PILOT PRESSURE HOSE
C. RED-BLACK F PILOT TANK HOSE
Remove plugs from hoses and caps from fittings.
Connect hoses to joystick controller and install in
hose mounting grommet halves as shown above. Go
to Step 56.
E F
H G
D
G B C
B A D
C
E F
A H D
A
C
B
A C
H
B D G
E F
BS01D178A
A. ORANGE-BLACK E. YELLOW-WHITE
E G H F B. YELLOW-BLACK F. RED-WHITE
BS01D178B C. RED-BLACK G. PILOT PRESSURE HOSE
D. GREEN-BLACK H. PILOT TANK HOSE
A. ORANGE-BLACK E. YELLOW-WHITE
B. YELLOW-BLACK F. RED-WHITE Remove plugs from hoses and caps from fittings.
C. RED-BLACK G. PILOT PRESSURE HOSE Connect hoses to three-lever controller and install in
D. GREEN-BLACK H. PILOT TANK HOSE hose mounting grommet halves as shown above. Go
Remove plugs from hoses and caps from fittings. to Step 56.
Connect hoses to joystick and one-lever controller
and install in hose mounting grommet halves as
shown above. Go to Step 56.
G H
E F
I
12 13
C
D BD01D269
A. ORANGE-BLACK F. RED-WHITE
B. YELLOW-BLACK G. ORANGE-WHITE
C. RED-BLACK H. GREEN-WHITE
D. GREEN-BLACK I. PILOT PRESSURE HOSE
E. YELLOW-WHITE J. PILOT TANK HOSE
BD01D271
Remove plugs from hoses and caps from fittings. Install access panel.
Connect hoses to joystick and two-lever controller
and install in hose mounting grommet halves as STEP 59
shown above. Go to Step 56.
STEP 56
9 11
8
10
15
14 BD01D267
4
5
BD01D264A BD01D262
If machine is equipped with a heater, install two Connect transmission wiring harness connector to
grommets (7) (if dislodged during removal) and bulkhead connector following tag installed during
heater hoses (4 and 5) up into cab. removal. Remove and discard tag.
STEP 61 STEP 64
4
3
3
5
6
6
7
BD01D265 BD01D261
Make sure grommets (7) are installed completely in At RH rear, bottom of cab, connect ground strap to
cab holes. Install clamps (6 an d 3) o n ho ses. rear chassis.
Connect hoses (4 and 5) and position clamps (6 and
3) as shown. STEP 65
STEP 62
1
BD01D259
STEP 70
BD00M031
STEP 71
Start engine and run engine at low idle. Run engine
at operating temperature for approximately five
minutes to completely mix Ethylene Glycol and
water. When coolant is at operating temperature,
stop engine. When engine has cooled, check coolant
level at reservoir.
WARNING: Hot coolant can spray out if radiator cap
is removed. To remove radiator cap: let system cool,
turn to first notch, then wait until all pressure is
BD00M031 released. Scalding can result from fast removal of
If machine is equipped with a heater and coolant was radiator cap.
drained, check that coolant drain cap is tight.
STEP 72
STEP 68 Lower and close hood.
If coolant was drained, fill engine coolant system with
a solution of 50% Ethylene Glycol and 50% water. STEP 73
Cooling system capacity is 34.1 liters (9 gallons). Put articulation lock in OPERATING position.
Install radiator cap. Fill coolant reservoir up to FULL
mark on reservoir.
Section
9010
9010
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright 2001 Case Corporation
3350 South Service Road Printed in U.S.A.
Burlington, ON L7N 3M6 CANADA Bur 6-42710 August, 2001
Copyright
9010-2
TABLE OF CONTENTS
PREPARATION FOR GLASS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GLASS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SILICONE SEALANT APPLICATION - FRONT WINDOWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GLASS INSTALLATION
NOTE: Once the adhesive is applied, the glass must 3. For front glass installations install a glass spacer
be installed within 5 minutes. If the glass is not 12 mm (1/2 inch) from each corner on bottom
installed within the 5 minute period, the adhesive edge of each glass section, refer to Figure 3.
must be removed and applied again.
4. Install the glass. The glass edges must not
1. Apply a 10 mm (3/8 inch) diameter bead of contact the metal frame at any point.
ad he sive (3 45 -1 35 ) to the p rim ed su rfac e
5. For front glass installations position the glass to
approximately 12 mm (1/2 inch) from edge.
maintain a uniform 3 mm (1/8 inch) gap between
2. The adhesive may be applied either to the front and front side glass sections.
primed glass or to the primed metal frame. DO
NOT apply the adhesive to both the glass and
the frame.
NOTE: When replacing two or more sections of the
front glass apply extra adhesive in corners, refer to
Figure 3.
6 MM 120
(1/2 INCH) R
120
4 MM
(3/16 INCH) R
496L93
FIGURE 2. SILICONE FORMING TOOL TEMPLATE
2
1
3
4
2
1
497L93
BLOCK MEMORY FUSE 1_H R-3.0 SHEET 4 - 59F (115) 30 30 19E Or-1.0 19E Or-1.0 E2 E1
6 RELAY BOX 226F SPL_D16 87 87 28P_A W-0.8 19F Or-1.0 F2 F1 13R Or-1.0
86
135
21C_B W-1.0 JUNCTION 1 1_K R-3.0 1_G R-3.0 87a 87A 0_DG Bk-0.8 SHEET 5 - 30F (83) 19G Or-2.0 G2 G1
BLOCK 85 85 0_DC Bk-0.8 SHEET 2 - 53F (35) 19H Or-1.0 H2 H1
85
132 0_GB Bk-2.0 238F 86 86 28C_A W-0.8 SHEET 5 - 35F (75) 19J_A Or-1.0 J2 J1
POS 1_NA R-62 224F 228F 1_J R-3.0 SHEET 5 SPL_D23 19K_A Or-1.0 K2 K1
52F
1_D R-2.0 18F 18F
NEG 0_NC Bk-62 1_N R-3.0 SHEET 4 - 33F (114) 10
23F_A W-2.0
1 1 23F W-2.0 30 30
137 237F
30 133F 133M 1_V R-5.0 SHEET 6 - 255F (92) 87 87 12P_A Or-1.0
192 FUEL AND STARTER ENGINE 87a 87A 0_DC Bk-0.8
87
RELAYS HARNESS HARNESS 85 85 0_DF Bk-0.8
0_P Bk-1.0 SHEET 3 - SPL_E9 86 86 12K_A Or-1.0
7 16 12K_B Or-0.8
0_E Bk-1.0 SHEET 3 - 104 (39) 172 SPL_G1 49F
REAR ENGINE 86 21C_A W-1.0 28P W-1.0 1 1
160 0_V Bk-1.0 SHEET 3 - 171 (40) 21C_C W-1.0 A A 21C_D W-1.0 11 11
BLOCK GROUND 85
173 0_GC Bk-2.0 0_GA Bk-2.0 B B 1_A R-1.0 21 21
STUD() SPL_G2 93M 93F
21M 21F 30 30 1_P R-0.8
0_G Bk-1.0 SHEET 5 - 2 (76) FUEL AND STARTER REAR A A 87 87 13V Or-1.0
13C Or-1.0 13M Or-1.0 9 REAR CAB
RELAYS HARNESS CHASSIS 28T_A W-1.0 B B 87a 87A 0_DG Bk-0.8
0_F Bk-1.0 SHEET 5 - 3 (78) A B 139F ENGINE HARNESS CHASSIS MAIN 0_DH Bk-0.8
A B
HARNESS 103 85 85
162 0_W Bk-1.0 SHEET 3 - 136 (41) 139M DISCONNECT HARNESS HARNESS HARNESS 86 86 13K_E Or-0.8
2.2 ohms at 25C (77F)
58F 13K_C Or-1.0
65F REAR CHASSIS HARNESS
13M_A Or-1.0
1
13C_E Or-1.0
REAR CHASSIS HARNESS 0_X Bk-1.0 SHEET 5 - 158 (56) 17
opens 133C (55.45.4F) 1 65M ENGINE HARNESS
163 closes 1.54.5C (34.78.1F)
A B C 134
A B C
30 30 1_T R-3.0
0_J Bk-1.0 SHEET 4 - 128F REAR HOOD 87 87 13R Or-1.0
B B 262F
A A 8 87a 87A 0_DF Bk-0.8 13K_C Or-1.0
164 0_D Bk-2.0 SHEET 4 - SPL_E4 A A 85 85 0_DE Bk-0.8
97 B B 86 86 13K_B Or-1.0 217F 217M
231F 230F 236F 235F
19R_D Or-0.8 C C 13K_A Or-1.0 13K_D Or-0.8 AA
3 28T W-1.0 48F SEE NOTE 4
0_U Bk-2.0 DIODE 13C_B Or-0.8
41.5 ohms 1.1 ohm 75 OHMS MODULE 15 30
165 0_Q Bk-1.0 SHEET 3 - 87 (53) 2 at 20C (68F) at 20C (68F) 87 13C_C Or-0.8 SHEET 5 - 140M DIODE
RESISTOR
AIR CONDITIONING 0_BJ Bk-1.0 SHEET 5 - 265F AIR CONDITIONING DIODE MODULE HOLD PULL-IN 1_M R-3.0
58 87A MODULE
215F 216F SHEET 4 - 211F FLASHER 85
DIODE HARNESS 268 SPL_D25 CIRCUIT BREAKER B 86 23C_A W-0.8 SHEET 3 - 13F CAB
19R_E Or-0.8 PEDESTAL
SPL_D17 57F 19F Or-1.0
0_BB Bk-2.0 19R_A Or-0.8 SHEET 5 - 1F CAB-FRONT
CHASSIS 1_S R-3.0
151 0_BC Bk-1.0
13C Or-1.0 1 1 13C_A Or-1.0 1 1 13C_D Or-0.8 13C_D Or-0.8
14 LG-1.0 5 5 14_A LG-1.0 2 2 14_B LG-0.8
ENGINE HARNESS 0_BG Bk-1.0 0_BG Bk-1.0 15 15 0_HC Bk-1.0 30 30 0_DAU Bk-0.8 SHEET 3 - 13F CAB PEDESTAL 1_L R-3.0 30 30
152 0_BF Bk-1.0 9 9 0_HA Bk-1.0 23 23 87 87
0_BH Bk-1.0 11 11 0_HB Bk-1.0 15 15 0_DL Bk-0.8 SHEET 3 - 13F CAB PEDESTAL 87a 87A 13P_A Or-1.0
213F IGNITION SWITCH 85 85
SHEET 3 - 138 (43) 0_BE Bk-1.0 SPL_B1
0_BA Bk-1.0 94M 94F 22M 22F 0_DAB Bk-0.8 SHEET 3 - 13F CAB PEDESTAL CIRCUIT 86 86
BREAKER A 21K_A W-0.8
150 SHEET 3 - 117 (44) 0_BD Bk-1.0 ENGINE TRANSMISSION TRANSMISSION CAB MAIN 47F
12.5 AMP 21C_F W-0.8 SHEET 5 - 140M DIODE
SECONDARY STEERING HARNESS HARNESS HARNESS HARNESS 214F 14 30 30 MODULE
MODULE HARNESS 0_CD Bk-1.0 SHEET 5 - SPL_C1 87 87 21C_E W-0.8
177 1A_D R-0.8 87a 87A 0_DH Bk-0.8
85 85 0_DJ Bk-0.8
13D Or-1.0 86 86 25T_E LU-0.8
SPL_D21
0_DZ Bk-2.0 SHEET 5 - 29M (85) 63M TIME DELAY MODULE 1A_E R-0.8
1 DELAY POWER-2-WAY 1
54F
CAB 0_DY Bk-1.0 SHEET 5 - 28M (82) 2 TIME DELAY POWER 2 0_DAS Bk-0.8 SHEET 4 - SPL_D14 12
REAR CHASSIS FRONT ENGINE GROUND SHEET 5 - 35F (75)
3 TIME DELAY MODULE GROUND 3
0_NB Bk-62 218F 0_DAR Bk-1.0 4 RESET SIGNAL 4 37R_C P-0.8 SHEET 3 - 13F CAB
GROUND WELD BLOCK GROUND SPL_D18
STUD () 234F JUNCTION 5 IGNITION SWITCH POWER 5 PEDESTAL
0_NA Bk-62 STUD () 6 NONE 6 SHEET 2 - 19F (26) 25T_D LU-0.8
BLOCK () 50G_G Bk-0.8 SHEET 2 - SPL_D7
13K_F Or-0.8
232F 233F 63M SPL_D22
0_DB Bk-0.8 SHEET 3 - 89M (54) 18
1 REAR
REAR CHASSIS 0_Y Bk-13.0 0_Y Bk-13.0 CHASSIS 219F
HARNESS 167 HARNESS
161 13
1A_C R-0.8
13K_G Or-0.8
REAR CHASSIS 0_DX Bk-0.8 SHEET 4 - 13F CAB PEDESTAL
GROUND WELD SHEET 3 - 75 (45) 1A_B R-0.8 5
SHEET 5 - SPL_A1 0_AJ Bk-2.0 0_DA Bk-0.8 SHEET 4 - 204F (102) 1 BAT
STUD () 0_CE Bk-1.0 SHEET 5 - 90M (66) FRONT 3 IGN
CHASSIS 220F 0_DAT Bk-0.8 SHEET 4 - SPL_D14 2 ST
176 HARNESS
SHEET 5 - SPL_A2 0_AK Bk-1.0 145 4 ACC
2 6
0_DQ Bk-0.8 SHEET 2 - 19F (26)
69
CAB 0_DP Bk-0.8 SHEET 2 - 19F (26)
UPPER PEDESTAL CAB GROUND REAR CHASSIS REAR CHASSIS SHEET 6 - 254F (92) 0_RA Bk-5.0 HARNESS
GROUND GROUND WELD 221F 0_DAV Bk-0.8 SHEET 2 - 108F (28) 12K_C Or-0.8 63 63 12K_B Or-0.8
WELD STUD () GROUND WELD 251F 21K W-0.8 64 64 21K_A W-0.8
SCREW () BRAIDED_STRAP_2 BRAIDED STRAP STUD () STUD () 0_ND Bk-62 SHEET 5 - 242F (68) CONVERTER 13K Or-0.8 56 56
HARNESS 0_DAD Bk-1.0 SHEET 5 SPL_D13 1A_A R-0.8 62 62
CAB STUD REAR 243F 52 52 28C_A W-0.8
CHASSIS SHEET 6 - 253F (93) 0_RB Bk-3.0 0_DJ Bk-0.8 11 25T_C LU-0.8
1 3 4 46 46
STUD 222F 0_DAC Bk-0.8 SHEET 3 - 13F CAB PEDESTAL
252F
182 13M 13F
1 28C W-0.8
LOWER PEDESTAL CAB GROUND REAR CHASSIS FRONT CHASSIS PEDESTAL CAB MAIN
0_DAX Bk-0.8 SHEET 5 - 140M DIODE MODULE GROUND WELD CIGAR 0_DS Bk-1.0 SHEET 4 - 24M CAB ROOF 92 HARNESS HARNESS
GROUND WELD STUD () GROUND WELD 1 25T_B LU-0.8
SCREW () 0_DU Bk-1.0 SHEET 4 - 23F CAB ROOF STUD () 0_AH Bk-5.0 STUD () SHEET 6 - 259F (91) 0_S Bk-3.0 LIGHTER 0_DR Bk-1.0 SHEET 4 - 24M CAB ROOF 25T_A LU-0.8 SHEET 2 - 70 (27)
261F HARNESS 0_DT Bk-1.0 SHEET 4 - 23F CAB ROOF
206F 0_DV Bk-0.8 SHEET 5 - 13F CAB PEDESTAL 144 143 223F
2 5
1. Batteries 13. Ignition Switch 25. Transmission Solenoid Valve and Temperature Sensors 36. Backup Alarm Disable Switch 47. Instrument Cluster 59. Detent Switch 69. Pin Engage Switch (Option) 81. Horn 93. Power Outlet (Option) 105. Flasher Module 117. Dome Lamp
2. Master Disconnect Switch 14. Ignition Relay - Number 1 26. Transmission Electronic Control Module (TUV road approved machines only) 48. Pilot Control Switch 60. Bucket Control Valve Electromagnetic Detents 70. Pin Engage Solenoid (Option) 82. Seat Compressor and Switch (Option) 94. Remote Radio or 24 Volt Radio (Option) 106. Left-Hand Rear Combination Lamp 118. Courtesy Lamp
3. Fuel Shutoff Solenoid 15. Ignition Relay - Number 2 27. Transmission Shifter 37. Backup Alarm 49. Up/Down Count Switch 61. Return-To-Travel/Float Switch 71. Ride Control Switch 83. Blower Switch 95. 12 Volt Radio (Option) 107. Right-Hand Rear Combination Lamp
4. Alternator 16. Accessory Relay - Number 3 28. Diagnostic Connector 38. Brake Warning Pressure Switch 50. Engine Oil Pressure Switch 62. Return-To-Dig Proximity Switch 72. Ride Control Relay - Number 4 84. Blower Motor Speed Resistors with Thermal Fuse 96. Radio Power Converter - 24 volts to 12 volts (Option) 108. Left-Hand Front Combination Lamp
5. Starter Motor 17. Voltmeter Relay - Number 12 29. Transmission Kick-down Switch 39. Coolant Level Sender 51. Pilot Control Relay - Number 10 63. Height Control/Return-To-Travel Proximity Switch 73. Ride Control Solenoid 85. Blower Motor 97. Left Speaker (Option) 109. Right-Hand Front Combination Lamp
6. Starting Relay 18. Time Delay Module 30. Transmission Auto Switch 40. Fuel Level Sender 52. Parking Brake Relay - Number 9 64. Float Pressure Switch 74. Front Wiper Motor 86. Air Conditioning Low Pressure Switch 98. Right Speaker (Option) 110. Left-Hand Rear Work Lamp
7. Fuel Relay 19. Output Speed Sensor 31. Declutch Switch 41. Hydraulic Oil Temperature Sender 53. Parking Brake Solenoid 64A. Rollback Pressure Switch (Option) 75. Front Wiper and Washer Switch 87. Air Conditioning High Pressure Switch 99. Beacon Switch 111. Right-Hand Rear Work Lamp
8. Ether Start Temperature Switch 20. Engine Speed Sensor 32. Brake Declutch Pressure Switch 42. Hydraulic Filter Restriction Switch 54. Pilot Pressure Solenoid 65. Float Solenoid 76. Front Washer Pump Motor 88. Thermostat Switch 100. Rotating Beacon 112. Left-Hand Front Work Lamp
9. Ether Start Solenoid 21. Intermediate Speed Sensor 33. Transmission Enable Switch 43. Engine Coolant Temperature Sender 55. Fan Reversing Switch (Option) 66. Secondary Steering Module (Option) 77. Rear Wiper and Washer Switch 89. Compressor Clutch Lockout Relay - Number 14 101. Brake Lamp Pressure Switch 113. Right-Hand Front Work Lamp
10. Ether Start Relay - Number 6 22. Turbine Speed Sensor 34. FNR Switch 44. Air Filter Restriction Switch 56. Fan Reversing Solenoid (Option) 67. Secondary Steering Pressure Switch (Option) 78. Rear Washer Pump Motor 90. Compressor Clutch 102. Brake Lamps Relay - Number 15 114. Five Position Rotary Lamp Switch
11. Ether Start Switch 23. Filter Maintenance Switch 35. Backup Alarm Relay - Number 7 45. Program Reset Switch 57. Redundant Brake Pressure Switches 68. Secondary Steering Motor (Option) 79. Rear Wiper Motor 91. Cigar Lighter (Option) 103. Hazard Switch 115. High/Low Beam Relay - Number 13
12. Neutral Start Relay - Number 8 24. Torque Converter Output Temperature Sender 46. Parking Brake Switch 58. Relay Socket - Number 11 68A. Secondary Steering Solenoid (Option) 80. Horn Relay - Number 5 92. Power Converter - 24 volts to 12 volts (Option) 104. Turn Signal, Hi/Low Beam, and Horn Switch 116. License Plate Lamp
WIRE IDENTIFICATION CIRCUIT LEGEND ACTUATOR SYMBOLS HOUSINGS CONTACT SYMBOLS FUSE AND CIRCUIT BREAKER NOTES
1 5 6 1 4 7 10 1 4 1 4 1
1. WIRE NUMBER 23F_A W-2.0 4 10 14 1. LEVER RELEASED 1. VACUUM SWITCH 1. SINGLE POLE, 1. FUSE 1. 209M and 209F disconnected when backup alarm disable switch is installed (TUV road approved machines only).
54 2. LEVER ACTUATED 2. PRESSURE SWITCH SINGLE THROW 2. CIRCUIT BREAKER,
2. WIRE COLOR SYMBOL SPL_G2 V M A2 A1 2. Resistors part of ground wire assembly.
3. WIRE SIZE 1 2 3 21C_C W-1.0 A A 1 1 14_B LG-0.8 SHEET 6 - 253F (54) 3. LIQUID LEVEL FLOAT 3. TEMPERATURE SWITCH 2. SINGLE POLE, AUTOMATIC RESET
0_GA Bk-2.0
D+ 3. 64M and 64F connected for North American machines, opposite side steady ON.
B B 2 2
R + 4. PRESSURE 4. MOTOR DOUBLE THROW 3. CIRCUIT BREAKER,
Bk = BLACK LU = LIGHT BLUE S = GRAY 2 93M 93F 7 9
5. HAND OPERATED 5. LAMP 3. DOUBLE POLE, MANUAL RESET 64M and 64F disconnected for European machines, opposite side OFF.
3 21M 21F 2 5 8 11 2 5 2 2
DU = DARK BLUE N = BROWN T = TAN XXXX XXXX 8 XXXX XXXX
11 12 13 6. TEMPERATURE SINGLE THROW 4. 217F and 217M disconnected when engine shutdown relay special feature is installed.
15
G = GREEN Or = ORANGE U = BLUE 7. COIL P 4. DOUBLE POLE,
K = PINK P = PURPLE (VIOLET) W = WHITE 8. VARIABLE RESISTOR DOUBLE THROW
LG = LIGHT GREEN R = RED Y = YELLOW
1.
2.
SPLICE IDENTIFICATION
CIRCUIT CROSSING (NOT CONNECTED)
6.
7.
FEMALE CONNECTOR
CONNECTOR IDENTIFICATION
11.
12.
SCHEMATIC SHEET NUMBER FOR CIRCUIT CONTINUATION
CONNECTION POINT ON SCHEMATIC
9. RESISTOR ELECTRICAL SCHEMATIC
3 6 9 12 10. DIODE 3 3 3
13M_A Or-1.0
HARNESS HARNESS
13C_E Or-1.0
REAR CHASSIS HARNESS 0_X Bk-1.0 SHEET 5 - 158 (56) 12.7 OHMS 17
AT 20C (68F) 3
163
30 30 1_T R-3.0
0_J Bk-1.0 SHEET 4 - 128F REAR HOOD 87 87 13R Or-1.0
262F 87a 87A 0_DF Bk-0.8
164 A A
13K_C Or-1.0
0_D Bk-2.0 SHEET 4 - SPL_E4 85 85 0_DE Bk-0.8
75 OHMS B B 86 86 13K_B Or-1.0 217F 217M
0_BC Bk-1.0 231F 230F 236F 235F RESISTOR 19R_D Or-0.8 C C 13K_A Or-1.0 13K_D Or-0.8 AA
48F SEE NOTE 4
0_U Bk-2.0 11B DIODE
15 13C_B Or-0.8
215F 216F MODULE 30 30
165 0_Q Bk-1.0 SHEET 3 - 87 (53) 2 SPL_D25 87 87 13C_C Or-0.8 SHEET 5 - 140M DIODE
A A 19R_E Or-0.8 87a 87A MODULE
AIR CONDITIONING 0_BJ Bk-1.0 SHEET 5 - 265F AIR CONDITIONING DIODE MODULE 0_BC Bk-1.0 B B 19R_A Or-0.8 SHEET 5 - 1F CAB-FRONT 1_M R-3.0 SHEET 4 - 211F FLASHER 85 85
DIODE HARNESS 268 CC
CHASSIS CIRCUIT BREAKER B 86 86 23C_A W-0.8 SHEET 3 - 13F CAB
290 2.26-2.76K OHMS 14_C LG-0.8 57F PEDESTAL
SPL_D17 19F Or-1.0
AT 20C (68F) 1_S R-3.0 58
13C Or-1.0 1 1 13C_A Or-1.0 1 1 13C_D Or-0.8 13C_D Or-0.8
14 LG-1.0 5 5 14_A LG-1.0 2 2 14_B LG-0.8
ENGINE HARNESS 0_BG Bk-1.0 0_BG Bk-1.0 15 15 0_HC Bk-1.0 30 30 0_DAU Bk-0.8 SHEET 3 - 13F CAB PEDESTAL 1_L R-3.0 30 30
152 0_BF Bk-1.0 9 9 0_HA Bk-1.0 23 23 87 87
0_BH Bk-1.0 11 11 0_HB Bk-1.0 15 15 0_DL Bk-0.8 SHEET 3 - 13F CAB PEDESTAL 87a 87A 13P_A Or-1.0
213F IGNITION SWITCH 85 85
SHEET 3 - 138 (43) 0_BE Bk-1.0 SPL_B1
0_BA Bk-1.0 94M 94F 22M 22F 0_DAB Bk-0.8 SHEET 3 - 13F CAB PEDESTAL CIRCUIT 86 86
BREAKER A 21K_A W-0.8
150 SHEET 3 - 117 (44) 0_BD Bk-1.0 ENGINE TRANSMISSION TRANSMISSION CAB MAIN 47F 21C_F W-0.8 SHEET 5 - 140M DIODE
SECONDARY STEERING 214F 12.5 AMP 14
HARNESS HARNESS HARNESS HARNESS 30 30 21C_G W-0.8 MODULE
MODULE HARNESS 0_CD Bk-1.0 SHEET 5 - SPL_C1 87 87 21C_E W-0.8
177 1A_D R-0.8 87a 87A 0_DH Bk-0.8
85 85 0_DJ Bk-0.8
13D Or-1.0 86 86 25T_E LU-0.8
SPL_D21
0_DZ Bk-2.0 SHEET 5 - 29M (85) 63M TIME DELAY MODULE 1A_E R-0.8 SPL_D18
1 DELAY POWER-2-WAY 1
54F
CAB 0_DY Bk-1.0 SHEET 5 - 28M (82) 2 TIME DELAY POWER 2 0_DAS Bk-0.8 SHEET 4 - SPL_D14 12
REAR CHASSIS FRONT ENGINE GROUND SHEET 5 - 35F (75)
3 TIME DELAY MODULE GROUND 3
0_NB Bk-62 218F 0_DAR Bk-1.0 4 RESET SIGNAL 4 37R_C P-0.8 SHEET 3 - 13F CAB
GROUND WELD BLOCK GROUND
STUD (-) 234F JUNCTION 5 IGNITION SWITCH POWER 5 PEDESTAL SHEET 2 - 19F (26) 25T_D LU-0.8
0_NA Bk-62 STUD (-) 6 NONE 6
BLOCK () 50G_G Bk-0.8 SHEET 2 - SPL_D7
13K_F Or-0.8
232F 233F 63M SPL_D22
0_DB Bk-0.8 SHEET 3 - 89M (54) 18
1 REAR
REAR CHASSIS 0_Y Bk-13.0 0_Y Bk-13.0 CHASSIS 219F 0_DBA Bk-0.8
HARNESS 167 HARNESS
161
REAR CHASSIS 0_DX Bk-0.8 SHEET 4 - 13F CAB PEDESTAL
GROUND WELD SHEET 3 - 75 (45) 1A_B R-0.8 5
1A_C R-0.8
13K_G Or-0.8
SHEET 5 - SPL_A1 0_AJ Bk-2.0 0_DA Bk-0.8 SHEET 5 - 203F (89) 1 BAT
STUD (-) 0_CE Bk-1.0 SHEET 5 - 90M (66) FRONT 3 IGN
CHASSIS 220F 0_DAT Bk-0.8 SHEET 4 - SPL_D14
PREHEATER 2 ST 13
176 HARNESS
SHEET 5 - SPL_A2 0_AK Bk-1.0 145 LIGHT
4 ACC
2 6
0_DQ Bk-0.8 SHEET 2 - 19F (26)
69
CAB 0_DP Bk-0.8 SHEET 2 - 19F (26) 13M 13F
UPPER PEDESTAL REAR CHASSIS HARNESS 1 2 3 4 5 6
CAB GROUND REAR CHASSIS SHEET 6 - 254F (92) 0_RA Bk-5.0
GROUND GROUND WELD 221F 0_DAV Bk-0.8 SHEET 2 - 108F (28) A B C D E F 97 12K_C Or-0.8 63 63 12K_B Or-0.8
WELD STUD (-) GROUND WELD 251F 21K W-0.8 64 64 21K_A W-0.8
SCREW (-) BRAIDED_STRAP_2 BRAIDED STRAP STUD (-) STUD (-) 0_ND Bk-62 SHEET 5 - 242F (68) CONVERTER 13K Or-0.8 56 56
HARNESS 0_DAD Bk-1.0 SHEET 5 SPL_D13 182 1A_A R-0.8 62 62
CAB STUD REAR 243F 1 28C W-0.8 52 52
CHASSIS SHEET 6 - 253F (93) 0_RB Bk-3.0 0_DJ Bk-0.8 25T_C LU-0.8
1 3 4 92 46 46
STUD 222F 0_DAC Bk-0.8 SHEET 3 - 13F CAB PEDESTAL 1 25T_B LU-0.8
252F
25T_A LU-0.8 SHEET 2 - 70 (27)
FRONT CHASSIS 18L_D Bk-0.8 9 9 18L_C Or-0.8
LOWER PEDESTAL CAB GROUND REAR CHASSIS 31Y_B Y-0.8 11 11 0_DBA Bk-0.8
GROUND 0_DAX Bk-0.8 SHEET 5 - 140M DIODE MODULE GROUND WELD CIGAR 0_DS Bk-1.0 SHEET 4 - 24M CAB ROOF
WELD STUD (-) GROUND WELD
SCREW (-) 0_DU Bk-1.0 SHEET 4 - 23F CAB ROOF STUD (-) SHEET 6 - 259F (91) 0_S Bk-3.0 LIGHTER 0_DR Bk-1.0 SHEET 4 - 24M CAB ROOF PEDESTAL CAB MAIN
STUD (-) 0_AH Bk-5.0 GRID HEATER CONTROLLER 201
HARNESS HARNESS HARNESS
0_DV Bk-0.8 SHEET 5 - 13F CAB PEDESTAL 144 143 261F 223F 0_DT Bk-1.0 SHEET 4 - 23F CAB ROOF 1 INDICATOR LIGHT 1
206F
2 NONE 2
2 5 3 FEED BACK OF GH 3 28GP W-1.0
4 ALTERNATOR D+ 4 14_C LG-0.8 SPL_D26
CONVERTER 5 CRANKING POWER 5 21C_G W-0.8
0_PD Bk-1.0 SHEET 6 - 109M (92) 11C 6 GRID HEATER ON SIGNAL 6 28GC W-0.8
HARNESS
247F 7 SWITCHED POWER 7 19E Or-1.0
8 GROUND 8 0_DBB Bk-0.8
202 9 NONE 9
10 TEMP SENDER SIGNAL 10
1. Batteries 11B. Grid Heater Temperature Sensor (Option) 22. Turbine Speed Sensor 34. FNR Switch 45. Program Reset Switch 57. Redundant Brake Pressure Switches 68. Secondary Steering Motor (Option) 79. Rear Wiper Motor 91. Cigar Lighter (Option) 103. Hazard Switch 114. Five Position Rotary Lamp
2. Master Disconnect Switch 11C. Grid Heater Controller (Option) 23. Filter Maintenance Switch 35. Backup Alarm Relay - Number 7 46. Parking Brake Switch 58. Relay Socket - Number 11 68A. Secondary Steering Solenoid (Option) 80. Horn Relay - Number 5 92. Power Converter - 24 volts to 12 volts (Option) 104. Turn Signal, Hi/Low Beam, and Horn Switch
3. Engine Fuel Solenoid 12. Neutral Start Relay - Number 8 24. Torque Converter Output Temperature Sender 36. Backup Alarm Disable Switch 47. Instrument Cluster 59. Detent Switch 69. Pin Engage Switch (Option) 81. Horn 93. Power Outlet (Option) Switch 115. High/Low Beam Relay -
4. Alternator 13. Ignition Switch 25. Transmission Solenoid Valve and Temperature Sensors (TUV road approved machines only) 48. Pilot Control Switch 60. Bucket Control Valve Electromagnetic Detents 70. Pin Engage Solenoid (Option) 82. Seat Compressor and Switch (Option) 94. Remote Radio or 24 Volt Radio (Option) 105. Flasher Module Number 13
5. Starter Motor 14. Ignition Relay - Number 1 26. Transmission Electronic Control Module 37. Backup Alarm 49. Up/Down Count Switch 61. Return-To-Travel/Float Switch 71. Ride Control Switch 83. Blower Switch 95. 12 Volt Radio (Option) 106. Left-Hand Rear Combination Lamp 116. License Plate Lamp
6. Starting Relay 15. Ignition Relay - Number 2 27. Transmission Shifter 38. Brake Warning Pressure Switch 50. Engine Oil Pressure Switch 62. Return-To-Dig Proximity Switch 72. Ride Control Relay - Number 4 84. Blower Motor Speed Resistors with Thermal Fuse 96. Radio Power Converter - 24 volts to 12 volts (Option) 107. Right-Hand Rear Combination Lamp 117. Dome Lamp
7. Fuel Filter Heater Relay - Number 16 16. Accessory Relay - Number 3 28. Diagnostic Connector 39. Coolant Level Sender 51. Pilot Control Relay - Number 10 63. Height Control/Return-To-Travel Proximity Switch 73. Ride Control Solenoid 85. Blower Motor 97. Left Speaker (Option) 108. Left-Hand Front Combination Lamp 118. Courtesy Lamp
8. Fuel Filter Heater Switch 17. Voltmeter Relay - Number 12 29. Transmission Kick-down Switch 40. Fuel Level Sender 52. Parking Brake Relay - Number 9 64. Float Pressure Switch 74. Front Wiper Motor 86. Air Conditioning Low Pressure Switch 98. Right Speaker (Option) 109. Right-Hand Front Combination Lamp
9. First Fuel Filter Heater 18. Time Delay Module 30. Transmission Auto Switch 41. Hydraulic Oil Temperature Sender 53. Parking Brake Solenoid 64A. Rollback Pressure Switch (Option) 75. Front Wiper and Washer Switch 87. Air Conditioning High Pressure Switch 99. Beacon Switch 110. Left-Hand Rear Work Lamp
10. Second Fuel Filter Heater 19. Output Speed Sensor 31. Declutch Switch 42. Hydraulic Filter Restriction Switch 54. Pilot Pressure Solenoid 65. Float Solenoid 76. Front Washer Pump Motor 88. Thermostat Switch 100. Rotating Beacon 111. Right-Hand Rear Work Lamp
11. Grid Heater Relay - Number 15 (Option) 20. Engine Speed Sensor 32. Brake Declutch Pressure Switch 43. Engine Coolant Temperature Sender 55. Fan Reversing Switch (Option) 66. Secondary Steering Module (Option) 77. Rear Wiper and Washer Switch 89. Compressor Clutch Lockout Relay - Number 14 101. Brake Lamp Pressure Switch 112. Left-Hand Front Work Lamp
11A. Grid Heater (Option) 21. Intermediate Speed Sensor 33. Transmission Enable Switch 44. Air Filter Restriction Switch 56. Fan Reversing Solenoid (Option) 67. Secondary Steering Pressure Switch (Option) 78. Rear Washer Pump Motor 90. Compressor Clutch 102. Brake Lamps Relay - Number 6 113. Right-Hand Front Work Lamp
WIRE IDENTIFICATION CIRCUIT LEGEND ACTUATOR SYMBOLS HOUSINGS CONTACT SYMBOLS FUSE AND CIRCUIT BREAKER NOTES
23F_A W-2.0 1 4 5 6
14
1 4 7 10
1. LEVER RELEASED
1 4
1. VACUUM SWITCH
1 4
1. SINGLE POLE,
1
1. FUSE 1. 209M and 209F disconnected when backup alarm disable switch is installed (TUV road approved machines only).
1. WIRE NUMBER 10
54 2. LEVER ACTUATED 2. PRESSURE SWITCH SINGLE THROW 2. CIRCUIT BREAKER, 2. Resistors part of ground wire assembly.
2. WIRE COLOR SYMBOL SPL_G2 V M A2 A1
3. 64M and 64F connected for North American machines, opposite side steady ON. 64M and 64F disconnected for European machines, opposite side OFF.
3. WIRE SIZE 1 2 3 21C_C W-1.0 A A 1 1 14_B LG-0.8 SHEET 6 - 253F (54) D+ 3. LIQUID LEVEL FLOAT 3. TEMPERATURE SWITCH 2. SINGLE POLE, AUTOMATIC RESET
0_GA Bk-2.0 B B 2 2
+ 4. PRESSURE 4. MOTOR DOUBLE THROW 3. CIRCUIT BREAKER, 4. 217F and 217M disconnected when engine shutdown relay special feature is installed.
9 R
Bk = BLACK LU = LIGHT BLUE S = GRAY 2 3 93M 93F 7 - 2 5 8 11 5. HAND OPERATED 2 5 5. LAMP 2 3. DOUBLE POLE, 2 MANUAL RESET 5. Used only on 621D.
21M 21F
DU = DARK BLUE N = BROWN T = TAN XXXX XXXX 8 11 12 13 6. TEMPERATURE SINGLE THROW
XXXX XXXX 15 6. On 521D connector 289 connected to fuel filter heater switch; on 621D connector 291 connected.
G = GREEN Or = ORANGE U = BLUE 7. COIL P 4. DOUBLE POLE, 7. Used only when grid heater option installed.
K = PINK P = PURPLE (VIOLET) W = WHITE 8. VARIABLE RESISTOR DOUBLE THROW
LG = LIGHT GREEN 1. SPLICE IDENTIFICATION 6. FEMALE CONNECTOR 11. SCHEMATIC SHEET NUMBER FOR CIRCUIT CONTINUATION 9. RESISTOR
R = RED Y = YELLOW
2. CIRCUIT CROSSING (NOT 7. CONNECTOR IDENTIFICATION 12. CONNECTION POINT ON SCHEMATIC 3 6 9 12 10. DIODE 3 3 3 ELECTRICAL SCHEMATIC P.I.N. JEE0135501AND ABOVE
CONNECTED) 8. HARNESS IDENTIFICATION 13. COMPONENT NUMBER (IF ASSIGNED)
SHOWS POWER - MASTER DISCONNECT SWITCH IN ON POSITION 3. CIRCUIT CONNECTED 9. INDICATES PARTIAL CONNECTOR 14. COMPONENT NUMBER
A 11.
12A.
LIGHT EMITTING DIODE
MOMENTARY CONTACT T 521D Z-BAR, 521D XR, and 521D XT WHEEL LOADERS
4. WIRE IDENTIFICATION 10. CIRCUIT IDENTIFICATION 15. INDICATES INTERNALLY GROUNDED COMPONENT B
SHOWS POWER - KEY SWITCH IN ON POSITION 12B. MAINTAINED CONTACT Additional copies of this Hydraulic and Electrical Schematic can be ordered throughTechnical Publications Distribution System. The Part Number is 6-49280
BC02M033
Copyright
19A_E Or-0.8
19A_C Or-0.8
P/N 409725A1 10 10 10 0_DAE Bk-1.0 SHEET 5 - SPL_D13
7 7 7 0_DAP Bk-1.0 SHEET 4 - 42F (99)
8 8 8 49_G S-0.8 SHEET 4 - SPL_D8
2.5K ohm 1 1 49_R S-1.0 SHEET 4 - 42F (99)
resistor 6 6 0_DAW Bk-1.0 SHEET 4 - 42F (99)
33 5 33 5
4 4 32J_C Y-0.8 10 0_DW Bk-0.8 SHEET 5 - 45F (77)
Used in place of 9 9 9 32J_B Y-0.8 7 7
transmission enable switch 3 3 3 26E LU-0.8 8 8 49_L S-0.8 SHEET 5 - 45F (77)
before Serial Number JEE0133334 2 2 2 19A_D Or-0.8 9
19A_E Or-0.8 6 49_T S-1.0 SHEET 4 - 42F (99)
199F 199F 36 5
1 1 35R_C Y-0.8
4
P/N 409726A1 JOYSTICK CONTROLLER SINGLE AXIS CONTROLLER 32J_A Y-0.8 3 3 35R_D Y-0.8
5 5 19A_F Or-0.8 5 5 32J_B Y-0.8 2 2 35A_F Y-0.8 AA NOTE 1
7 7
6 R 6 8 8 6 6 209M 209F
Or-0.8 1 N 1 5 5 19A_B Or-0.8 1 1 19A_C Or-0.8 118F 35A_E Y-0.8
34 2 34 N Y 2 4 4 26J LU-0.8 2 2 26F_B LU-0.8
4 K 4 9 4 4 26R_B LU-0.8
3
F
P 3 34 6 6 26F_A LU-0.8 3 3 26N_B LU-0.8
Used in place of FNR switch 1 1 26R_A LU-0.8 19H Or-1.0 SHEET 1 - 18F FUSE BLOCK
before Serial Number JEE0133334 10 197M 197F
3 3 26N_A LU-0.8 FNR CAB MAIN 35A_E Y-0.8
2 2 30 30
HARNESS HARNESS
87 87 35A_D Y-0.8 SHEET 4 - 21F CAB REAR
198
35 87a 87A
25 SPL_D12 85 85 35C Y-0.8
25S_A LU-0.8 25S_A LU-0.8 25S_C LU-0.8 86 86
25S_B LU-0.8 19A_P Or-0.8 SHEET 1 - 18F FUSE BLOCK
53F
CLUTCH FORWARD REVERSE NEUTRAL 26
102 TRANSMISSION CONTROL 19F 19F
NUMBER 1 2 3 4 1 2 3 1 2 3 4 19F TECM 19F TECM
1 TRANSMISSION SOLENOID VALVE Y1 K4 1 25K LU-0.8 25K LU-0.8 16 16 25K_A LU-0.8 56 56 TRANSMISSION SOLENOID VALVE Y1 1 DIAGNOSTIC TECM GROUND 1 0_DP Bk-0.8 SHEET 1 - 221F GROUND CAB
2 TRANSMISSION SOLENOID VALVE Y2 KR 2 25L LU-0.8 25L LU-0.8 17 17 25L_A LU-0.8 10 10 TRANSMISSION SOLENOID VALVE Y2 2 DIAGNOSTIC TECM GROUND 2 0_DQ Bk-0.8 SHEET 1 - 221F GROUND CAB
3 TRANSMISSION SOLENOID VALVE Y3 K1 3 25M LU-0.8 25M LU-0.8 18 18 25M_A LU-0.8 32 32 TRANSMISSION SOLENOID VALVE Y3 5 TRANSMISSION ENABLE LAMP SIGNAL 5 32J_C Y-0.8
4 TRANSMISSION SOLENOID VALVE Y4 K3 4 25N LU-0.8 25N LU-0.8 19 19 25N_A LU-0.8 55 55 TRANSMISSION SOLENOID VALVE Y4 6 NONE 6
5 TRANSMISSION SOLENOID VALVE Y5 KV 5 25P LU-0.8 25P LU-0.8 20 20 25P_A LU-0.8 9 9 TRANSMISSION SOLENOID VALVE Y5 7 BACKUP ALARM PULL-DOWN 7 35C Y-0.8
6 TRANSMISSION SOLENOID VALVE Y6 K2 6 25J LU-0.8 25J LU-0.8 21 21 25J_A LU-0.8 51 51 TRANSMISSION SOLENOID VALVE Y6 8 RIDE CONTROL SWITCHED POWER VPS2 8 58H_B W-0.8 SHEET 5 - 50F (72)
7 OUTPUT SWITCHED POWER VPSI 7 25S LU-0.8 25S LU-0.8 22 22 39 39 VALVE BODY TEMPERATURE SENDER 11 NONE 11 0_DAV Bk-0.8 SHEET 1 - 221F GROUND CAB
8 VALVE BODY TEMPERATURE SIGNAL 8 36T P-0.8 36T P-0.8 5 5 36T_A P-0.8 17 17 TRANSMISSION FILTER MAINTENANCE SWITCH 12 OUTPUT SWITCHED POWER VPS1 12
9 VALVE BODY TEMPERATURE RETURN 9 36R_C P-0.8 32F Y-1.0 31 31 32F_A Y-0.8 4 4 OUTPUT SPEED SENSOR GROUND 13 OUTPUT SWITCHED POWER VPS2 13 3
10 NONE 10 0_HE Bk-1.0 28 28 0_DN Bk-0.8 62 62 OUTPUT SPEED SIGNAL 14 NONE 14 5 28
11 NONE 11 25D LU-1.0 10 10 25D_A LU-0.8 46 46 TEMPERATURE/FILTER RETURN 15 DIAGNOSTIC SIGNAL 15 37D_A P-0.8 37D_A P-0.8 2 10
12 NONE 12 19A Or-1.0 29 29 19A_M Or-0.8 49 49 TORQUE CONVERTER OUTPUT TEMPERATURE SENDER 16 NONE 16 6 7 7 0_DAM Bk-1.0 SHEET 5 - 44F (71) 174
13 NONE 13 24 24 19 19 ENGINE SPEED SIGNAL 18 DIAGNOSTIC SIGNAL 18 37E P-0.8 37E P-0.8 4 8 8 49_Q S-1.0 SHEET 5 - 44F (71) SHEET 4 - SPL_J1 0_JB Bk-1.0
14 NONE 14 36R_A P-1.0 12 12 36R_E P-0.8 3 3 SPEED SENSOR GROUND 20 FNR FORWARD SIGNAL 20 26F_B LU-0.8 1 9 37
15 NONE 15 36G P-1.0 13 13 36G_A P-1.0 42 42 INTERMEDIATE SPEED 21 PARKING BRAKE RELAY OUT 21 52P_A W-0.8 SHEET 3 - 55F (52) 6
35R_A Y-1.0
108F BB
16 NONE 16 14 14 41 41 TURBINE SPEED SIGNAL 22 TRANSMISSION KICKDOWN SIGNAL 22 25Y_B LU-0.8 5
MODULATED AND CURRENT CONTROLLED 102 25A W-0.8 7 7 25A_A LU-0.8 23 TIME DELAY FUSED POWER 23 19T_A Or-0.8 SHEET 1 - 18F FUSE BLOCK 4 128F 128M 175
0_DM Bk-0.8
19A_D Or-0.8
0_HD Bk-1.0 11 11 24 NONE 24 1
REAR HOOD
25C W-0.8 9 9 25C_A LU-0.8 25 CONTROLLER AREA NETWORK H 25 50H_A Y-0.5 SHEET 3 - 13F CAB PEDESTAL 3 3 25H LU-0.8 26 26
25B W-0.8 8 8 25B_A LU-0.8 26 CONTROLLER AREA NETWORK L 26 50L_B G-0.5 30 2 2 19A_Q Or-0.8 23 23 CHASSIS HARNESS
27 CONTROLLER AREA NETWORK L 27 50L_C G-0.5 50L_A G-0.5 SHEET 3 - 13F CAB 22 22 HARNESS
22M 22F 41F
28 NONE 28 SPL_D5 PEDESTAL 20 20
TRANSMISSION CAB MAIN 29 TRANSMISSION AUTO SIGNAL 29 25H LU-0.8 19 19
11 32F Y-1.0 HARNESS HARNESS 30 FNR REVERSE SIGNAL 30 26R_B LU-0.8 17 17
23 22 36R_B P-1.0 36R_A P-1.0 31 TRANSMISSION ENABLE SIGNAL 31 26E LU-0.8 2 2
510 OHMS 31 SPL_H1 33 NONE 33
SPL_D15 6 6 35R_B Y-1.0
34 NONE 34 19A_L Or-0.8 19A_T Or-0.8 30 30 19A_A Or-1.0 AA
35 NONE 35 31 31 25G LU-1.0 BB 32
36 NONE 36 SHEET 3 - 13F CAB PEDESTAL 19A_S Or-0.8
4
37 NONE 37 21F 21M
22 36R_D P-1.0 38 NONE SHEET 1 - 18F FUSE BLOCK 19A_N Or-0.8 Normally Closed
24 11 36G P-1.0
38
CAB REAR CHASSIS Opens at 24.1 bar (350 psi)
40 NONE 40
MAIN HARNESS
19A_M Or-0.8
142 43 FORWARD SIGNAL 43 25F_A LU-0.8
44 FNR NEUTRAL SIGNAL 44 26N_B LU-0.8 HARNESS
3521 ohms at 20C (68F)
45 CAB SWITCHED POWER 45 19A_K Or-0.8 19A_K Or-0.8
11 0_HE Bk-1.0 47 NONE 47
19 22 25D LU-1.0 48 NONE 48
33 19A Or-1.0 50 NONE 50 10
100 52 NONE 52 7 7 0_DAK Bk-1.0 SHEET 5 - 36F (54)
53 NONE 53 8 8 49_N S-1.0 SHEET 5 - 36F (54)
54 NONE 54 9
11 25A W-0.8 57 RIDE CONTROL RELAY SINK 0_DD Bk-0.8 SHEET 5 - 50F (72)
20 22 0_HF Bk-0.8 SPL_H2
57
31
6
58 NONE 58 5
101 59 NONE 59 1 1 25G_A LU-0.8
60 NONE 60 4 25G_B LU-0.8
61 NONE 61 3 3
63 1ST AND 4TH GEAR SIGNAL 63 25Z_A LU-0.8 2 2 19A_R Or-0.8
11 0_HG Bk-0.8 64 REVERSE SIGNAL 64 25R_A LU-0.8
21 22 25C W-0.8 65 3RD AND 4TH GEAR SIGNAL 65 25W_A LU-0.8 38F
95 66 DECLUTCH SWITCH 66 25G_B LU-0.8
67 NEUTRAL SIGNAL 67 25T_D LU-0.8 SHEET 1 - SPL_D18
68 TIME DELAY FUSED POWER 68 19T_B Or-0.8 SHEET 1 - 18F FUSE BLOCK
22 0_HH Bk-0.8 29
22 11 25B W-0.8
96
2 1
2 1 20M
SPL_D11
25Y_C LU-0.8 19A_U Or-0.8
183
FORWARD REVERSE NEUTRAL Bk A A
183 TRANSMISSION SHIFTER G B B 25W LU-0.8
1 2 3 4 1 2 3 4 1 2 3 4 U C C 25Z LU-0.8 25W LU-0.8 48 48 25W_A LU-0.8
A NONE D D 25Y LU-0.8 25Z LU-0.8 49 49 25Z_A LU-0.8
B THIRD AND FOURTH GEAR SIGNAL 25Y LU-0.8 50 50 25Y_A LU-0.8
C FIRST AND FOURTH GEAR SIGNAL 70 24 24
D TRANSMISSION KICKDOWN SIGNAL R A A 19A_H Or-0.8 SHEET 3 - 72 (46) 47 47
INDICATES HIGH (24 VOLTS) Y B B 25F LU-0.8 25F LU-0.8 44 44 25F_A LU-0.8
K C C 25R LU-0.8 25R LU-0.8 45 45 25R_A LU-0.8
S D D 25T_A LU-0.8 SHEET 1 - 92 (11) 27 27
FORWARD REVERSE NEUTRAL 33 33
70 TRANSMISSION SHIFTER
1 2 3 4 1 2 3 4 1 2 3 4 SPL_K2 37 37 SPL_D6 50G_E Bk-0.5 SPL_D7
A TRANSMISSION CONTROL POWER 27 50G_C R-0.5 50G_A Bk-0.8 34 34 50G_D Bk-0.8 50G_G Bk-0.8 SHEET 1 - 219F GROUND CAB
B FORWARD SIGNAL 50G_F R-0.5
C REVERSE SIGNAL SPL_K3 50G_B Bk-0.5 13M 13F
D NEUTRAL SIGNAL PEDESTAL CAB MAIN LOCATED NEAR TECM
INDICATES HIGH (24 VOLTS) HARNESS HARNESS CONNECTOR 19F
LOCATED NEAR INSTRUMENT
CLUSTER CONNECTOR 76
1. Batteries 13. Ignition Switch 25. Transmission Solenoid Valve and Temperature Sensors 36. Backup Alarm Disable Switch 47. Instrument Cluster 59. Detent Switch 69. Pin Engage Switch (Option) 81. Horn 93. Power Outlet (Option) 105. Flasher Module 117. Dome Lamp
2. Master Disconnect Switch 14. Ignition Relay - Number 1 26. Transmission Electronic Control Module (TUV road approved machines only) 48. Pilot Control Switch 60. Bucket Control Valve Electromagnetic Detents 70. Pin Engage Solenoid (Option) 82. Seat Compressor and Switch (Option) 94. Remote Radio or 24 Volt Radio (Option) 106. Left-Hand Rear Combination Lamp 118. Courtesy Lamp
3. Fuel Shutoff Solenoid 15. Ignition Relay - Number 2 27. Transmission Shifter 37. Backup Alarm 49. Up/Down Count Switch 61. Return-To-Travel/Float Switch 71. Ride Control Switch 83. Blower Switch 95. 12 Volt Radio (Option) 107. Right-Hand Rear Combination Lamp
4. Alternator 16. Accessory Relay - Number 3 28. Diagnostic Connector 38. Brake Warning Pressure Switch 50. Engine Oil Pressure Switch 62. Return-To-Dig Proximity Switch 72. Ride Control Relay - Number 4 84. Blower Motor Speed Resistors with Thermal Fuse 96. Radio Power Converter - 24 volts to 12 volts (Option) 108. Left-Hand Front Combination Lamp
5. Starter Motor 17. Voltmeter Relay - Number 12 29. Transmission Kick-down Switch 39. Coolant Level Sender 51. Pilot Control Relay - Number 10 63. Height Control/Return-To-Travel Proximity Switch 73. Ride Control Solenoid 85. Blower Motor 97. Left Speaker (Option) 109. Right-Hand Front Combination Lamp
6. Starting Relay 18. Time Delay Module 30. Transmission Auto Switch 40. Fuel Level Sender 52. Parking Brake Relay - Number 9 64. Float Pressure Switch 74. Front Wiper Motor 86. Air Conditioning Low Pressure Switch 98. Right Speaker (Option) 110. Left-Hand Rear Work Lamp
7. Fuel Relay 19. Output Speed Sensor 31. Declutch Switch 41. Hydraulic Oil Temperature Sender 53. Parking Brake Solenoid 64A. Rollback Pressure Switch (Option) 75. Front Wiper and Washer Switch 87. Air Conditioning High Pressure Switch 99. Beacon Switch 111. Right-Hand Rear Work Lamp
8. Ether Start Temperature Switch 20. Engine Speed Sensor 32. Brake Declutch Pressure Switch 42. Hydraulic Filter Restriction Switch 54. Pilot Pressure Solenoid 65. Float Solenoid 76. Front Washer Pump Motor 88. Thermostat Switch 100. Rotating Beacon 112. Left-Hand Front Work Lamp
9. Ether Start Solenoid 21. Intermediate Speed Sensor 33. Transmission Enable Switch 43. Engine Coolant Temperature Sender 55. Fan Reversing Switch (Option) 66. Secondary Steering Module (Option) 77. Rear Wiper and Washer Switch 89. Compressor Clutch Lockout Relay - Number 14 101. Brake Lamp Pressure Switch 113. Right-Hand Front Work Lamp
10. Ether Start Relay - Number 6 22. Turbine Speed Sensor 34. FNR Switch 44. Air Filter Restriction Switch 56. Fan Reversing Solenoid (Option) 67. Secondary Steering Pressure Switch (Option) 78. Rear Washer Pump Motor 90. Compressor Clutch 102. Brake Lamps Relay - Number 15 114. Five Position Rotary Lamp Switch
11. Ether Start Switch 23. Filter Maintenance Switch 35. Backup Alarm Relay - Number 7 45. Program Reset Switch 57. Redundant Brake Pressure Switches 68. Secondary Steering Motor (Option) 79. Rear Wiper Motor 91. Cigar Lighter (Option) 103. Hazard Switch 115. High/Low Beam Relay - Number 13
12. Neutral Start Relay - Number 8 24. Torque Converter Output Temperature Sender 46. Parking Brake Switch 58. Relay Socket - Number 11 68A. Secondary Steering Solenoid (Option) 80. Horn Relay - Number 5 92. Power Converter - 24 volts to 12 volts (Option) 104. Turn Signal, Hi/Low Beam, and Horn Switch 116. License Plate Lamp
WIRE IDENTIFICATION CIRCUIT LEGEND ACTUATOR SYMBOLS HOUSINGS CONTACT SYMBOLS FUSE AND CIRCUIT BREAKER NOTES
1 5 6 1 4 7 10 1 4 1 4 1
1. WIRE NUMBER 23F_A W-2.0 4 10 14 1. LEVER RELEASED 1. VACUUM SWITCH 1. SINGLE POLE, 1. FUSE 1. 209M and 209F disconnected when backup alarm disable switch is installed (TUV road approved machines only).
54 2. LEVER ACTUATED 2. PRESSURE SWITCH SINGLE THROW 2. CIRCUIT BREAKER,
2. WIRE COLOR SYMBOL SPL_G2 V M A2 A1 2. Resistors part of ground wire assembly.
3. WIRE SIZE 1 2 3 21C_C W-1.0 A A 1 1 14_B LG-0.8 SHEET 6 - 253F (54) 3. LIQUID LEVEL FLOAT 3. TEMPERATURE SWITCH 2. SINGLE POLE, AUTOMATIC RESET
0_GA Bk-2.0
D+ 3. 64M and 64F connected for North American machines, opposite side steady ON.
B B 2 2
R + 4. PRESSURE 4. MOTOR DOUBLE THROW 3. CIRCUIT BREAKER,
Bk = BLACK LU = LIGHT BLUE S = GRAY 2 93M 93F 7 9
5. HAND OPERATED 5. LAMP 3. DOUBLE POLE, MANUAL RESET 64M and 64F disconnected for European machines, opposite side OFF.
3 21M 21F 2 5 8 11 2 5 2 2
DU = DARK BLUE N = BROWN T = TAN XXXX XXXX 8 XXXX XXXX
11 12 13 6. TEMPERATURE SINGLE THROW 4. 217F and 217M disconnected when engine shutdown relay special feature is installed.
15
G = GREEN Or = ORANGE U = BLUE 7. COIL P 4. DOUBLE POLE,
K = PINK P = PURPLE (VIOLET) W = WHITE 8. VARIABLE RESISTOR DOUBLE THROW
LG = LIGHT GREEN R = RED Y = YELLOW
1.
2.
SPLICE IDENTIFICATION
CIRCUIT CROSSING (NOT CONNECTED)
6.
7.
FEMALE CONNECTOR
CONNECTOR IDENTIFICATION
11.
12.
SCHEMATIC SHEET NUMBER FOR CIRCUIT CONTINUATION
CONNECTION POINT ON SCHEMATIC
9. RESISTOR ELECTRICAL SCHEMATIC
3 6 9 12 10. DIODE 3 3 3
19A_E Or-0.8
19A_C Or-0.8
10 10 0_DAE Bk-1.0 SHEET 5 - SPL_D13
7 7 0_DAP Bk-1.0 SHEET 4 - 42F (99)
8 8 49_G S-0.8 SHEET 4 - SPL_D8
1 49_R S-1.0 SHEET 4 - 42F (99)
6 0_DAW Bk-1.0 SHEET 4 - 42F (99)
33 5
4 32J_C Y-0.8 10 0_DW Bk-0.8 SHEET 5 - 45F (77)
9 9 32J_B Y-0.8 7 7
3 3 26E LU-0.8 8 8 49_L S-0.8 SHEET 5 - 45F (77)
2 2 19A_D Or-0.8 9
19A_E Or-0.8 6 49_T S-1.0 SHEET 4 - 42F (99)
199F 36 5
1 1 35R_C Y-0.8
4
JOYSTICK CONTROLLER SINGLE AXIS CONTROLLER 32J_A Y-0.8 3 3 35R_D Y-0.8
5 19A_F Or-0.8 5 5 32J_B Y-0.8 2 2 35A_F Y-0.8 AA NOTE 1
7 7
R 6 8 8 6 6 209M 209F
N 1 5 5 19A_B Or-0.8 1 1 19A_C Or-0.8 118F 35A_E Y-0.8
34 N Y 2 4 4 26J LU-0.8 2 2 26F_B LU-0.8
K 4 9 4 4 26R_B LU-0.8
F
P 3 34 6 6 26F_A LU-0.8 3 3 26N_B LU-0.8
1 1 26R_A LU-0.8 19H Or-1.0 SHEET 1 - 18F FUSE BLOCK
10 197M 197F
3 3 26N_A LU-0.8 FNR CAB MAIN 35A_E Y-0.8
2 2 30 30
HARNESS HARNESS
87 87 35A_D Y-0.8 SHEET 4 - 21F CAB REAR
198
35 87a 87A
25 SPL_D12 85 85 35C Y-0.8
25S_A LU-0.8 25S_A LU-0.8 25S_C LU-0.8 86 86
25S_B LU-0.8 19A_P Or-0.8 SHEET 1 - 18F FUSE BLOCK
53F
CLUTCH FORWARD REVERSE NEUTRAL 26
102 TRANSMISSION CONTROL 19F 19F
NUMBER 1 2 3 4 1 2 3 1 2 3 4 19F TECM 19F TECM
1 TRANSMISSION SOLENOID VALVE Y1 K4 1 25K LU-0.8 25K LU-0.8 16 16 25K_A LU-0.8 56 56 TRANSMISSION SOLENOID VALVE Y1 1 DIAGNOSTIC TECM GROUND 1 0_DP Bk-0.8 SHEET 1 - 221F GROUND CAB
2 TRANSMISSION SOLENOID VALVE Y2 KR 2 25L LU-0.8 25L LU-0.8 17 17 25L_A LU-0.8 10 10 TRANSMISSION SOLENOID VALVE Y2 2 DIAGNOSTIC TECM GROUND 2 0_DQ Bk-0.8 SHEET 1 - 221F GROUND CAB
3 TRANSMISSION SOLENOID VALVE Y3 K1 3 25M LU-0.8 25M LU-0.8 18 18 25M_A LU-0.8 32 32 TRANSMISSION SOLENOID VALVE Y3 5 TRANSMISSION ENABLE LAMP SIGNAL 5 32J_C Y-0.8
4 TRANSMISSION SOLENOID VALVE Y4 K3 4 25N LU-0.8 25N LU-0.8 19 19 25N_A LU-0.8 55 55 TRANSMISSION SOLENOID VALVE Y4 6 NONE 6
5 TRANSMISSION SOLENOID VALVE Y5 KV 5 25P LU-0.8 25P LU-0.8 20 20 25P_A LU-0.8 9 9 TRANSMISSION SOLENOID VALVE Y5 7 BACKUP ALARM PULL-DOWN 7 35C Y-0.8
6 TRANSMISSION SOLENOID VALVE Y6 K2 6 25J LU-0.8 25J LU-0.8 21 21 25J_A LU-0.8 51 51 TRANSMISSION SOLENOID VALVE Y6 8 RIDE CONTROL SWITCHED POWER VPS2 8 58H_B W-0.8 SHEET 5 - 50F (72)
7 OUTPUT SWITCHED POWER VPSI 7 25S LU-0.8 25S LU-0.8 22 22 39 39 VALVE BODY TEMPERATURE SENDER 11 NONE 11 0_DAV Bk-0.8 SHEET 1 - 221F GROUND CAB
8 VALVE BODY TEMPERATURE SIGNAL 8 36T P-0.8 36T P-0.8 5 5 36T_A P-0.8 17 17 TRANSMISSION FILTER MAINTENANCE SWITCH 12 OUTPUT SWITCHED POWER VPS1 12
9 VALVE BODY TEMPERATURE RETURN 9 36R_C P-0.8 32F Y-1.0 31 31 32F_A Y-0.8 4 4 OUTPUT SPEED SENSOR GROUND 13 OUTPUT SWITCHED POWER VPS2 13 3
10 NONE 10 0_HE Bk-1.0 28 28 0_DN Bk-0.8 62 62 OUTPUT SPEED SIGNAL 14 NONE 14 5 28
11 NONE 11 25D LU-1.0 10 10 25D_A LU-0.8 46 46 TEMPERATURE/FILTER RETURN 15 DIAGNOSTIC SIGNAL 15 37D_A P-0.8 37D_A P-0.8 2 10
12 NONE 12 19A Or-1.0 29 29 19A_M Or-0.8 49 49 TORQUE CONVERTER OUTPUT TEMPERATURE SENDER 16 NONE 16 6 7 7 0_DAM Bk-1.0 SHEET 5 - 44F (71) 174
13 NONE 13 24 24 19 19 ENGINE SPEED SIGNAL 18 DIAGNOSTIC SIGNAL 18 37E P-0.8 37E P-0.8 4 8 8 49_Q S-1.0 SHEET 5 - 44F (71) SHEET 4 - SPL_J1 0_JB Bk-1.0
14 NONE 14 36R_A P-1.0 12 12 36R_E P-0.8 3 3 SPEED SENSOR GROUND 20 FNR FORWARD SIGNAL 20 26F_B LU-0.8 1 9 37
15 NONE 15 36G P-1.0 13 13 36G_A P-1.0 42 42 INTERMEDIATE SPEED 21 PARKING BRAKE RELAY OUT 21 52P_A W-0.8 SHEET 3 - 55F (52) 6
35R_A Y-1.0
108F BB
16 NONE 16 14 14 41 41 TURBINE SPEED SIGNAL 22 TRANSMISSION KICKDOWN SIGNAL 22 25Y_B LU-0.8 5
Q MODULATED AND CURRENT CONTROLLED 102 25A W-0.8 7 7 25A_A LU-0.8 23 TIME DELAY FUSED POWER 23 19T_A Or-0.8 SHEET 1 - 18F FUSE BLOCK 4 128F 128M 175
0_DM Bk-0.8
19A_D Or-0.8
0_HD Bk-1.0 11 11 24 NONE 24 1
REAR HOOD
25C W-0.8 9 9 25C_A LU-0.8 25 CONTROLLER AREA NETWORK H 25 50H_A Y-0.5 SHEET 3 - 13F CAB PEDESTAL 3 3 25H LU-0.8 26 26
25B W-0.8 8 8 25B_A LU-0.8 26 CONTROLLER AREA NETWORK L 26 50L_B G-0.5 30 2 2 19A_Q Or-0.8 23 23 CHASSIS HARNESS
27 CONTROLLER AREA NETWORK L 27 50L_C G-0.5 50L_A G-0.5 SHEET 3 - 13F CAB 22 22 HARNESS
22M 22F 41F
28 NONE 28 SPL_D5 PEDESTAL 20 20
TRANSMISSION CAB MAIN 29 TRANSMISSION AUTO SIGNAL 29 25H LU-0.8 19 19
11 32F Y-1.0 HARNESS HARNESS 30 FNR REVERSE SIGNAL 30 26R_B LU-0.8 17 17
23 22 36R_B P-1.0 36R_A P-1.0 31 TRANSMISSION ENABLE SIGNAL 31 26E LU-0.8 2 2
510 OHMS 31 SPL_H1 33 NONE 33
SPL_D15 6 6 35R_B Y-1.0
34 NONE 34 19A_L Or-0.8 19A_T Or-0.8 30 30 19A_A Or-1.0 AA
35 NONE 35 31 31 25G LU-1.0 BB 32
36 NONE 36 SHEET 3 - 13F CAB PEDESTAL 19A_S Or-0.8
4
37 NONE 37 21F 21M
22 36R_D P-1.0 38 NONE SHEET 1 - 18F FUSE BLOCK 19A_N Or-0.8 Normally Closed
24 11 36G P-1.0
38
CAB REAR CHASSIS Opens at 24.1 bar (350 psi)
40 NONE 40
MAIN HARNESS
19A_M Or-0.8
142 43 FORWARD SIGNAL 43 25F_A LU-0.8
44 FNR NEUTRAL SIGNAL 44 26N_B LU-0.8 HARNESS
3521 ohms at 20C (68F)
45 CAB SWITCHED POWER 45 19A_K Or-0.8 19A_K Or-0.8
11 0_HE Bk-1.0 47 NONE 47
19 22 25D LU-1.0 48 NONE 48
33 19A Or-1.0 50 NONE 50 10
100 52 NONE 52 7 7 0_DAK Bk-1.0 SHEET 5 - 36F (54)
53 NONE 53 8 8 49_N S-1.0 SHEET 5 - 36F (54)
54 NONE 54 9
11 25A W-0.8 57 RIDE CONTROL RELAY SINK 0_DD Bk-0.8 SHEET 5 - 50F (72)
20 22 0_HF Bk-0.8 SPL_H2
57
31
6
58 NONE 58 5
101 59 NONE 59 1 1 25G_A LU-0.8
60 NONE 60 4 25G_B LU-0.8
61 NONE 61 3 3
63 1ST AND 4TH GEAR SIGNAL 63 25Z_A LU-0.8 2 2 19A_R Or-0.8
22 0_HG Bk-0.8 64 REVERSE SIGNAL 64 25R_A LU-0.8
21 11 25C W-0.8 65 3RD AND 4TH GEAR SIGNAL 65 25W_A LU-0.8 38F
95 66 DECLUTCH SWITCH 66 25G_B LU-0.8
67 NEUTRAL SIGNAL 67 25T_D LU-0.8 SHEET 1 - SPL_D18
68 TIME DELAY FUSED POWER 68 19T_B Or-0.8 SHEET 1 - 18F FUSE BLOCK
22 0_HH Bk-0.8 29
22 11 25B W-0.8
96
2 1
2 1 20M
SPL_D11
25Y_C LU-0.8 19A_U Or-0.8
183
FORWARD REVERSE NEUTRAL Bk A A
183 TRANSMISSION SHIFTER G B B 25W LU-0.8
1 2 3 4 1 2 3 4 1 2 3 4 U C C 25Z LU-0.8 25W LU-0.8 48 48 25W_A LU-0.8
A NONE D D 25Y LU-0.8 25Z LU-0.8 49 49 25Z_A LU-0.8
B THIRD AND FOURTH GEAR SIGNAL 25Y LU-0.8 50 50 25Y_A LU-0.8
C FIRST AND FOURTH GEAR SIGNAL 70 24 24
D TRANSMISSION KICKDOWN SIGNAL R A A 19A_H Or-0.8 SHEET 3 - 72 (46) 47 47
Q INDICATES HIGH (24 VOLTS) Y B B 25F LU-0.8 25F LU-0.8 44 44 25F_A LU-0.8
K C C 25R LU-0.8 25R LU-0.8 45 45 25R_A LU-0.8
S D D 25T_A LU-0.8 SHEET 1 - 92 27 27
FORWARD REVERSE NEUTRAL 33 33
70 TRANSMISSION SHIFTER
1 2 3 4 1 2 3 4 1 2 3 4 SPL_K2 37 37 SPL_D6 50G_E Bk-0.5 SPL_D7
A TRANSMISSION CONTROL POWER 27 50G_C R-0.5 50G_A Bk-0.8 34 34 50G_D Bk-0.8 50G_G Bk-0.8 SHEET 1 - 219F GROUND CAB
B FORWARD SIGNAL 50G_F R-0.5
C REVERSE SIGNAL SPL_K3 50G_B Bk-0.5 13M 13F
D NEUTRAL SIGNAL PEDESTAL CAB MAIN LOCATED NEAR TECM
Q INDICATES HIGH (24 VOLTS) HARNESS HARNESS CONNECTOR 19F
LOCATED NEAR INSTRUMENT
CLUSTER CONNECTOR 76
1. Batteries 11B. Grid Heater Temperature Sensor (Option) 22. Turbine Speed Sensor 34. FNR Switch 45. Program Reset Switch 57. Redundant Brake Pressure Switches 68. Secondary Steering Motor (Option) 79. Rear Wiper Motor 91. Cigar Lighter (Option) 103. Hazard Switch 114. Five Position Rotary Lamp
2. Master Disconnect Switch 11C. Grid Heater Controller (Option) 23. Filter Maintenance Switch 35. Backup Alarm Relay - Number 7 46. Parking Brake Switch 58. Relay Socket - Number 11 68A. Secondary Steering Solenoid (Option) 80. Horn Relay - Number 5 92. Power Converter - 24 volts to 12 volts (Option) 104. Turn Signal, Hi/Low Beam, and Horn Switch
3. Engine Fuel Solenoid 12. Neutral Start Relay - Number 8 24. Torque Converter Output Temperature Sender 36. Backup Alarm Disable Switch 47. Instrument Cluster 59. Detent Switch 69. Pin Engage Switch (Option) 81. Horn 93. Power Outlet (Option) Switch 115. High/Low Beam Relay -
4. Alternator 13. Ignition Switch 25. Transmission Solenoid Valve and Temperature Sensors (TUV road approved machines only) 48. Pilot Control Switch 60. Bucket Control Valve Electromagnetic Detents 70. Pin Engage Solenoid (Option) 82. Seat Compressor and Switch (Option) 94. Remote Radio or 24 Volt Radio (Option) 105. Flasher Module Number 13
5. Starter Motor 14. Ignition Relay - Number 1 26. Transmission Electronic Control Module 37. Backup Alarm 49. Up/Down Count Switch 61. Return-To-Travel/Float Switch 71. Ride Control Switch 83. Blower Switch 95. 12 Volt Radio (Option) 106. Left-Hand Rear Combination Lamp 116. License Plate Lamp
6. Starting Relay 15. Ignition Relay - Number 2 27. Transmission Shifter 38. Brake Warning Pressure Switch 50. Engine Oil Pressure Switch 62. Return-To-Dig Proximity Switch 72. Ride Control Relay - Number 4 84. Blower Motor Speed Resistors with Thermal Fuse 96. Radio Power Converter - 24 volts to 12 volts (Option) 107. Right-Hand Rear Combination Lamp 117. Dome Lamp
7. Fuel Filter Heater Relay - Number 16 16. Accessory Relay - Number 3 28. Diagnostic Connector 39. Coolant Level Sender 51. Pilot Control Relay - Number 10 63. Height Control/Return-To-Travel Proximity Switch 73. Ride Control Solenoid 85. Blower Motor 97. Left Speaker (Option) 108. Left-Hand Front Combination Lamp 118. Courtesy Lamp
8. Fuel Filter Heater Switch 17. Voltmeter Relay - Number 12 29. Transmission Kick-down Switch 40. Fuel Level Sender 52. Parking Brake Relay - Number 9 64. Float Pressure Switch 74. Front Wiper Motor 86. Air Conditioning Low Pressure Switch 98. Right Speaker (Option) 109. Right-Hand Front Combination Lamp
9. First Fuel Filter Heater 18. Time Delay Module 30. Transmission Auto Switch 41. Hydraulic Oil Temperature Sender 53. Parking Brake Solenoid 64A. Rollback Pressure Switch (Option) 75. Front Wiper and Washer Switch 87. Air Conditioning High Pressure Switch 99. Beacon Switch 110. Left-Hand Rear Work Lamp
10. Second Fuel Filter Heater 19. Output Speed Sensor 31. Declutch Switch 42. Hydraulic Filter Restriction Switch 54. Pilot Pressure Solenoid 65. Float Solenoid 76. Front Washer Pump Motor 88. Thermostat Switch 100. Rotating Beacon 111. Right-Hand Rear Work Lamp
11. Grid Heater Relay - Number 15 (Option) 20. Engine Speed Sensor 32. Brake Declutch Pressure Switch 43. Engine Coolant Temperature Sender 55. Fan Reversing Switch (Option) 66. Secondary Steering Module (Option) 77. Rear Wiper and Washer Switch 89. Compressor Clutch Lockout Relay - Number 14 101. Brake Lamp Pressure Switch 112. Left-Hand Front Work Lamp
11A. Grid Heater (Option) 21. Intermediate Speed Sensor 33. Transmission Enable Switch 44. Air Filter Restriction Switch 56. Fan Reversing Solenoid (Option) 67. Secondary Steering Pressure Switch (Option) 78. Rear Washer Pump Motor 90. Compressor Clutch 102. Brake Lamps Relay - Number 6 113. Right-Hand Front Work Lamp
WIRE IDENTIFICATION CIRCUIT LEGEND ACTUATOR SYMBOLS HOUSINGS CONTACT SYMBOLS FUSE AND CIRCUIT BREAKER NOTES
23F_A W-2.0 1 4 5 6
14
1 4 7 10
1. LEVER RELEASED
1 4
1. VACUUM SWITCH
1 4
1. SINGLE POLE,
1
1. FUSE 1. 209M and 209F disconnected when backup alarm disable switch is installed (TUV road approved machines only).
1. WIRE NUMBER 10
54 2. LEVER ACTUATED 2. PRESSURE SWITCH SINGLE THROW 2. CIRCUIT BREAKER, 2. Resistors part of ground wire assembly.
2. WIRE COLOR SYMBOL SPL_G2 V M A2 A1
3. 64M and 64F connected for North American machines, opposite side steady ON. 64M and 64F disconnected for European machines, opposite side OFF.
3. WIRE SIZE 1 2 3 21C_C W-1.0 A A 1 1 14_B LG-0.8 SHEET 6 - 253F (54) D+ 3. LIQUID LEVEL FLOAT 3. TEMPERATURE SWITCH 2. SINGLE POLE, AUTOMATIC RESET
0_GA Bk-2.0 B B 2 2
+ 4. PRESSURE 4. MOTOR DOUBLE THROW 3. CIRCUIT BREAKER, 4. 217F and 217M disconnected when engine shutdown relay special feature is installed.
9 R
Bk = BLACK LU = LIGHT BLUE S = GRAY 2 3 93M 93F 7 - 2 5 8 11 5. HAND OPERATED 2 5 5. LAMP 2 3. DOUBLE POLE, 2 MANUAL RESET 5. Used only on 621D.
21M 21F
DU = DARK BLUE N = BROWN T = TAN XXXX XXXX 8 11 12 13 6. TEMPERATURE SINGLE THROW
XXXX XXXX 15 6. On 521D connector 289 connected to fuel filter heater switch; on 621D connector 291 connected.
G = GREEN Or = ORANGE U = BLUE 7. COIL P 4. DOUBLE POLE, 7. Used only when grid heater option installed.
K = PINK P = PURPLE (VIOLET) W = WHITE 8. VARIABLE RESISTOR DOUBLE THROW
LG = LIGHT GREEN 1. SPLICE IDENTIFICATION 6. FEMALE CONNECTOR 11. SCHEMATIC SHEET NUMBER FOR CIRCUIT CONTINUATION 9. RESISTOR
R = RED Y = YELLOW
2. CIRCUIT CROSSING (NOT 7. CONNECTOR IDENTIFICATION 12. CONNECTION POINT ON SCHEMATIC 3 6 9 12 10. DIODE 3 3 3 ELECTRICAL SCHEMATIC P.I.N. JEE0135501 AND ABOVE
CONNECTED) 8. HARNESS IDENTIFICATION 13. COMPONENT NUMBER (IF ASSIGNED)
SHOWS POWER - MASTER DISCONNECT SWITCH IN ON POSITION 3. CIRCUIT CONNECTED 9. INDICATES PARTIAL CONNECTOR 14. COMPONENT NUMBER
A 11.
12A.
LIGHT EMITTING DIODE
MOMENTARY CONTACT T 521D Z-BAR, 521D XR, and 521D XT WHEEL LOADERS
4. WIRE IDENTIFICATION 10. CIRCUIT IDENTIFICATION 15. INDICATES INTERNALLY GROUNDED COMPONENT B
SHOWS POWER - KEY SWITCH IN ON POSITION 12B. MAINTAINED CONTACT Additional copies of this Hydraulic and Electrical Schematic can be ordered throughTechnical Publications Distribution System. The Part Number is 6-49280
BC02M034
Copyright
Normally Open
Closes at 62 bar (900 psi)
AA 33R_A Y-1.0
57 BB 0_L Bk-1.0
157
Normally Open
Closes at 62 bar (900 psi)
76 INSTRUMENT CLUSTER
1 CLUSTER MAIN FUSED POWER 1 19V_A Or-0.8 19V_A Or-0.8 1 1 19V Or-0.8 SHEET 1 - 18F FUSE BLOCK 19D_A Or-1.0 SHEET 1 - 18F FUSE BLOCK
2 INSTRUMENT CLUSTER FUSED DELAYED POWER 2 19S_B Or-0.8 29 29 30 30 19D_B Or-1.0
3 LOW BRAKE PRESSURE WARNING 3 33P_B Y-0.8 33P_B Y-0.8 3 3 33P_A Y-0.8 87 87 52P_B W-0.8
4 COOLANT LEVEL SIGNAL 4 31D_B Y-0.8 31D_B Y-0.8 4 4 31D_A Y-0.8 52 87a 87A 52P_A W-0.8 SHEET 2 - 19F (26)
5 SECONDARY STEERING LOW PRESSURE SIGNAL 5 35X_F Y-0.8 35X_F Y-0.8 5 5 35X_E Y-0.8 SHEET 5 - 1F CAB FRONT CHASSIS 85 85 52C_A W-0.8
6 AIR FILTER RESTRICTION SWITCH SIGNAL 6 31F_C Y-0.8 31F_C Y-0.8 6 6 31F_B Y-0.8 86 86
7 HYDRAULIC FILTER RESTRICTION SWITCH SIGNAL 7 31H_B Y-0.8 31H_B Y-0.8 7 7 31H_A Y-0.8 55F
8 ANALOG GROUND 8 0_KP Bk-0.8 0_KP Bk-0.8 8 8 0_DAU Bk-0.8 SHEET 1 - 22F CAB TRANSMISSION
9 PARKING BRAKE SIGNAL 9 33U Y-0.8 9 9
10 AIR CONDITIONING TELLTALE 10 61R_G Or-0.8 61R_G Or-0.8 10 10 61R_F Or-0.8 SHEET 5 - SPL_D1
11 NONE 11 11 11
12 WORK LAMP TELLTALE SIGNAL 12 42R_A Y-0.8 42R_A Y-0.8 12 12 42R_C DU-0.8 SHEET 4 - 32F (114)
13 BEACON TELLTALE 13 46_B K-0.8 46_B K-0.8 13 13 46_A K-0.8 SHEET 4 - 23F CAB ROOF
14 NONE 14 14 14
15 HIGH BEAM TELLTALE 15 18C_C Or-0.8 18C_C Or-0.8 15 15 18C_B Or-0.8 SHEET 1 - 18F FUSE BLOCK
16 LEFT TURN SIGNAL 16 45L_F N-0.8 45L_F N-0.8 16 16 45L_E N-0.8 SHEET 4 - SPL_D10
17 RIGHT TURN SIGNAL 17 45R_F N-0.8 45R_F N-0.8 17 17 45R_C N-0.8 SHEET 4 - SPL_D20
18 ENGINE COOLANT TEMPERATURE SIGNAL 18 36C_C P-0.8 36C_C P-0.8 18 18 36C_B P-0.8
19 FUEL LEVEL SIGNAL 19 36F_B P-0.8 36F_B P-0.8 19 19 36F_A P-0.8 19C_D Or-1.0 SHEET 1 - 18F FUSE BLOCK
20 HYDRAULIC OIL TEMPERATURE SIGNAL 20 36H_B P-0.8 36H_B P-0.8 20 20 36H_A P-0.8 19C_E Or-1.0
21 CONTROLLER AREA NETWORK T 21 50T Bk-0.8 21 21 30 30 53P_C W-0.8 SHEET 5 - 1F CAB FRONT CHASSIS
22 ENGINE OIL PRESSURE SIGNAL 22 36P_C P-0.8 36P_C P-0.8 22 22 36P_B P-0.8 87 87 53P_B W-0.8 SHEET 5 - 36F (59)
23 ENGINE SHUTDOWN SIGNAL 23 23C W-0.8 23C W-0.8 23 23 23C_A W-0.8 SHEET 1 - 57F (58) 51 87a 87A 53P_A W-0.8
24 PROGRAM SIGNAL 24 37P P-0.8 33R_E Y-0.8 28 28 33R_D Y-0.8 85 85 53C_A W-0.8
25 RESET SIGNAL 25 37R_B P-0.8 52C W-0.8 30 30 52C_A W-0.8 86 86 19C_E Or-1.0
26 UP COUNT SIGNAL 26 37U P-0.8 50L G-0.5 31 31 50L_A G-0.5 SHEET 2 - SPL_D5 56F
27 DOWN COUNT SIGNAL 27 37D P-0.8 50H Y-0.5 32 32 50H_A Y-0.5 SHEET 2 - 19F (26) 0_DB Bk-0.8 SHEET 1 - 219F GROUND CAB
28 REDUNDANT BRAKE SWITCH SIGNAL 28 33R_E Y-0.8 54 54
29 PILOT LOCKOUT SIGNAL 29 31L Y-0.8 26 26
30 PARKING BRAKE SIGNAL 30 52C W-0.8 44_G T-0.8 35 35 44_F T-0.8 SHEET 4 - SPL_D9 A B 89M
31 CONTROLLER AREA NETWORK L 31 50L G-0.5 53C W-0.8 36 36 53C_A W-0.8 A B
32 CONTROLLER AREA NETWORK H 32 50H Y-0.5 0_KR Bk-0.8 38 38 0_DAB Bk-0.8 SHEET 1 - 22F CAB TRANSMISSION
33 CONTROLLER AREA NETWORK T 33 50T Bk-0.8 0_KM Bk-0.8 53 53 0_DAC Bk-0.8 SHEET 1 - 222F RELAY GROUND
34 NONE 34 0_KD Bk-0.8 39 39 0_DL Bk-0.8 SHEET 1 - 22F CAB TRANSMISSION 54
35 BRAKE LAMP SIGNAL 35 44_G T-0.8 37R_A P-0.8 25 25 37R_C P-0.8 SHEET 1 - 63M (18)
36 PILOT CONTROL SIGNAL 36 53C W-0.8 19S_A Or-0.8 2 2 19S Or-0.8 SHEET 1 - 18F FUSE BLOCK
37 SIGNAL GROUND 37 0_KQ Bk-0.8 0_KQ Bk-0.8 SPL_K1 19C Or-0.8 68 68 19C_C Or-0.8 SHEET 5 - SPL_D24 29.9 ohms at 20C (68F) Joystick
38 SIGNAL GROUND 38 0_KE Bk-0.8 0_KE Bk-0.8 19A_G Or-0.8 43 43 19A_S Or-0.8 SHEET 2 - SPL_D15 27.4 ohms at 20C (68F) Single Axis
39 SIGNAL GROUND 39 0_KD Bk-0.8 40 40
40 NONE 40
76 6 13M 13F
7 7 0_KM Bk-0.8 PEDESTAL CAB MAIN
8 8 0_KL Bk-0.8 HARNESS HARNESS
10 49_E S-0.8
4
45 9 6 0_KL Bk-0.8
1 1 37R_A P-0.8 7 7 0_KK Bk-0.8 3521 ohms at 20C (68F)
5 37R_B P-0.8 8 8 49_E S-0.8 BB 0_BE Bk-1.0 SHEET1 - SPL_B1
3 3 37P P-0.8 4 49_D S-0.8 43 AA 36C P-1.0
2 2 1A_B R-0.8 SHEET 1 - 69 (13) 10
49 5 138
75
1 1 37D P-0.8
9
3 3 37U P-0.8
2 2 19S_A Or-0.8 36C_B P-0.8 4 4 36C_A P-1.0 13 13
74 31F_B Y-0.8 3 3 31F_A Y-1.0 7 7 31F Y-1.0 0_BD Bk-1.0 SHEET1 - SPL_B1
36P_B P-0.8 6 6 36P_A P-1.0 6 6 36P P-1.0
19S_B Or-0.8
22F 22M 94F 94M
117 A B
CAB MAIN TRANSMISSION TRANSMISSION ENGINE 148 A B
HARNESS HARNESS HARNESS HARNESS COMMON
Normally Closed
9 0_KK Bk-0.8 50 Opens at 0.69 bar (10 psi) 44
7 7 0_KJ Bk-0.8
8 8 49_D S-0.8 NORMALLY NORMALLY
5 49_C S-0.8 OPEN CLOSED Normally Open
6 Closes at 0.06 bar ( 0.928 psi)
46 10
4
1
3 3 33U Y-0.8 91 OHM RESISTOR 240 OHM RESISTOR
2 2 19A_H Or-0.8 SHEET 2 - 70 (27) YELLOW WIRE BLACK WIRE
19A_G Or-0.8 (NOTE 2) (NOTE 2)
72
ENGINE GROUND
10 0_KJ Bk-0.8
7 7 0_KH Bk-0.8 SHEET 4 - 71 (103)
8 8 49_C S-0.8
1 49_B S-0.8 SHEET 4 - 71 (103)
9
48 5
6
4
3 3 31L Y-0.8
2 2 19C Or-0.8
37
1. Batteries 13. Ignition Switch 25. Transmission Solenoid Valve and Temperature Sensors 36. Backup Alarm Disable Switch 47. Instrument Cluster 59. Detent Switch 69. Pin Engage Switch (Option) 81. Horn 93. Power Outlet (Option) 105. Flasher Module 117. Dome Lamp
2. Master Disconnect Switch 14. Ignition Relay - Number 1 26. Transmission Electronic Control Module (TUV road approved machines only) 48. Pilot Control Switch 60. Bucket Control Valve Electromagnetic Detents 70. Pin Engage Solenoid (Option) 82. Seat Compressor and Switch (Option) 94. Remote Radio or 24 Volt Radio (Option) 106. Left-Hand Rear Combination Lamp 118. Courtesy Lamp
3. Fuel Shutoff Solenoid 15. Ignition Relay - Number 2 27. Transmission Shifter 37. Backup Alarm 49. Up/Down Count Switch 61. Return-To-Travel/Float Switch 71. Ride Control Switch 83. Blower Switch 95. 12 Volt Radio (Option) 107. Right-Hand Rear Combination Lamp
4. Alternator 16. Accessory Relay - Number 3 28. Diagnostic Connector 38. Brake Warning Pressure Switch 50. Engine Oil Pressure Switch 62. Return-To-Dig Proximity Switch 72. Ride Control Relay - Number 4 84. Blower Motor Speed Resistors with Thermal Fuse 96. Radio Power Converter - 24 volts to 12 volts (Option) 108. Left-Hand Front Combination Lamp
5. Starter Motor 17. Voltmeter Relay - Number 12 29. Transmission Kick-down Switch 39. Coolant Level Sender 51. Pilot Control Relay - Number 10 63. Height Control/Return-To-Travel Proximity Switch 73. Ride Control Solenoid 85. Blower Motor 97. Left Speaker (Option) 109. Right-Hand Front Combination Lamp
6. Starting Relay 18. Time Delay Module 30. Transmission Auto Switch 40. Fuel Level Sender 52. Parking Brake Relay - Number 9 64. Float Pressure Switch 74. Front Wiper Motor 86. Air Conditioning Low Pressure Switch 98. Right Speaker (Option) 110. Left-Hand Rear Work Lamp
7. Fuel Relay 19. Output Speed Sensor 31. Declutch Switch 41. Hydraulic Oil Temperature Sender 53. Parking Brake Solenoid 64A. Rollback Pressure Switch (Option) 75. Front Wiper and Washer Switch 87. Air Conditioning High Pressure Switch 99. Beacon Switch 111. Right-Hand Rear Work Lamp
8. Ether Start Temperature Switch 20. Engine Speed Sensor 32. Brake Declutch Pressure Switch 42. Hydraulic Filter Restriction Switch 54. Pilot Pressure Solenoid 65. Float Solenoid 76. Front Washer Pump Motor 88. Thermostat Switch 100. Rotating Beacon 112. Left-Hand Front Work Lamp
9. Ether Start Solenoid 21. Intermediate Speed Sensor 33. Transmission Enable Switch 43. Engine Coolant Temperature Sender 55. Fan Reversing Switch (Option) 66. Secondary Steering Module (Option) 77. Rear Wiper and Washer Switch 89. Compressor Clutch Lockout Relay - Number 14 101. Brake Lamp Pressure Switch 113. Right-Hand Front Work Lamp
10. Ether Start Relay - Number 6 22. Turbine Speed Sensor 34. FNR Switch 44. Air Filter Restriction Switch 56. Fan Reversing Solenoid (Option) 67. Secondary Steering Pressure Switch (Option) 78. Rear Washer Pump Motor 90. Compressor Clutch 102. Brake Lamps Relay - Number 15 114. Five Position Rotary Lamp Switch
11. Ether Start Switch 23. Filter Maintenance Switch 35. Backup Alarm Relay - Number 7 45. Program Reset Switch 57. Redundant Brake Pressure Switches 68. Secondary Steering Motor (Option) 79. Rear Wiper Motor 91. Cigar Lighter (Option) 103. Hazard Switch 115. High/Low Beam Relay - Number 13
12. Neutral Start Relay - Number 8 24. Torque Converter Output Temperature Sender 46. Parking Brake Switch 58. Relay Socket - Number 11 68A. Secondary Steering Solenoid (Option) 80. Horn Relay - Number 5 92. Power Converter - 24 volts to 12 volts (Option) 104. Turn Signal, Hi/Low Beam, and Horn Switch 116. License Plate Lamp
WIRE IDENTIFICATION CIRCUIT LEGEND ACTUATOR SYMBOLS HOUSINGS CONTACT SYMBOLS FUSE AND CIRCUIT BREAKER NOTES
1 5 6 1 4 7 10 1 4 1 4 1
1. WIRE NUMBER 23F_A W-2.0 4 10 14 1. LEVER RELEASED 1. VACUUM SWITCH 1. SINGLE POLE, 1. FUSE 1. 209M and 209F disconnected when backup alarm disable switch is installed (TUV road approved machines only).
54 2. LEVER ACTUATED 2. PRESSURE SWITCH SINGLE THROW 2. CIRCUIT BREAKER, 2. Resistors part of ground wire assembly.
2. WIRE COLOR SYMBOL SPL_G2 V M A2 A1
3. WIRE SIZE 1 2 3 21C_C W-1.0 A A 1 1 14_B LG-0.8 SHEET 6 - 253F (54) D+ 3. LIQUID LEVEL FLOAT 3. TEMPERATURE SWITCH 2. SINGLE POLE, AUTOMATIC RESET 3. 64M and 64F connected for North American machines, opposite side steady ON.
0_GA Bk-2.0 B B 2 2
+ 4. PRESSURE 4. MOTOR DOUBLE THROW 3. CIRCUIT BREAKER,
9 R 64M and 64F disconnected for European machines, opposite side OFF.
Bk = BLACK LU = LIGHT BLUE S = GRAY 2 3 93M 93F 7 2 5 8 11 5. HAND OPERATED 2 5 5. LAMP 2 3. DOUBLE POLE, 2 MANUAL RESET
21M 21F 4. 217F and 217M disconnected when engine shutdown relay special feature is installed.
DU = DARK BLUE N = BROWN T = TAN XXXX XXXX 8 11 12 13 6. TEMPERATURE SINGLE THROW
XXXX XXXX 15
G = GREEN Or = ORANGE U = BLUE 7. COIL P 4. DOUBLE POLE,
K = PINK P = PURPLE (VIOLET) W = WHITE 8. VARIABLE RESISTOR DOUBLE THROW
LG = LIGHT GREEN R = RED Y = YELLOW
1.
2.
SPLICE IDENTIFICATION
CIRCUIT CROSSING (NOT CONNECTED)
6.
7.
FEMALE CONNECTOR
CONNECTOR IDENTIFICATION
11.
12.
SCHEMATIC SHEET NUMBER FOR CIRCUIT CONTINUATION
CONNECTION POINT ON SCHEMATIC
9. RESISTOR ELECTRICAL SCHEMATIC
3 6 9 12 10. DIODE 3 3 3
Normally Open
Closes at 62 bar (900 psi)
AA 33R_A Y-1.0
57 BB 0_L Bk-1.0
157
Normally Open
Closes at 62 bar (900 psi)
76 INSTRUMENT CLUSTER
1 CLUSTER MAIN FUSED POWER 1 19V_A Or-0.8 19V_A Or-0.8 1 1 19V Or-0.8 SHEET 1 - 18F FUSE BLOCK 19D_A Or-1.0 SHEET 1 - 18F FUSE BLOCK
2 INSTRUMENT CLUSTER FUSED DELAYED POWER 2 19S_B Or-0.8 29 29 30 30 19D_B Or-1.0
3 LOW BRAKE PRESSURE WARNING 3 33P_B Y-0.8 33P_B Y-0.8 3 3 33P_A Y-0.8 87 87 52P_B W-0.8
4 COOLANT LEVEL SIGNAL 4 31D_B Y-0.8 31D_B Y-0.8 4 4 31D_A Y-0.8 52 87a 87A 52P_A W-0.8 SHEET 2 - 19F (26)
5 SECONDARY STEERING LOW PRESSURE SIGNAL 5 35X_F Y-0.8 35X_F Y-0.8 5 5 35X_E Y-0.8 SHEET 5 - 1F CAB FRONT CHASSIS 85 85 52C_A W-0.8
6 AIR FILTER RESTRICTION SWITCH SIGNAL 6 31F_C Y-0.8 31F_C Y-0.8 6 6 31F_B Y-0.8 86 86
7 HYDRAULIC FILTER RESTRICTION SWITCH SIGNAL 7 31H_B Y-0.8 31H_B Y-0.8 7 7 31H_A Y-0.8 55F
8 ANALOG GROUND 8 0_KP Bk-0.8 0_KP Bk-0.8 8 8 0_DAU Bk-0.8 SHEET 1 - 22F CAB TRANSMISSION
9 PARKING BRAKE SIGNAL 9 33U Y-0.8 9 9
10 AIR CONDITIONING TELLTALE 10 61R_G Or-0.8 61R_G Or-0.8 10 10 61R_F Or-0.8 SHEET 5 - SPL_D1
11 NONE 11 11 11
12 WORK LAMP TELLTALE SIGNAL 12 42R_A Y-0.8 42R_A Y-0.8 12 12 42R_C DU-0.8 SHEET 4 - 32F (114)
13 BEACON TELLTALE 13 46_B K-0.8 46_B K-0.8 13 13 46_A K-0.8 SHEET 4 - 23F CAB ROOF
14 NONE 14 14 14
15 HIGH BEAM TELLTALE 15 18C_C Or-0.8 18C_C Or-0.8 15 15 18C_B Or-0.8 SHEET 1 - 18F FUSE BLOCK
16 LEFT TURN SIGNAL 16 45L_F N-0.8 45L_F N-0.8 16 16 45L_E N-0.8 SHEET 4 - SPL_D10
17 RIGHT TURN SIGNAL 17 45R_F N-0.8 45R_F N-0.8 17 17 45R_C N-0.8 SHEET 4 - SPL_D20
18 ENGINE COOLANT TEMPERATURE SIGNAL 18 36C_C P-0.8 36C_C P-0.8 18 18 36C_B P-0.8
19 FUEL LEVEL SIGNAL 19 36F_B P-0.8 36F_B P-0.8 19 19 36F_A P-0.8 19C_D Or-1.0 SHEET 1 - 18F FUSE BLOCK
20 HYDRAULIC OIL TEMPERATURE SIGNAL 20 36H_B P-0.8 36H_B P-0.8 20 20 36H_A P-0.8 19C_E Or-1.0
21 CONTROLLER AREA NETWORK T 21 50T Bk-0.8 21 21 30 30 53P_C W-0.8 SHEET 5 - 1F CAB FRONT CHASSIS
22 ENGINE OIL PRESSURE SIGNAL 22 36P_C P-0.8 36P_C P-0.8 22 22 36P_B P-0.8 87 87 53P_B W-0.8 SHEET 5 - 36F (59)
23 ENGINE SHUTDOWN SIGNAL 23 23C W-0.8 23C W-0.8 23 23 23C_A W-0.8 SHEET 1 - 57F (58) 51 87a 87A 53P_A W-0.8
24 PROGRAM SIGNAL 24 37P P-0.8 33R_E Y-0.8 28 28 33R_D Y-0.8 85 85 53C_A W-0.8
25 RESET SIGNAL 25 37R_B P-0.8 52C W-0.8 30 30 52C_A W-0.8 86 86 19C_E Or-1.0
26 UP COUNT SIGNAL 26 37U P-0.8 50L G-0.5 31 31 50L_A G-0.5 SHEET 2 - SPL_D5 56F
27 DOWN COUNT SIGNAL 27 37D P-0.8 50H Y-0.5 32 32 50H_A Y-0.5 SHEET 2 - 19F (26) 0_DB Bk-0.8 SHEET 1 - 219F GROUND CAB
28 REDUNDANT BRAKE SWITCH SIGNAL 28 33R_E Y-0.8 54 54
29 PILOT LOCKOUT SIGNAL 29 31L Y-0.8 26 26
30 PARKING BRAKE SIGNAL 30 52C W-0.8 44_G T-0.8 35 35 44_F T-0.8 SHEET 4 - SPL_D9 A B 89M
31 CONTROLLER AREA NETWORK L 31 50L G-0.5 53C W-0.8 36 36 53C_A W-0.8 A B
32 CONTROLLER AREA NETWORK H 32 50H Y-0.5 0_KR Bk-0.8 38 38 0_DAB Bk-0.8 SHEET 1 - 22F CAB TRANSMISSION
33 CONTROLLER AREA NETWORK T 33 50T Bk-0.8 0_KM Bk-0.8 53 53 0_DAC Bk-0.8 SHEET 1 - 222F RELAY GROUND
34 NONE 34 0_KD Bk-0.8 39 39 0_DL Bk-0.8 SHEET 1 - 22F CAB TRANSMISSION 54
35 BRAKE LAMP SIGNAL 35 44_G T-0.8 37R_A P-0.8 25 25 37R_C P-0.8 SHEET 1 - 63M (18)
36 PILOT CONTROL SIGNAL 36 53C W-0.8 19S_A Or-0.8 2 2 19S Or-0.8 SHEET 1 - 18F FUSE BLOCK
37 SIGNAL GROUND 37 0_KQ Bk-0.8 0_KQ Bk-0.8 SPL_K1 19C Or-0.8 68 68 19C_C Or-0.8 SHEET 5 - SPL_D24 29.9 ohms at 20C (68F) Joystick
38 SIGNAL GROUND 38 0_KE Bk-0.8 0_KE Bk-0.8 19A_G Or-0.8 43 43 19A_S Or-0.8 SHEET 2 - SPL_D15 27.4 ohms at 20C (68F) Single Axis
39 SIGNAL GROUND 39 0_KD Bk-0.8 40 40
40 NONE 40
76 6 13M 13F
7 7 0_KM Bk-0.8 PEDESTAL CAB MAIN
8 8 0_KL Bk-0.8 HARNESS HARNESS
10 49_E S-0.8
4
45 9 6 0_KL Bk-0.8
1 1 37R_A P-0.8 7 7 0_KK Bk-0.8 3521 ohms at 20C (68F)
5 37R_B P-0.8 8 8 49_E S-0.8 BB 0_BE Bk-1.0 SHEET 1 - SPL_B1
3 3 37P P-0.8 4 49_D S-0.8 43 AA 36C P-1.0
2 2 1A_B R-0.8 SHEET 1 - 69 (13) 10
49 5 138
75
1 1 37D P-0.8
9
3 3 37U P-0.8
2 2 19S_A Or-0.8 36C_B P-0.8 4 4 36C_A P-1.0 13 13
74 31F_B Y-0.8 3 3 31F_A Y-1.0 7 7 31F Y-1.0 0_BD Bk-1.0 SHEET 1 - SPL_B1
36P_B P-0.8 6 6 36P_A P-1.0 6 6 36P P-1.0
19S_B Or-0.8
22F 22M 94F 94M
117 1 2
CAB MAIN TRANSMISSION TRANSMISSION ENGINE 148 A B
HARNESS HARNESS HARNESS HARNESS COMMON
Normally Closed
9 0_KK Bk-0.8 50 Opens at 0.69 bar (10 psi) 44
7 7 0_KJ Bk-0.8
8 8 49_D S-0.8 NORMALLY NORMALLY
5 49_C S-0.8 OPEN CLOSED Normally Open
6 Closes at - 0.06 bar (- 0.928 psi)
46 10
4
1
3 3 33U Y-0.8 91 OHM RESISTOR 240 OHM RESISTOR
2 2 19A_H Or-0.8 SHEET 2 - 70 (27) YELLOW WIRE BLACK WIRE
19A_G Or-0.8 (NOTE 2) (NOTE 2)
72
ENGINE GROUND
10 0_KJ Bk-0.8
7 7 0_KH Bk-0.8 SHEET 4 - 71 (103)
8 8 49_C S-0.8
1 49_B S-0.8 SHEET 4 - 71 (103)
9
48 5
6
4
3 3 31L Y-0.8
2 2 19C Or-0.8
37
1. Batteries 11B. Grid Heater Temperature Sensor (Option) 22. Turbine Speed Sensor 34. FNR Switch 45. Program Reset Switch 57. Redundant Brake Pressure Switches 68. Secondary Steering Motor (Option) 79. Rear Wiper Motor 91. Cigar Lighter (Option) 103. Hazard Switch 114. Five Position Rotary Lamp
2. Master Disconnect Switch 11C. Grid Heater Controller (Option) 23. Filter Maintenance Switch 35. Backup Alarm Relay - Number 7 46. Parking Brake Switch 58. Relay Socket - Number 11 68A. Secondary Steering Solenoid (Option) 80. Horn Relay - Number 5 92. Power Converter - 24 volts to 12 volts (Option) 104. Turn Signal, Hi/Low Beam, and Horn Switch
3. Engine Fuel Solenoid 12. Neutral Start Relay - Number 8 24. Torque Converter Output Temperature Sender 36. Backup Alarm Disable Switch 47. Instrument Cluster 59. Detent Switch 69. Pin Engage Switch (Option) 81. Horn 93. Power Outlet (Option) Switch 115. High/Low Beam Relay -
4. Alternator 13. Ignition Switch 25. Transmission Solenoid Valve and Temperature Sensors (TUV road approved machines only) 48. Pilot Control Switch 60. Bucket Control Valve Electromagnetic Detents 70. Pin Engage Solenoid (Option) 82. Seat Compressor and Switch (Option) 94. Remote Radio or 24 Volt Radio (Option) 105. Flasher Module Number 13
5. Starter Motor 14. Ignition Relay - Number 1 26. Transmission Electronic Control Module 37. Backup Alarm 49. Up/Down Count Switch 61. Return-To-Travel/Float Switch 71. Ride Control Switch 83. Blower Switch 95. 12 Volt Radio (Option) 106. Left-Hand Rear Combination Lamp 116. License Plate Lamp
6. Starting Relay 15. Ignition Relay - Number 2 27. Transmission Shifter 38. Brake Warning Pressure Switch 50. Engine Oil Pressure Switch 62. Return-To-Dig Proximity Switch 72. Ride Control Relay - Number 4 84. Blower Motor Speed Resistors with Thermal Fuse 96. Radio Power Converter - 24 volts to 12 volts (Option) 107. Right-Hand Rear Combination Lamp 117. Dome Lamp
7. Fuel Filter Heater Relay - Number 16 16. Accessory Relay - Number 3 28. Diagnostic Connector 39. Coolant Level Sender 51. Pilot Control Relay - Number 10 63. Height Control/Return-To-Travel Proximity Switch 73. Ride Control Solenoid 85. Blower Motor 97. Left Speaker (Option) 108. Left-Hand Front Combination Lamp 118. Courtesy Lamp
8. Fuel Filter Heater Switch 17. Voltmeter Relay - Number 12 29. Transmission Kick-down Switch 40. Fuel Level Sender 52. Parking Brake Relay - Number 9 64. Float Pressure Switch 74. Front Wiper Motor 86. Air Conditioning Low Pressure Switch 98. Right Speaker (Option) 109. Right-Hand Front Combination Lamp
9. First Fuel Filter Heater 18. Time Delay Module 30. Transmission Auto Switch 41. Hydraulic Oil Temperature Sender 53. Parking Brake Solenoid 64A. Rollback Pressure Switch (Option) 75. Front Wiper and Washer Switch 87. Air Conditioning High Pressure Switch 99. Beacon Switch 110. Left-Hand Rear Work Lamp
10. Second Fuel Filter Heater 19. Output Speed Sensor 31. Declutch Switch 42. Hydraulic Filter Restriction Switch 54. Pilot Pressure Solenoid 65. Float Solenoid 76. Front Washer Pump Motor 88. Thermostat Switch 100. Rotating Beacon 111. Right-Hand Rear Work Lamp
11. Grid Heater Relay - Number 15 (Option) 20. Engine Speed Sensor 32. Brake Declutch Pressure Switch 43. Engine Coolant Temperature Sender 55. Fan Reversing Switch (Option) 66. Secondary Steering Module (Option) 77. Rear Wiper and Washer Switch 89. Compressor Clutch Lockout Relay - Number 14 101. Brake Lamp Pressure Switch 112. Left-Hand Front Work Lamp
11A. Grid Heater (Option) 21. Intermediate Speed Sensor 33. Transmission Enable Switch 44. Air Filter Restriction Switch 56. Fan Reversing Solenoid (Option) 67. Secondary Steering Pressure Switch (Option) 78. Rear Washer Pump Motor 90. Compressor Clutch 102. Brake Lamps Relay - Number 6 113. Right-Hand Front Work Lamp
WIRE IDENTIFICATION CIRCUIT LEGEND ACTUATOR SYMBOLS HOUSINGS CONTACT SYMBOLS FUSE AND CIRCUIT BREAKER NOTES
23F_A W-2.0 1 4 5 6
14
1 4 7 10
1. LEVER RELEASED
1 4
1. VACUUM SWITCH
1 4
1. SINGLE POLE,
1
1. FUSE 1. 209M and 209F disconnected when backup alarm disable switch is installed (TUV road approved machines only).
1. WIRE NUMBER 10
54 2. LEVER ACTUATED 2. PRESSURE SWITCH SINGLE THROW 2. CIRCUIT BREAKER, 2. Resistors part of ground wire assembly.
2. WIRE COLOR SYMBOL SPL_G2 V M A2 A1
3. 64M and 64F connected for North American machines, opposite side steady ON. 64M and 64F disconnected for European machines, opposite side OFF.
3. WIRE SIZE 1 2 3 21C_C W-1.0 A A 1 1 14_B LG-0.8 SHEET 6 - 253F (54) D+ 3. LIQUID LEVEL FLOAT 3. TEMPERATURE SWITCH 2. SINGLE POLE, AUTOMATIC RESET
0_GA Bk-2.0 B B 2 2
+ 4. PRESSURE 4. MOTOR DOUBLE THROW 3. CIRCUIT BREAKER, 4. 217F and 217M disconnected when engine shutdown relay special feature is installed.
9 R
Bk = BLACK LU = LIGHT BLUE S = GRAY 2 3 93M 93F 7 - 2 5 8 11 5. HAND OPERATED 2 5 5. LAMP 2 3. DOUBLE POLE, 2 MANUAL RESET 5. Used only on 621D.
21M 21F
DU = DARK BLUE N = BROWN T = TAN XXXX XXXX 8 11 12 13 6. TEMPERATURE SINGLE THROW
XXXX XXXX 15 6. On 521D connector 289 connected to fuel filter heater switch; on 621D connector 291 connected.
G = GREEN Or = ORANGE U = BLUE 7. COIL P 4. DOUBLE POLE, 7. Used only when grid heater option installed.
K = PINK P = PURPLE (VIOLET) W = WHITE 8. VARIABLE RESISTOR DOUBLE THROW
LG = LIGHT GREEN 1. SPLICE IDENTIFICATION 6. FEMALE CONNECTOR 11. SCHEMATIC SHEET NUMBER FOR CIRCUIT CONTINUATION 9. RESISTOR
R = RED Y = YELLOW
2. CIRCUIT CROSSING (NOT 7. CONNECTOR IDENTIFICATION 12. CONNECTION POINT ON SCHEMATIC 3 6 9 12 10. DIODE 3 3 3 ELECTRICAL SCHEMATIC P.I.N. JEE0135501 AND ABOVE
CONNECTED) 8. HARNESS IDENTIFICATION 13. COMPONENT NUMBER (IF ASSIGNED)
SHOWS POWER - MASTER DISCONNECT SWITCH IN ON POSITION 3. CIRCUIT CONNECTED 9. INDICATES PARTIAL CONNECTOR 14. COMPONENT NUMBER
A 11.
12A.
LIGHT EMITTING DIODE
MOMENTARY CONTACT T 521D Z-BAR, 521D XR, and 521D XT WHEEL LOADERS
4. WIRE IDENTIFICATION 10. CIRCUIT IDENTIFICATION 15. INDICATES INTERNALLY GROUNDED COMPONENT B
SHOWS POWER - KEY SWITCH IN ON POSITION 12B. MAINTAINED CONTACT Additional copies of this Hydraulic and Electrical Schematic can be ordered throughTechnical Publications Distribution System. The Part Number is 6-49280
BC02M035
Copyright
185
31 1 0_KG Bk-0.8
H 45 1 64C Or-0.8
184
2 1 45B N-0.8
R 68
104 5 1 19B Or-0.8
67
L 1 1 45A N-0.8
66
B 1 0_KF Bk-0.8
187
A 1 64D Or-0.8
186
6
7 7 0_KH Bk-0.8 SHEET 3 - 37 (48)
8 8 49_B S-0.8 SHEET 3 - 37 (48)
9 49_A S-0.8
4
103 5
1
10
3 3 45H N-0.8
2 2 1B R-0.8
0_KG Bk-0.8
71
49_A S-0.8
64D Or-0.8
64C Or-0.8
19B Or-0.8
45H N-0.8
45A N-0.8
45B N-0.8
1B R-0.8
106 107
65 67 51 55 69 66 70 42 41 13M PEDESTAL HARNESS
STOP TURN TAIL REVERSE STOP TURN TAIL REVERSE 65 67 51 55 69 66 70 42 41 13F CAB MAIN HARNESS
64D_A Or-0.8
45H_A N-0.8
0_J Bk-1.0 0_JC Bk-1.0
45A_A N-0.8
45B_A N-0.8
C C 0_JA Bk-1.0 BB
1B_C R-0.8
49_F S-0.8
SPL_J1 168
128F 128M
REAR HOOD 10 0_DAW Bk-1.0 SHEET 2 - 118F (36)
0_JB Bk-1.0 SHEET 2 - 174 (37) 0_DAP Bk-1.0 SHEET 2 - 199F (33)
CHASSIS HARNESS 7 7
HARNESS 8 8 49_R S-1.0 SHEET 2 - 199F (33)
0_DX Bk-0.8 SHEET 1 - 220F GROUND CAB 9 49_T S-1.0 SHEET 2 - 118F (36)
6
SHEET 5 - 51F (80)
99 5
1 6 2 3 4 5 1 6 2 3 4 5 64C_A Or-0.8
1 6 2 3 4 5 125 1 6 2 3 4 5 127 4
SHEET 1 - 164 ENGINE GROUND 19B_A Or-0.8 SHEET 1 - 18F FUSE BLOCK 1
3 3 46_C K-1.0
18G_A Or-1.0
35A_B K-1.0
0_C Bk-1.0
44_B T-1.O
1B_E R-0.8
18G_A Or-1.0 SPL_E8 SHEET 1 - SPL_D17 1_M R-3.0
SPL_E2 SHEET 2 - 53F (35) 211F SHEET 1 - 18F FUSE BLOCK 41L_A K-2.0 3 3 56b
35A_A K-1.0 35A_C K-1.0 35A_C K-1.0 7 7 35A_D Y-08
SHEET 1 - 18F FUSE BLOCK FLASHER SHEET 1 - 18F FUSE BLOCK 41H K-2.0 4 4
56a
18F_A Or-1.0 18F_A Or-1.0 5 5 18F_D Or-0.8
18G_D Or-1.0 9 9 18G_F Or-0.8 SHEET 1 - 18F FUSE BLOCK CIRCUIT 41J_A K-2.0 1 1 56 115
BREAKER B SHEET 1 - SPL_D16 30
45R_A N-1.0 12 12 45R_B N-0.8 1_H R-3.0 8 8
S
45L_A N-1.0 45L_A N-1.0 10 10 45L_B N-0.8 12.5 AMPERES 212F 64D_A Or-0.8 6 6
44_A T-1.0 44_C T-1.0 8 8 44_D T-0.8 59F
SPL_E1 1B_A R-1.0 28 28 1B_D R-0.8 1B_F R-0.8
44 T-1.0 29 29 44A_B T-0.8 SPL_D19
21M 21F
1B_B R-0.8
REAR CAB
49_U S-0.8 SHEET 5 - 210F (55)
CHASSIS MAIN
HARNESS HARNESS 49_G S-0.8 SHEET 2 - 199F (33)
49_F S-0.8 49_S S-1.0
1 2 SPL_D8
1 2 159
0_MA Bk-1.0 SHEET 5 - 82M (77)
101
1_N R-3.0 SHEET 1 - 224F POWER CAB
SHEET 1 - 206F CAB FLOOR WELD STUD 0_DU Bk-1.0 SPL_M6
0_DAS Bk-0.8 SHEET 1 - 63M (18) 49_K S-1.0 SHEET 5 - 39F (61) 46_A K-0.8 0_MD Bk-1.0 0_MC Bk-1.0
SHEET 3 - 13F CAB PEDESTAL C C BB
Normally Open SPL_D14 42C_A DU-1.0 46_C K-1.0 E E 46_D K-1.0 46_D K-1.0 AA
M 100
Closes at 4.1 bar (60 psi) 105 0_DAT Bk-0.8 SHEET 1 - 220F GROUND CAB 42R_B DU-0.8 H H 42R_F DU-1.0
19Z Or-1.0 SHEET 1 - 18F FUSE BLOCK 85F
SHEET 1 - 223F GROUND CAB 0_DT Bk-1.0 B B 0_MG Bk-1.0
19U_A Or-1.0 19U_D Or-1.0
41T_B K-1.0
41T_B K-1.0
41T_A K-1.0 SHEET 1 - 18F FUSE BLOCK SHEET 1 - 18F FUSE BLOCK
41J_B K-2.0
D D
62M FLASHER MODULE SPL_M4
49_J S-0.8
1B_B R-0.8 42R_E DU-1.0 AA
1 FLASHER MODULE POWER 1
42R_B DU-0.8 23F 23M 0_MF Bk-1.0 BB 111
2 FLASHER OPP SIDE CONTROL 2 45N_A N-0.8 SPL_M3
3 FLASHER MODULE GROUND 3 0_DAN Bk-0.8 CAB CAB 80F
4 FLASHER MODULE GROUND 4 0_DAQ Bk-0.8 42R_C DU-0.8 SHEET 1 - 13F CAB PEDESTAL MAIN ROOF
5 NONE 5 HARNESS HARNESS
6 6 18A Or-2.0 SHEET 1 - 18F FUSE BLOCK 42R_D DU-1.0 AA
NONE SPL_D20 0_ME Bk-1.0 BB 110
7 RIGHT-HAND TURN SIGNAL 7 45R_E N-0.8 45R_C N-0.8 SHEET 3 - 13F CAB PEDESTAL 25F A B A C 33F B A C 34F C A B 32F
8 LEFT-HAND TURN SIGNAL 8 45L_D N-0.8 45L_E N-0.8 SHEET 3 - 13F CAB PEDESTAL A B A C B A C C A B 83F
9 RIGHT-HAND TURN SWITCH POWER 9 45B_A N-0.8 SPL_D10
10 LEFT-HAND TURN SWITCH POWER 10 45A_A N-0.8
11 HAZARD SWITCH POWER 11 45H_A N-0.8 HD TL F4 B1 IL F1 B3 F3 F2 B2 LAMPS 1
12 FLASHER OPP SIDE CONTROL 12 45N_B N-0.8 1 1 45N_A N-0.8 SWITCH 19U_D Or-1.0 AA
2 3 4 2 3 4 2 3 4 POSITION 0_MB Bk-0.8 BB
POSITION DRIVE FLOOD ILLUMINATION
62M 64M 64F 1 5 1 5 1 5 AND TAIL CC 117
NOTE 3 1 OFF OFF OFF OFF 0_MM Bk-0.8 2
84F
2 ON OFF OFF OFF
114 3 ON ON OFF ON
4 ON ON ON ON A A
SPL_M5
5 ON OFF ON ON B B 0_ML Bk-0.8 BB
C C 49_V S-0.8 AA 118
D D
77F
SHEET 1 - 223F GROUND CAB 0_DR Bk-1.0 E E 0_MN Bk-0.8
49_S S-1.0 F F 49_V S-0.8 SPL_M2
SHEET 1 - 223F GROUND CAB 0_DS Bk-1.0 G G 0_MK Bk-1.0 0_MJ Bk-1.0 BB
42C_A DU-1.0 H H 42C_D DU-1.0 42C_C DU-1.0 AA 113
108 109 SPL_M1
78F
24M 24F
HIGH LOW HIGH LOW CAB CAB
MAIN ROOF 42C_B DU-1.0 AA
BEAM POSITION BEAM TURN BEAM POSITION BEAM TURN
0_MH Bk-1.0 BB 112
HARNESS HARNESS
79F
3 6 4 2 5 1 3 6 4 2 5 1
3 6 4 2 5 1 6 3 6 4 2 5 1 8
1F 1
CAB MAIN FRONT
HARNESS CHASSIS
HARNESS
SHEET 4 - LIGHTING
COMPONENTS
1. Batteries 13. Ignition Switch 25. Transmission Solenoid Valve and Temperature Sensors 36. Backup Alarm Disable Switch 47. Instrument Cluster 59. Detent Switch 69. Pin Engage Switch (Option) 81. Horn 93. Power Outlet (Option) 105. Flasher Module 117. Dome Lamp
2. Master Disconnect Switch 14. Ignition Relay - Number 1 26. Transmission Electronic Control Module (TUV road approved machines only) 48. Pilot Control Switch 60. Bucket Control Valve Electromagnetic Detents 70. Pin Engage Solenoid (Option) 82. Seat Compressor and Switch (Option) 94. Remote Radio or 24 Volt Radio (Option) 106. Left-Hand Rear Combination Lamp 118. Courtesy Lamp
3. Fuel Shutoff Solenoid 15. Ignition Relay - Number 2 27. Transmission Shifter 37. Backup Alarm 49. Up/Down Count Switch 61. Return-To-Travel/Float Switch 71. Ride Control Switch 83. Blower Switch 95. 12 Volt Radio (Option) 107. Right-Hand Rear Combination Lamp
4. Alternator 16. Accessory Relay - Number 3 28. Diagnostic Connector 38. Brake Warning Pressure Switch 50. Engine Oil Pressure Switch 62. Return-To-Dig Proximity Switch 72. Ride Control Relay - Number 4 84. Blower Motor Speed Resistors with Thermal Fuse 96. Radio Power Converter - 24 volts to 12 volts (Option) 108. Left-Hand Front Combination Lamp
5. Starter Motor 17. Voltmeter Relay - Number 12 29. Transmission Kick-down Switch 39. Coolant Level Sender 51. Pilot Control Relay - Number 10 63. Height Control/Return-To-Travel Proximity Switch 73. Ride Control Solenoid 85. Blower Motor 97. Left Speaker (Option) 109. Right-Hand Front Combination Lamp
6. Starting Relay 18. Time Delay Module 30. Transmission Auto Switch 40. Fuel Level Sender 52. Parking Brake Relay - Number 9 64. Float Pressure Switch 74. Front Wiper Motor 86. Air Conditioning Low Pressure Switch 98. Right Speaker (Option) 110. Left-Hand Rear Work Lamp
7. Fuel Relay 19. Output Speed Sensor 31. Declutch Switch 41. Hydraulic Oil Temperature Sender 53. Parking Brake Solenoid 64A. Rollback Pressure Switch (Option) 75. Front Wiper and Washer Switch 87. Air Conditioning High Pressure Switch 99. Beacon Switch 111. Right-Hand Rear Work Lamp
8. Ether Start Temperature Switch 20. Engine Speed Sensor 32. Brake Declutch Pressure Switch 42. Hydraulic Filter Restriction Switch 54. Pilot Pressure Solenoid 65. Float Solenoid 76. Front Washer Pump Motor 88. Thermostat Switch 100. Rotating Beacon 112. Left-Hand Front Work Lamp
9. Ether Start Solenoid 21. Intermediate Speed Sensor 33. Transmission Enable Switch 43. Engine Coolant Temperature Sender 55. Fan Reversing Switch (Option) 66. Secondary Steering Module (Option) 77. Rear Wiper and Washer Switch 89. Compressor Clutch Lockout Relay - Number 14 101. Brake Lamp Pressure Switch 113. Right-Hand Front Work Lamp
10. Ether Start Relay - Number 6 22. Turbine Speed Sensor 34. FNR Switch 44. Air Filter Restriction Switch 56. Fan Reversing Solenoid (Option) 67. Secondary Steering Pressure Switch (Option) 78. Rear Washer Pump Motor 90. Compressor Clutch 102. Brake Lamps Relay - Number 15 114. Five Position Rotary Lamp Switch
11. Ether Start Switch 23. Filter Maintenance Switch 35. Backup Alarm Relay - Number 7 45. Program Reset Switch 57. Redundant Brake Pressure Switches 68. Secondary Steering Motor (Option) 79. Rear Wiper Motor 91. Cigar Lighter (Option) 103. Hazard Switch 115. High/Low Beam Relay - Number 13
12. Neutral Start Relay - Number 8 24. Torque Converter Output Temperature Sender 46. Parking Brake Switch 58. Relay Socket - Number 11 68A. Secondary Steering Solenoid (Option) 80. Horn Relay - Number 5 92. Power Converter - 24 volts to 12 volts (Option) 104. Turn Signal, Hi/Low Beam, and Horn Switch 116. License Plate Lamp
WIRE IDENTIFICATION CIRCUIT LEGEND ACTUATOR SYMBOLS HOUSINGS CONTACT SYMBOLS FUSE AND CIRCUIT BREAKER NOTES
1 5 6 1 4 7 10 1 4 1 4 1
1. WIRE NUMBER 23F_A W-2.0 4 10 14 1. LEVER RELEASED 1. VACUUM SWITCH 1. SINGLE POLE, 1. FUSE 1. 209M and 209F disconnected when backup alarm disable switch is installed (TUV road approved machines only).
54 2. LEVER ACTUATED 2. PRESSURE SWITCH SINGLE THROW 2. CIRCUIT BREAKER,
2. WIRE COLOR SYMBOL SPL_G2 V M A2 A1 2. Resistors part of ground wire assembly.
3. WIRE SIZE 21C_C W-1.0 A A 1 1 14_B LG-0.8 SHEET 6 - 253F (54) 3. LIQUID LEVEL FLOAT 3. TEMPERATURE SWITCH 2. SINGLE POLE, AUTOMATIC RESET
1 2 3
0_GA Bk-2.0
D+ 3. 64M and 64F connected for North American machines, opposite side steady ON.
B B 2 2
R + 4. PRESSURE 4. MOTOR DOUBLE THROW 3. CIRCUIT BREAKER,
Bk = BLACK LU = LIGHT BLUE S = GRAY 93M 93F 7 9
5. HAND OPERATED 5. LAMP 3. DOUBLE POLE, MANUAL RESET 64M and 64F disconnected for European machines, opposite side OFF.
2 3 21M 21F 2 5 8 11 2 5 2 2
DU = DARK BLUE N = BROWN T = TAN XXXX XXXX 8 11 12 13 6. TEMPERATURE SINGLE THROW 4. 217F and 217M disconnected when engine shutdown relay special feature is installed.
XXXX XXXX 15
G = GREEN Or = ORANGE U = BLUE 7. COIL P 4. DOUBLE POLE,
K = PINK P = PURPLE (VIOLET) W = WHITE 8. VARIABLE RESISTOR DOUBLE THROW
LG = LIGHT GREEN R = RED Y = YELLOW
1.
2.
SPLICE IDENTIFICATION
CIRCUIT CROSSING (NOT CONNECTED)
6.
7.
FEMALE CONNECTOR
CONNECTOR IDENTIFICATION
11.
12.
SCHEMATIC SHEET NUMBER FOR CIRCUIT CONTINUATION
CONNECTION POINT ON SCHEMATIC
9. RESISTOR ELECTRICAL SCHEMATIC
3 6 9 12 10. DIODE 3 3 3
185
31 1 0_KG Bk-0.8
H 45 1 64C Or-0.8
184
2 1 45B N-0.8
R 68
104 5 1 19B Or-0.8
67
L 1 1 45A N-0.8
66
B 1 0_KF Bk-0.8
187
A 1 64D Or-0.8
186
6
7 7 0_KH Bk-0.8 SHEET 3 - 37 (48)
8 8 49_B S-0.8 SHEET 3 - 37 (48)
9 49_A S-0.8
4
103 5
1
10
3 3 45H N-0.8
2 2 1B R-0.8
0_KG Bk-0.8
71
49_A S-0.8
64D Or-0.8
64C Or-0.8
19B Or-0.8
45H N-0.8
45A N-0.8
45B N-0.8
1B R-0.8
106 107
65 67 51 55 69 66 70 42 41 13M PEDESTAL HARNESS
STOP TURN TAIL REVERSE STOP TURN TAIL REVERSE 65 67 51 55 69 66 70 42 41 13F CAB MAIN HARNESS
64D_A Or-0.8
45H_A N-0.8
0_J Bk-1.0 0_JC Bk-1.0
45A_A N-0.8
45B_A N-0.8
C C 0_JA Bk-1.0 BB
1B_C R-0.8
49_F S-0.8
SPL_J1 168
128F 128M
REAR HOOD 10 0_DAW Bk-1.0 SHEET 2 - 118F (36)
0_JB Bk-1.0 SHEET 2 - 174 (37) 0_DAP Bk-1.0 SHEET 2 - 199F (33)
CHASSIS HARNESS 7 7
HARNESS 8 8 49_R S-1.0 SHEET 2 - 199F (33)
0_DX Bk-0.8 SHEET 1 - 220F GROUND CAB 9 49_T S-1.0 SHEET 2 - 118F (36)
6
SHEET 5 - 51F (80)
99 5
1 6 2 3 4 5 1 6 2 3 4 5 64C_A Or-0.8
1 6 2 3 4 5 125 1 6 2 3 4 5 127 4
SHEET 1 - 164 ENGINE GROUND 19B_A Or-0.8 SHEET 1 - 18F FUSE BLOCK 1
3 3 46_C K-1.0
18G_A Or-1.0
35A_B K-1.0
0_C Bk-1.0
1B_E R-0.8
44_B T-1.0
42F
30 30
SPL_D9
87 87 44_E T-0.8 44_F T-0.8 SHEET 3 - 13F CAB PEDESTAL
102 87a 87A 0_DG Bk-0.8 SHEET 1 - 58F (17)
85 85 0_DC Bk-0.8 SHEET 1 - 49F (16)
86 86
0_A Bk-1.0 0_D Bk-2.0 SHEET 1 - 164 ENGINE 204F
SPL_E4 GROUND
1B_E R-0.8
18G_A Or-1.0 SPL_E8 SHEET 1 - SPL_D17 1_M R-3.0
SPL_E2 SHEET 2 - 53F (35) 211F SHEET 1 - 18F FUSE BLOCK 41L_A K-2.0 3 3 56b
35A_A K-1.0 35A_C K-1.0 35A_C K-1.0 7 7 35A_D Y-08
SHEET 1 - 18F FUSE BLOCK FLASHER SHEET 1 - 18F FUSE BLOCK 41H K-2.0 4 4
56a
18F_A Or-1.0 18F_A Or-1.0 5 5 18F_D Or-0.8
18G_D Or-1.0 9 9 18G_F Or-0.8 SHEET 1 - 18F FUSE BLOCK CIRCUIT 41J_A K-2.0 1 1 56 115
BREAKER B SHEET 1 - SPL_D16 30
45R_A N-1.0 12 12 45R_B N-0.8 1_H R-3.0 8 8
S
45L_A N-1.0 45L_A N-1.0 10 10 45L_B N-0.8 12.5 AMPERES 212F 64D_A Or-0.8 6 6
44_A T-1.0 44_C T-1.0 8 8 44_D T-0.8 59F
SPL_E1 1B_A R-1.0 28 28 1B_D R-0.8 1B_F R-0.8
44 T-1.0 29 29 44A_B T-0.8 SPL_D19
21M 21F
1B_B R-0.8
REAR CAB
49_U S-0.8 SHEET 5 - 210F (55)
CHASSIS MAIN
HARNESS HARNESS 49_G S-0.8 SHEET 2 - 199F (33)
49_F S-0.8 49_S S-1.0
1 2 SPL_D8
1 2 159
0_MA Bk-1.0 SHEET 5 - 82M (77)
101
1_N R-3.0 SHEET 1 - 224F POWER CAB
SHEET 1 - 206F CAB FLOOR WELD STUD 0_DU Bk-1.0 SPL_M6
0_DAS Bk-0.8 SHEET 1 - 63M (18) 49_K S-1.0 SHEET 5 - 39F (61) 46_A K-0.8 0_MD Bk-1.0 0_MC Bk-1.0
SHEET 3 - 13F CAB PEDESTAL C C BB
Normally Open SPL_D14 42C_A DU-1.0 46_C K-1.0 E E 46_D K-1.0 46_D K-1.0 AA
M 100
Closes at 4.1 bar (60 psi) 105 0_DAT Bk-0.8 SHEET 1 - 220F GROUND CAB 42R_B DU-0.8 H H 42R_F DU-1.0
19Z Or-1.0 SHEET 1 - 18F FUSE BLOCK 85F
SHEET 1 - 223F GROUND CAB 0_DT Bk-1.0 B B 0_MG Bk-1.0
19U_A Or-1.0 19U_D Or-1.0
41T_B K-1.0
41T_B K-1.0
41T_A K-1.0 SHEET 1 - 18F FUSE BLOCK SHEET 1 - 18F FUSE BLOCK
41J_B K-2.0
D D
62M FLASHER MODULE SPL_M4
49_J S-0.8
1B_B R-0.8 42R_E DU-1.0 AA
1 FLASHER MODULE POWER 1
42R_B DU-0.8 23F 23M 0_MF Bk-1.0 BB 111
2 FLASHER OPP SIDE CONTROL 2 45N_A N-0.8 SPL_M3
3 FLASHER MODULE GROUND 3 0_DAN Bk-0.8 CAB CAB 80F
4 FLASHER MODULE GROUND 4 0_DAQ Bk-0.8 42R_C DU-0.8 SHEET 3 - 13F CAB PEDESTAL MAIN ROOF
5 NONE 5 HARNESS HARNESS
6 6 18A Or-2.0 SHEET 1 - 18F FUSE BLOCK 42R_D DU-1.0 AA
NONE SPL_D20 0_ME Bk-1.0 BB 110
7 RIGHT-HAND TURN SIGNAL 7 45R_E N-0.8 45R_C N-0.8 SHEET 3 - 13F CAB PEDESTAL 25F A B A C 33F B A C 34F C A B 32F
8 LEFT-HAND TURN SIGNAL 8 45L_D N-0.8 45L_E N-0.8 SHEET 3 - 13F CAB PEDESTAL A B A C B A C C A B 83F
9 RIGHT-HAND TURN SWITCH POWER 9 45B_A N-0.8 SPL_D10
10 LEFT-HAND TURN SWITCH POWER 10 45A_A N-0.8
11 HAZARD SWITCH POWER 11 45H_A N-0.8 HD TL F4 B1 IL F1 B3 F3 F2 B2 LAMPS 1
12 FLASHER OPP SIDE CONTROL 12 45N_B N-0.8 1 1 45N_A N-0.8 SWITCH 19U_D Or-1.0 AA
2 3 4 2 3 4 2 3 4 POSITION 0_MB Bk-0.8 BB
POSITION DRIVE FLOOD ILLUMINATION
62M 64M 64F 1 5 1 5 1 5 AND TAIL CC 117
NOTE 3 1 OFF OFF OFF OFF 0_MM Bk-0.8 2
84F
2 ON OFF OFF OFF
114 3 ON ON OFF ON
4 ON ON ON ON A A
SPL_M5
5 ON OFF ON ON B B 0_ML Bk-0.8 BB
C C 49_V S-0.8 AA 118
D D
77F
SHEET 1 - 223F GROUND CAB 0_DR Bk-1.0 E E 0_MN Bk-0.8
49_S S-1.0 F F 49_V S-0.8 SPL_M2
SHEET 1 - 223F GROUND CAB 0_DS Bk-1.0 G G 0_MK Bk-1.0 0_MJ Bk-1.0 BB
42C_A DU-1.0 H H 42C_D DU-1.0 42C_C DU-1.0 AA 113
108 109 SPL_M1
78F
24M 24F
HIGH LOW HIGH LOW CAB CAB
MAIN ROOF 42C_B DU-1.0 AA
BEAM POSITION BEAM TURN BEAM POSITION BEAM TURN
0_MH Bk-1.0 BB 112
HARNESS HARNESS
79F
3 6 4 2 5 1 3 6 4 2 5 1
3 6 4 2 5 1 6 3 6 4 2 5 1 8
1F 1
CAB MAIN FRONT
HARNESS CHASSIS
HARNESS
SHEET 4 - LIGHTING
COMPONENTS
1. Batteries 11B. Grid Heater Temperature Sensor (Option) 22. Turbine Speed Sensor 34. FNR Switch 45. Program Reset Switch 57. Redundant Brake Pressure Switches 68. Secondary Steering Motor (Option) 79. Rear Wiper Motor 91. Cigar Lighter (Option) 103. Hazard Switch 114. Five Position Rotary Lamp
2. Master Disconnect Switch 11C. Grid Heater Controller (Option) 23. Filter Maintenance Switch 35. Backup Alarm Relay - Number 7 46. Parking Brake Switch 58. Relay Socket - Number 11 68A. Secondary Steering Solenoid (Option) 80. Horn Relay - Number 5 92. Power Converter - 24 volts to 12 volts (Option) 104. Turn Signal, Hi/Low Beam, and Horn Switch
3. Engine Fuel Solenoid 12. Neutral Start Relay - Number 8 24. Torque Converter Output Temperature Sender 36. Backup Alarm Disable Switch 47. Instrument Cluster 59. Detent Switch 69. Pin Engage Switch (Option) 81. Horn 93. Power Outlet (Option) Switch 115. High/Low Beam Relay -
4. Alternator 13. Ignition Switch 25. Transmission Solenoid Valve and Temperature Sensors (TUV road approved machines only) 48. Pilot Control Switch 60. Bucket Control Valve Electromagnetic Detents 70. Pin Engage Solenoid (Option) 82. Seat Compressor and Switch (Option) 94. Remote Radio or 24 Volt Radio (Option) 105. Flasher Module Number 13
5. Starter Motor 14. Ignition Relay - Number 1 26. Transmission Electronic Control Module 37. Backup Alarm 49. Up/Down Count Switch 61. Return-To-Travel/Float Switch 71. Ride Control Switch 83. Blower Switch 95. 12 Volt Radio (Option) 106. Left-Hand Rear Combination Lamp 116. License Plate Lamp
6. Starting Relay 15. Ignition Relay - Number 2 27. Transmission Shifter 38. Brake Warning Pressure Switch 50. Engine Oil Pressure Switch 62. Return-To-Dig Proximity Switch 72. Ride Control Relay - Number 4 84. Blower Motor Speed Resistors with Thermal Fuse 96. Radio Power Converter - 24 volts to 12 volts (Option) 107. Right-Hand Rear Combination Lamp 117. Dome Lamp
7. Fuel Filter Heater Relay - Number 16 16. Accessory Relay - Number 3 28. Diagnostic Connector 39. Coolant Level Sender 51. Pilot Control Relay - Number 10 63. Height Control/Return-To-Travel Proximity Switch 73. Ride Control Solenoid 85. Blower Motor 97. Left Speaker (Option) 108. Left-Hand Front Combination Lamp 118. Courtesy Lamp
8. Fuel Filter Heater Switch 17. Voltmeter Relay - Number 12 29. Transmission Kick-down Switch 40. Fuel Level Sender 52. Parking Brake Relay - Number 9 64. Float Pressure Switch 74. Front Wiper Motor 86. Air Conditioning Low Pressure Switch 98. Right Speaker (Option) 109. Right-Hand Front Combination Lamp
9. First Fuel Filter Heater 18. Time Delay Module 30. Transmission Auto Switch 41. Hydraulic Oil Temperature Sender 53. Parking Brake Solenoid 64A. Rollback Pressure Switch (Option) 75. Front Wiper and Washer Switch 87. Air Conditioning High Pressure Switch 99. Beacon Switch 110. Left-Hand Rear Work Lamp
10. Second Fuel Filter Heater 19. Output Speed Sensor 31. Declutch Switch 42. Hydraulic Filter Restriction Switch 54. Pilot Pressure Solenoid 65. Float Solenoid 76. Front Washer Pump Motor 88. Thermostat Switch 100. Rotating Beacon 111. Right-Hand Rear Work Lamp
11. Grid Heater Relay - Number 15 (Option) 20. Engine Speed Sensor 32. Brake Declutch Pressure Switch 43. Engine Coolant Temperature Sender 55. Fan Reversing Switch (Option) 66. Secondary Steering Module (Option) 77. Rear Wiper and Washer Switch 89. Compressor Clutch Lockout Relay - Number 14 101. Brake Lamp Pressure Switch 112. Left-Hand Front Work Lamp
11A. Grid Heater (Option) 21. Intermediate Speed Sensor 33. Transmission Enable Switch 44. Air Filter Restriction Switch 56. Fan Reversing Solenoid (Option) 67. Secondary Steering Pressure Switch (Option) 78. Rear Washer Pump Motor 90. Compressor Clutch 102. Brake Lamps Relay - Number 6 113. Right-Hand Front Work Lamp
WIRE IDENTIFICATION CIRCUIT LEGEND ACTUATOR SYMBOLS HOUSINGS CONTACT SYMBOLS FUSE AND CIRCUIT BREAKER NOTES
23F_A W-2.0 1 4 5 6
14
1 4 7 10
1. LEVER RELEASED
1 4
1. VACUUM SWITCH
1 4
1. SINGLE POLE,
1
1. FUSE 1. 209M and 209F disconnected when backup alarm disable switch is installed (TUV road approved machines only).
1. WIRE NUMBER 10
54 2. LEVER ACTUATED 2. PRESSURE SWITCH SINGLE THROW 2. CIRCUIT BREAKER, 2. Resistors part of ground wire assembly.
2. WIRE COLOR SYMBOL SPL_G2 V M A2 A1
3. 64M and 64F connected for North American machines, opposite side steady ON. 64M and 64F disconnected for European machines, opposite side OFF.
3. WIRE SIZE 1 2 3 21C_C W-1.0 A A 1 1 14_B LG-0.8 SHEET 6 - 253F (54) D+ 3. LIQUID LEVEL FLOAT 3. TEMPERATURE SWITCH 2. SINGLE POLE, AUTOMATIC RESET
0_GA Bk-2.0 B B 2 2
+ 4. PRESSURE 4. MOTOR DOUBLE THROW 3. CIRCUIT BREAKER, 4. 217F and 217M disconnected when engine shutdown relay special feature is installed.
9 R
Bk = BLACK LU = LIGHT BLUE S = GRAY 2 3 93M 93F 7 - 2 5 8 11 5. HAND OPERATED 2 5 5. LAMP 2 3. DOUBLE POLE, 2 MANUAL RESET 5. Used only on 621D.
21M 21F
DU = DARK BLUE N = BROWN T = TAN XXXX XXXX 8 11 12 13 6. TEMPERATURE SINGLE THROW
XXXX XXXX 15 6. On 521D connector 289 connected to fuel filter heater switch; on 621D connector 291 connected.
G = GREEN Or = ORANGE U = BLUE 7. COIL P 4. DOUBLE POLE, 7. Used only when grid heater option installed.
K = PINK P = PURPLE (VIOLET) W = WHITE 8. VARIABLE RESISTOR DOUBLE THROW
LG = LIGHT GREEN 1. SPLICE IDENTIFICATION 6. FEMALE CONNECTOR 11. SCHEMATIC SHEET NUMBER FOR CIRCUIT CONTINUATION 9. RESISTOR
R = RED Y = YELLOW
2. CIRCUIT CROSSING (NOT 7. CONNECTOR IDENTIFICATION 12. CONNECTION POINT ON SCHEMATIC 3 6 9 12 10. DIODE 3 3 3 ELECTRICAL SCHEMATIC P.I.N. JEE0135501 AND ABOVE
CONNECTED) 8. HARNESS IDENTIFICATION 13. COMPONENT NUMBER (IF ASSIGNED)
SHOWS POWER - MASTER DISCONNECT SWITCH IN ON POSITION 3. CIRCUIT CONNECTED 9. INDICATES PARTIAL CONNECTOR 14. COMPONENT NUMBER
A 11.
12A.
LIGHT EMITTING DIODE
MOMENTARY CONTACT T 521D Z-BAR, 521D XR, and 521D XT WHEEL LOADERS
4. WIRE IDENTIFICATION 10. CIRCUIT IDENTIFICATION 15. INDICATES INTERNALLY GROUNDED COMPONENT B
SHOWS POWER - KEY SWITCH IN ON POSITION 12B. MAINTAINED CONTACT Additional copies of this Hydraulic and Electrical Schematic can be ordered throughTechnical Publications Distribution System. The Part Number is 6-49280
BC02M036
Copyright
58S W-0.8
30 30 58_A W-0.8
61R_B Or-0.8 27 27 61R_A Or-1.0 3 3 61R Or-1.0 BB Normally Open 87 87 58_B W-0.8
61A_B Or-0.8 61A_B Or-0.8 26 26 61A_A Or-1.0 2 2 61A Or-1.0 AA 87 Closes at 27.6 bar (400 psi)
61A_C Or-0.8
72 87a 87A
61C_B Or-0.8 25 25 61C_A Or-1.0 4 4 61C Or-1.0 85 85 0_DD Bk-0.8 SHEET 2 - 19F (26)
61R_B Or-0.8 8 8 98
30 30 86 86 58H_B W-0.8 SHEET 2 - 19F (26)
87 87 61R_C Or-0.8 22F 22M 10 10
89 87a 87A 61R_D Or-0.8 12 12 50F
CAB TRANSMISSION
85 85 61C_B Or-0.8 MAIN HARNESS 14 14
86 86 0_DK Bk-0.8 SHEET 4 - 204F (102) 16 16 SHEET 1 - 18F FUSE BLOCK 19U_B Or-1.0
HARNESS 17 17 19U_C Or-0.8 30 30
61R_C Or-0.8 61C_D Or-1.0 1_W R-1.0
203F 18 18 10 0_DAM Bk-1.0 SHEET 2 - 41F (30) 64A_A Or-0.8 87 87
19 19 99 267F
7 7 0_DAL Bk-1.0 87A 87a 80 51_B W-1.0 1_NC R-50 SHEET 1 - 245F (5) B+ STUD
ENGINE AIR CONDITIONING 8 8 49_Q S-1.0 SHEET 2 - 41F (30) SHEET 4 - 13F CAB PEDESTAL 64C_A Or-0.8 85 85
94F 94M HARNESS DIODE HARNESS 19U_C Or-0.8 86 86
DIODE 9 49_P S-1.0 181 253F 244F
TRANSMISSION ENGINE 5
MODULE 51F
HARNESS HARNESS SPL_N1 265F 71 6 6 58_B W-0.8
61C_E Or-1.0 61C_C Or-1.0 A A 4
B B 1
266M 0_BJ Bk-1.0 C C 3 3 58S W-0.8
2 2 19C_B Or-1.0 19C_C Or-0.8 SHEET 3 - 13F CAB PEDESTAL 242F
44F SPL_D24 19C_A Or-1.0 SHEET 1 - 18F FUSE BLOCK M 68
SHEET 1 - 268 REAR ENGINE BLOCK
1 1 19G Or-2.0 SHEET 1 - 18F FUSE BLOCK GROUND STUD 147
B
2 2 61T Or-1.0
C 64 Or-1.0
6 6
83 L
5 5 62L Or-1.0 1 1 W 1
207F AIR CONDITIONING DIODE HARNESS 81
M USED ONLY ON LOADERS WITH BOTH 10 10 49_P S-1.0 0_AD Bk-1.0 0_ND Bk-62 SHEET 1 - 243F REAR CHASSIS GROUND STUD
4 4 62M Or-2.0 2 2 R 2 2 A 61T Or-1.0 3 49_H S-0.8
H
3 3 62H Or-2.0 3 3 Bk 3 88 90 AIR CONDITIONING AND TAPE DECK 146
8
30F 4 4 N N 1 A 61A_D Or-0.8 7
29M 4 3 208F 6 0_AJ Bk-2.0 SHEET 1 - 145 GROUND CAB
84 69 5
SHEET 1 - 218F GROUND CAB 0_DZ Bk-2.0 SPL_D3 61A_C Or-0.8 1 1 57_A W-0.8
M 0_AL Bk-1.0 SHEET 4 - 6 (108)
9 9 0_DAL Bk-1.0
4 0_DAF Bk-1.0 0_AG Bk-1.0 SHEET 4 - 8 (109)
BB 61A_E Or-0.8 2 2 19P_A Or-1.0 SHEET 1 - 18F FUSE BLOCK
85 86 AA 61R_E Or-0.8 61R_D Or-0.8
40F 19P_B Or-1.0 SPL_A1
27M SPL_D1
SPL_C2
Normally Closed 0_AB Bk-1.0 BB 51_C W-1.0 AA
61R_F Or-0.8 SHEET 3 - 13F CAB PEDESTAL 57 W-1.0 AA 70 28.8 ohms at 20C (68F)
0_CF Bk-1.0 BB 68A 39.3 ohms at 20C (68F)
Opens at 1.4 bar (20 psi)
10 0_DAY Bk-1.0 107M 264M
7 7 0_DAF Bk-1.0
8 8 49_H S-0.8
9 49_U S-0.8 SHEET 4 - SPL_D8
6
55 5 0_AC Bk-1.0 2 2
73 22.7 ohms at 20C (68F)
BB 0_X Bk-1.0 SHEET 1 - 163 ENGINE GROUND 58_C W-1.0 1 1 66
56 1 1
AA 52 W-1.0 4 5F
158 3 3 52_A W-0.8
19P_B Or-1.0 64A_A Or-0.8 N N 64 Or-1.0 90M SECONDARY STEERING MODULE
2 2 19R_C Or-1.0
39.3 ohms at 20C (68F) X X 1 1 SECONDARY STEERING IGNITION
210F 57_A W-0.8 U U 57 W-1.0 51_A W-1.0 2 2 SECONDARY STEERING MOTOR RELEASE
27 27 52_A W-0.8 W W 1_W R-1.0 3 3 SECONDARY STEERING MODULE B+
1 1 68W Or-1.0 24 24 68W_A Or-1.0 D D SPL_A7 SHEET 1 - 176 REAR CHASSIS GROUND STUD 0_CE Bk-1.0 4 4 SECONDARY STEERING CHASSIS GROUND
78 M
2 2 0_F Bk-1.0 SHEET 1 - 162 ENGINE GROUND 25 25 63W_A Or-0.8 SHEET 2 - 199F (33) 0_DAE Bk-1.0 58_A W-0.8 V V 58 W-1.0 5 5 NONE
63W Or-1.0 SPL_D13 SHEET 1 - 18F FUSE BLOCK 19M_A Or-0.8 H H 19M_B Or-1.0 19M_B Or-1.0 1 1 19M_C Or-1.0 6 6 NONE
3 21M 21F SHEET 1 - 222F GROUND CAB 0_DAD Bk-1.0 SHEET 1 - SPL_D25 19R_A Or-0.8 J J 19R_B Or-1.0 19R_B Or-1.0 2 2 7 7 SECONDARY STEERING ACCESSORY
REAR CAB SHEET 3 - 13F CAB PEDESTAL 35X_E Y-0.8 K K 35X_B Y-1.0 35X_C Y-1.0 3 3 35X_D Y-1.0 8 8 SECONDARY STEERING LOW PRESSURE SIGNAL
1 1 S S SPL_A4 51P_B W-1.0 4 4 51P_A W-1.0 9 9 SECONDARY STEERING HIGH PRESSURE
76 M
2 2 0_G Bk-1.0 SHEET 1 - 162 ENGINE GROUND
CHASSIS MAIN 10 0_DAH Bk-1.0 R R 54B W-1.0 AA C 0_AN Bk-1.0 5 5 0_CC Bk-1.0 0_CA Bk-1.0 10 10 NONE
HARNESS HARNESS 7 7 0_DAG Bk-1.0 54B_A W-0.8 54B W-1.0 0_AA Bk-1.0
2 L L BB 63 6 6 SPL_C1 11 11 SECONDARY STEERING SIGNAL GROUND
8 8 49_K S-1.0 SHEET 4 - 34F (114) 56_J W-0.8 T T 56_C W-1.0 56_A W-1.0 CC + 0_CB Bk-1.0 12 12 SECONDARY STEERING SIGNAL GROUND
9 49_M S-1.0 53B_B W-0.8 180F 180M
M M 53B W-1.0 SPL_A3 10 90M
6 53P_C W-0.8 B B 53P_D W-1.0 FRONT SECONDARY
61 NORMALLY
56_B W-1.0
5 0_DAH Bk-1.0 CHASSIS STEERING
0_DW Bk-0.8 SHEET 2 - 118F (36) 1 1 0_DAJ Bk-1.0 1F 1 CLOSED
54B_A W-0.8 HARNESS MODULE
7 7 49_L S-0.8 SHEET 2 - 118F (36) 4 CAB FRONT 0_CD Bk-1.0 SHEET 1 - 177 REAR ENGINE BLOCK GROUND STUD
8 8 3 3 54B_B W-0.8 SPL_D2 HARNESS
SPL_D23 54B_C W-0.8 MAIN CHASSIS
5 5 19K_D Or-0.8 19K_A Or-1.0 SHEET 1 - 18F FUSE BLOCK 2 2 55A W-0.8 HARNESS HARNESS
10 39F
9
77 6 6 68W_A Or-1.0 SHEET 3 - 56F (51) 51P_B W-1.0 A A N.O.
1 1 68C_A Or-1.0 0_AN Bk-1.0 B B COM
67 Closes at 2.4 bar (35 psi)
4 19K_B Or-1.0 F F 19K_E Or-1.0 35X_A Y-1.0 C C
0_AA Bk-1.0
19K_C Or-1.0 68C_A Or-1.0 68C_B Or-1.0 N.C.
3 3 A A 10 0_DAJ Bk-1.0
2 2 68L_A Or-1.0 68L_A Or-1.0 G G 68L_C Or-1.0 7 7 0_DAK Bk-1.0 SHEET 2 - 38F (31) 131F
45F 68L_B Or-0.8 8 8 49_M S-1.0
23F 23M 9 49_N S-1.0 SHEET 2 - 38F (31)
CAB ROOF 6
MAIN HARNESS 59 5 53B W-1.0 A A 53B_A W-1.0 AA C
HARNESS 4 0_AF Bk-1.0 0_AF Bk-1.0 B B 0_AM Bk-1.0 BB 62
1 SPL_A2 56_B W-1.0 C C 56_D W-1.0 CC +
81M 56_H W-0.8 SPL_D4
3 3 12F 12M 200
A A 2 2 53P_B W-0.8 SHEET 3 - 56F (51) 0_AK Bk-1.0 SHEET 1 - 145 GROUND CAB
B B 68L_C Or-1.0 XT MODELS: NORMALLY CLOSED
79 M 36F RETURN-TO-DIG HARNESS Z-BAR MODELS: NORMALLY OPEN
C C 19K_E Or-1.0 FOR XT CHASSIS
D D 68C_B Or-1.0
0_AR Bk-1.0
1 1 0_MA Bk-1.0 SHEET 4 - SPL_M6
82M
RETURN-TO-DIG 3 3 53B_B W-0.8
F F 68L_B Or-0.8 4 4 56_G W-0.8
A A 63L_B Or-0.8 2 2 54B_C W-0.8
DIODE C C 0_DAX Bk-0.8 SHEET 1 - 206F CAB FLOOR WELD STUD
60 HEIGHT CONTROL
5 5 56_F W-0.8 58_E W-1.0 AA
MODULE B B 63H_B Or-0.8 RETURN-TO-TRAVEL 1 1 55A W-0.8 53S_D W-1.0 BB
D D 13C_C Or-0.8 SHEET 1 - 57F (58) 6 6 56_E W-0.8 0_AQ Bk-1.0 0_AQ Bk-1.0 CC DIODE
E E 21C_F W-0.8 SHEET 1 - 54F (12) 17M SPL_A6 DD MODULE
140M 75 68.2 ohms - Joystick EE
MOMENTARY 305 ohms - Single Axis F F
PARK INTERMITTENT LOW HIGH 0_AP Bk-1.0 2 2
35F WIPER AND WASHER SWITCH PUSH 65 229M 64A
SHEET 1 - 218F GROUND CAB 0_DAR Bk-1.0 53S_B W-1.0 1 1
SHEET 1 - 18F FUSE BLOCK 19J_A Or-1.0 1 1 BLOWER WIPER SEAT GROUND
19J_B Or-0.8 2 2 FRONT WIPER WASHER FUSED POWER 24V 24V 24V 24V 24V 179F ROLLBACK PRESSURE
63W_A Or-0.8 3 3 FRONT WASHER PUMP 24V 39.7 ohms at 20C (68F) 58_D W-1.0 AA 58_F W-1.0 BB
61 SWITCH (OPTION)
63C_A Or-0.8 4 4 FRONT WIPER PARK 24V PULSE 53S_D W-1.0 BB 58A_A W-1.0 AA
A A 63H Or-0.8 57 57 63H_A Or-0.8 63H_A Or-0.8 5 5 FRONT WIPER HIGH SPEED 24V 53S_C W-1.0 53S_C W-1.0 CC Normally Closed
B B 63L Or-0.8 58 58 63L_A Or-0.8 63L_A Or-0.8 6 6 FRONT WIPER LOW SPEED 24V PULSE 24V 272F Opens at 6.2 bar (90 psi)
74 M SPL_A5
C C 19J Or-0.8 60 60 19J_B Or-0.8 63H_B Or-0.8 202F 271M
63L_B Or-0.8 35F PINS 4 AND 6 ARE CONNECTED INTERNALLY
D D 63C Or-0.8 59 59 63C_A Or-0.8
61 61 0_DV Bk-0.8 SHEET 1 - 206F CAB GROUND WELD STUD BY THE LIMIT SWITCH INSIDE MOTOR 58A_A W-1.0 AA DIODE
1 1 0_KN Bk-0.8 BB
53S_E W-1.0 C C MODULE
60 13M 13F
PEDESTAL CAB 53S_A W-1.0 BB 273F
53P_D W-1.0 AA 64
HARNESS MAIN
HARNESS 178M ROLLBACK PRESSURE SWITCH
Normally Open JUMPER HARNESS FOR XT CHASSIS
Closes at 19 bar (275 psi)
1. 24V REMOTE RADIO (ALL CIRCUITS SHOWN INCLUDING BOX B BUT EXCLUDING BOXES A AND C (109M CONNECTED TO 110F)) AIR SEAT OPTION
2. 24V REMOTE RADIO WITH TAPE DECK (ALL CIRCUITS SHOWN INCLUDING BOXES B AND C BUT EXCLUDING BOX A (109M CONNECTED TO 110F)) 24 VOLT - 12 VOLT POWER CONVERTER OPTION
3. 24V RADIO READY (ALL CIRCUITS SHOWN EXCLUDING BOXES A, B, AND C (109M CONNECTED TO 110F))
4. 12V RADIO READY (ALL CIRCUITS SHOWN INCLUDING BOX A BUT EXCLUDING BOXES B AND C)
RADIO OPTIONS
SHEET 6 - OPTIONS
COMPONENTS
1. Batteries 13. Ignition Switch 25. Transmission Solenoid Valve and Temperature Sensors 36. Backup Alarm Disable Switch 47. Instrument Cluster 59. Detent Switch 69. Pin Engage Switch (Option) 81. Horn 93. Power Outlet (Option) 105. Flasher Module 117. Dome Lamp
2. Master Disconnect Switch 14. Ignition Relay - Number 1 26. Transmission Electronic Control Module (TUV road approved machines only) 48. Pilot Control Switch 60. Bucket Control Valve Electromagnetic Detents 70. Pin Engage Solenoid (Option) 82. Seat Compressor and Switch (Option) 94. Remote Radio or 24 Volt Radio (Option) 106. Left-Hand Rear Combination Lamp 118. Courtesy Lamp
3. Fuel Shutoff Solenoid 15. Ignition Relay - Number 2 27. Transmission Shifter 37. Backup Alarm 49. Up/Down Count Switch 61. Return-To-Travel/Float Switch 71. Ride Control Switch 83. Blower Switch 95. 12 Volt Radio (Option) 107. Right-Hand Rear Combination Lamp
4. Alternator 16. Accessory Relay - Number 3 28. Diagnostic Connector 38. Brake Warning Pressure Switch 50. Engine Oil Pressure Switch 62. Return-To-Dig Proximity Switch 72. Ride Control Relay - Number 4 84. Blower Motor Speed Resistors with Thermal Fuse 96. Radio Power Converter - 24 volts to 12 volts (Option) 108. Left-Hand Front Combination Lamp
5. Starter Motor 17. Voltmeter Relay - Number 12 29. Transmission Kick-down Switch 39. Coolant Level Sender 51. Pilot Control Relay - Number 10 63. Height Control/Return-To-Travel Proximity Switch 73. Ride Control Solenoid 85. Blower Motor 97. Left Speaker (Option) 109. Right-Hand Front Combination Lamp
6. Starting Relay 18. Time Delay Module 30. Transmission Auto Switch 40. Fuel Level Sender 52. Parking Brake Relay - Number 9 64. Float Pressure Switch 74. Front Wiper Motor 86. Air Conditioning Low Pressure Switch 98. Right Speaker (Option) 110. Left-Hand Rear Work Lamp
7. Fuel Relay 19. Output Speed Sensor 31. Declutch Switch 41. Hydraulic Oil Temperature Sender 53. Parking Brake Solenoid 64A. Rollback Pressure Switch (Option) 75. Front Wiper and Washer Switch 87. Air Conditioning High Pressure Switch 99. Beacon Switch 111. Right-Hand Rear Work Lamp
8. Ether Start Temperature Switch 20. Engine Speed Sensor 32. Brake Declutch Pressure Switch 42. Hydraulic Filter Restriction Switch 54. Pilot Pressure Solenoid 65. Float Solenoid 76. Front Washer Pump Motor 88. Thermostat Switch 100. Rotating Beacon 112. Left-Hand Front Work Lamp
9. Ether Start Solenoid 21. Intermediate Speed Sensor 33. Transmission Enable Switch 43. Engine Coolant Temperature Sender 55. Fan Reversing Switch (Option) 66. Secondary Steering Module (Option) 77. Rear Wiper and Washer Switch 89. Compressor Clutch Lockout Relay - Number 14 101. Brake Lamp Pressure Switch 113. Right-Hand Front Work Lamp
10. Ether Start Relay - Number 6 22. Turbine Speed Sensor 34. FNR Switch 44. Air Filter Restriction Switch 56. Fan Reversing Solenoid (Option) 67. Secondary Steering Pressure Switch (Option) 78. Rear Washer Pump Motor 90. Compressor Clutch 102. Brake Lamps Relay - Number 15 114. Five Position Rotary Lamp Switch
11. Ether Start Switch 23. Filter Maintenance Switch 35. Backup Alarm Relay - Number 7 45. Program Reset Switch 57. Redundant Brake Pressure Switches 68. Secondary Steering Motor (Option) 79. Rear Wiper Motor 91. Cigar Lighter (Option) 103. Hazard Switch 115. High/Low Beam Relay - Number 13
12. Neutral Start Relay - Number 8 24. Torque Converter Output Temperature Sender 46. Parking Brake Switch 58. Relay Socket - Number 11 68A. Secondary Steering Solenoid (Option) 80. Horn Relay - Number 5 92. Power Converter - 24 volts to 12 volts (Option) 104. Turn Signal, Hi/Low Beam, and Horn Switch 116. License Plate Lamp
WIRE IDENTIFICATION CIRCUIT LEGEND ACTUATOR SYMBOLS HOUSINGS CONTACT SYMBOLS FUSE AND CIRCUIT BREAKER NOTES
1 5 6 1 4 7 10 1 4 1 4 1
1. WIRE NUMBER 23F_A W-2.0 4 10 14 1. LEVER RELEASED 1. VACUUM SWITCH 1. SINGLE POLE, 1. FUSE 1. 209M and 209F disconnected when backup alarm disable switch is installed (TUV road approved machines only).
54 2. LEVER ACTUATED 2. PRESSURE SWITCH SINGLE THROW 2. CIRCUIT BREAKER,
2. WIRE COLOR SYMBOL SPL_G2 V M A2 A1 2. Resistors part of ground wire assembly.
3. WIRE SIZE 21C_C W-1.0 A A 1 1 14_B LG-0.8 SHEET 6 - 253F (54) 3. LIQUID LEVEL FLOAT 3. TEMPERATURE SWITCH 2. SINGLE POLE, AUTOMATIC RESET
1 2 3
0_GA Bk-2.0
D+ 3. 64M and 64F connected for North American machines, opposite side steady ON.
B B 2 2
R + 4. PRESSURE 4. MOTOR DOUBLE THROW 3. CIRCUIT BREAKER,
Bk = BLACK LU = LIGHT BLUE S = GRAY 93M 93F 7 9
5. HAND OPERATED 5. LAMP 3. DOUBLE POLE, MANUAL RESET 64M and 64F disconnected for European machines, opposite side OFF.
2 3 21M 21F 2 5 8 11 2 5 2 2
DU = DARK BLUE N = BROWN T = TAN XXXX XXXX 8 11 12 13 6. TEMPERATURE SINGLE THROW 4. 217F and 217M disconnected when engine shutdown relay special feature is installed.
XXXX XXXX 15
G = GREEN Or = ORANGE U = BLUE 7. COIL P 4. DOUBLE POLE,
K = PINK P = PURPLE (VIOLET) W = WHITE 8. VARIABLE RESISTOR DOUBLE THROW
LG = LIGHT GREEN R = RED Y = YELLOW
1.
2.
SPLICE IDENTIFICATION
CIRCUIT CROSSING (NOT CONNECTED)
6.
7.
FEMALE CONNECTOR
CONNECTOR IDENTIFICATION
11.
12.
SCHEMATIC SHEET NUMBER FOR CIRCUIT CONTINUATION
CONNECTION POINT ON SCHEMATIC
9. RESISTOR ELECTRICAL SCHEMATIC
3 6 9 12 10. DIODE 3 3 3
58S W-0.8
30 30 58_A W-0.8
61R_B Or-0.8 27 27 61R_A Or-1.0 3 3 61R Or-1.0 BB Normally Open 87 87 58_B W-0.8
61A_B Or-0.8 61A_B Or-0.8 26 26 61A_A Or-1.0 2 2 61A Or-1.0 AA 87 Closes at 27.6 bar (400 psi)
61A_C Or-0.8
72 87a 87A
61C_B Or-0.8 25 25 61C_A Or-1.0 4 4 61C Or-1.0 85 85 0_DD Bk-0.8 SHEET 2 - 19F (26)
61R_B Or-0.8 8 8 98
30 30 86 86 58H_B W-0.8 SHEET 2 - 19F (26)
87 87 61R_C Or-0.8 22F 22M 10 10
89 87a 87A 61R_D Or-0.8 12 12 50F
CAB TRANSMISSION
85 85 61C_B Or-0.8 MAIN HARNESS 14 14
86 86 0_DA Bk-0.8 SHEET 1 - 220F 16 16 SHEET 1 - 18F FUSE BLOCK 19U_B Or-1.0
HARNESS 17 17 19U_C Or-0.8 30 30
61R_C Or-0.8 61C_D Or-1.0 1_W R-1.0
203F 18 18 10 0_DAM Bk-1.0 SHEET 2 - 41F (30) 64A_A Or-0.8 87 87
19 19 99 267F
7 7 0_DAL Bk-1.0 87A 87a 80 51_B W-1.0 1_NC R-50 SHEET 1 - 245F RELAY BOX
ENGINE AIR CONDITIONING 8 8 49_Q S-1.0 SHEET 2 - 41F (30) SHEET 4 - 13F CAB PEDESTAL 64C_A Or-0.8 85 85
94F 94M JUNCTION BLOCK
HARNESS DIODE HARNESS 9 49_P S-1.0 19U_C Or-0.8 86 86
TRANSMISSION ENGINE DIODE 181 263F 244F
MODULE 5 51F
HARNESS HARNESS SPL_N1 265F 71 6 6 58_B W-0.8
61C_E Or-1.0 61C_C Or-1.0 C C 4
B B 1
266M 0_BJ Bk-1.0 A A 3 3 58S W-0.8
2 2 19C_B Or-1.0 19C_C Or-0.8 SHEET 3 - 13F CAB PEDESTAL 242F
44F SPL_D24 19C_A Or-1.0 SHEET 1 - 18F FUSE BLOCK M 68
SHEET 1 - 268 REAR ENGINE BLOCK
1 1 19G Or-2.0 SHEET 1 - 18F FUSE BLOCK GROUND STUD 147
B
2 2 61T Or-1.0
C 64 Or-1.0
6 6
83 L
5 5 62L Or-1.0 1 1 W 1
207F AIR CONDITIONING DIODE HARNESS 81
M USED ONLY ON LOADERS WITH BOTH 10 10 49_P S-1.0 0_AD Bk-1.0 0_ND Bk-62 SHEET 1 - 243F REAR CHASSIS GROUND STUD
4 4 62M Or-2.0 2 2 R 2 2 A 61T Or-1.0 3 49_H S-0.8
H
3 3 62H Or-2.0 3 3 Bk 3 88 90 AIR CONDITIONING AND TAPE DECK 146
8
30F 4 4 N N 1 A 61A_D Or-0.8 7
29M 4 3 208F 6 0_AJ Bk-2.0 SHEET 1 - 145 GROUND CAB
84 69 5
SHEET 1 - 218F GROUND CAB 0_DZ Bk-2.0 SPL_D3 61A_C Or-0.8 1 1 57_A W-0.8
M 0_AL Bk-1.0 SHEET 4 - 6 (108)
9 9 0_DAL Bk-1.0
4 0_DAF Bk-1.0 0_AG Bk-1.0 SHEET 4 - 8 (109)
BB 61A_E Or-0.8 2 2 19P_A Or-1.0 SHEET 1 - 18F FUSE BLOCK
85 86 AA 61R_E Or-0.8 61R_D Or-0.8
40F 19P_B Or-1.0 SPL_A1
27M SPL_D1
SPL_C2
Normally Closed 0_AB Bk-1.0 BB 51_C W-1.0 AA
61R_F Or-0.8 SHEET 3 - 13F CAB PEDESTAL 57 W-1.0 AA 70 28.8 ohms at 20C (68F)
0_CF Bk-1.0 BB 68A 39.3 ohms at 20C (68F)
Opens at 1.4 bar (20 psi)
10 0_DAY Bk-1.0 107M 264M
7 7 0_DAF Bk-1.0
8 8 49_H S-0.8
9 49_U S-0.8 SHEET 4 - SPL_D8
6
55 5 0_AC Bk-1.0 2 2
73 22.7 ohms at 20C (68F)
22 0_X Bk-1.0 SHEET 1 - 163 ENGINE GROUND 58_C W-1.0 1 1 66
56 1 1
11 52 W-1.0 4 5F
158 3 3 52_A W-0.8
19P_B Or-1.0 64A_A Or-0.8 N N 64 Or-1.0 90M SECONDARY STEERING MODULE
2 2 19R_C Or-1.0
39.3 ohms at 20C (68F) X X 1 1 SECONDARY STEERING IGNITION
210F 57_A W-0.8 U U 57 W-1.0 51_A W-1.0 2 2 SECONDARY STEERING MOTOR RELEASE
27 27 52_A W-0.8 W W 1_W R-1.0 3 3 SECONDARY STEERING MODULE B+
1 1 68W Or-1.0 24 24 68W_A Or-1.0 D D SPL_A7 SHEET 1 - 176 REAR CHASSIS GROUND STUD 0_CE Bk-1.0 4 4 SECONDARY STEERING CHASSIS GROUND
78 M
2 2 0_F Bk-1.0 SHEET 1 - 162 ENGINE GROUND 25 25 63W_A Or-0.8 SHEET 2 - 199F (33) 0_DAE Bk-1.0 58_A W-0.8 V V 58 W-1.0 5 5 NONE
63W Or-1.0 SPL_D13 SHEET 1 - 18F FUSE BLOCK 19M_A Or-0.8 H H 19M_B Or-1.0 19M_B Or-1.0 1 1 19M_C Or-1.0 6 6 NONE
3 21M 21F SHEET 1 - 222F GROUND CAB 0_DAD Bk-1.0 SHEET 1 - SPL_D25 19R_A Or-0.8 J J 19R_B Or-1.0 19R_B Or-1.0 2 2 7 7 SECONDARY STEERING ACCESSORY
REAR CAB SHEET 3 - 13F CAB PEDESTAL 35X_E Y-0.8 K K 35X_B Y-1.0 35X_C Y-1.0 3 3 35X_D Y-1.0 8 8 SECONDARY STEERING LOW PRESSURE SIGNAL
1 1 S S SPL_A4 51P_B W-1.0 4 4 51P_A W-1.0 9 9 SECONDARY STEERING HIGH PRESSURE
76 M
2 2 0_G Bk-1.0 SHEET 1 - 162 ENGINE GROUND
CHASSIS MAIN 10 0_DAH Bk-1.0 R R 54B W-1.0 AA C 0_AN Bk-1.0 5 5 0_CC Bk-1.0 0_CA Bk-1.0 10 10 NONE
HARNESS HARNESS 7 7 0_DAG Bk-1.0 54B_A W-0.8 54B W-1.0 0_AA Bk-1.0
2 L L BB - 63 6 6 SPL_C1 11 11 SECONDARY STEERING SIGNAL GROUND
8 8 49_K S-1.0 SHEET 4 - 34F (114) 56_J W-0.8 T T 56_C W-1.0 56_A W-1.0 CC + 0_CB Bk-1.0 12 12 SECONDARY STEERING SIGNAL GROUND
9 49_M S-1.0 53B_B W-0.8 180F 180M
M M 53B W-1.0 SPL_A3 10 90M
6 53P_C W-0.8 B B 53P_D W-1.0 FRONT SECONDARY
61 NORMALLY
56_B W-1.0
5 0_DAH Bk-1.0 CHASSIS STEERING
0_DW Bk-0.8 SHEET 2 - 118F (36) 1 1 0_DAJ Bk-1.0 1F 1 CLOSED
54B_A W-0.8 HARNESS MODULE
7 7 49_L S-0.8 SHEET 2 - 118F (36) 4 CAB FRONT 0_CD Bk-1.0 SHEET 1 - 177 REAR ENGINE BLOCK GROUND STUD
8 8 3 3 54B_B W-0.8 SPL_D2 HARNESS
SPL_D23 54B_C W-0.8 MAIN CHASSIS
5 5 19K_D Or-0.8 19K_A Or-1.0 SHEET 1 - 18F FUSE BLOCK 2 2 55A W-0.8 HARNESS HARNESS
10 39F
9
77 6 6 68W_A Or-1.0 SHEET 3 - 56F (51) 51P_B W-1.0 A A N.O.
1 1 68C_A Or-1.0 0_AN Bk-1.0 B B COM
67 Closes at 2.4 bar (35 psi)
4 19K_B Or-1.0 F F 19K_E Or-1.0 35X_A Y-1.0 C C
0_AA Bk-1.0
19K_C Or-1.0 68C_A Or-1.0 68C_B Or-1.0 N.C.
3 3 A A 10 0_DAJ Bk-1.0
2 2 68L_A Or-1.0 68L_A Or-1.0 G G 68L_C Or-1.0 7 7 0_DAK Bk-1.0 SHEET 2 - 38F (31) 131F
45F 68L_B Or-0.8 8 8 49_M S-1.0
23F 23M 9 49_N S-1.0 SHEET 2 - 38F (31)
CAB ROOF 6
MAIN HARNESS 59 5 53B W-1.0 A A 53B_A W-1.0 AA C
HARNESS 4 0_AF Bk-1.0 0_AF Bk-1.0 B B 0_AM Bk-1.0 BB - 62
1 SPL_A2 56_B W-1.0 C C 56_D W-1.0 CC +
81M 56_H W-0.8 SPL_D4
3 3 12F 12M 200
A A 2 2 53P_B W-0.8 SHEET 3 - 56F (51) 0_AK Bk-1.0 SHEET 1 - 145 GROUND CAB
B B 68L_C Or-1.0 XT MODELS: NORMALLY CLOSED
79 M 36F RETURN-TO-DIG HARNESS Z-BAR MODELS: NORMALLY OPEN
C C 19K_E Or-1.0 FOR XT CHASSIS
D D 68C_B Or-1.0
0_AR Bk-1.0
1 1 0_MA Bk-1.0 SHEET 4 - SPL_M6
82M
RETURN-TO-DIG 3 3 53B_B W-0.8
F F 68L_B Or-0.8 4 4 56_G W-0.8
A A 63L_B Or-0.8 2 2 54B_C W-0.8
DIODE C C 0_DAX Bk-0.8 SHEET 1 - 206F CAB FLOOR WELD STUD
60 HEIGHT CONTROL
5 5 56_F W-0.8 58_E W-1.0 AA
MODULE B B 63H_B Or-0.8 RETURN-TO-TRAVEL 1 1 55A W-0.8 53S_D W-1.0 BB
D D 13C_C Or-0.8 SHEET 1 - 57F (58) 6 6 56_E W-0.8 0_AQ Bk-1.0 0_AQ Bk-1.0 CC DIODE
E E 21C_F W-0.8 SHEET 1 - 54F (12) 17M SPL_A6 DD MODULE
140M 75 68.2 ohms - Joystick EE
MOMENTARY 305 ohms - Single Axis F F
PARK INTERMITTENT LOW HIGH 0_AP Bk-1.0 2 2
35F WIPER AND WASHER SWITCH PUSH 65 229M 64A
SHEET 1 - 218F GROUND CAB 0_DAR Bk-1.0 53S_B W-1.0 1 1
SHEET 1 - 18F FUSE BLOCK 19J_A Or-1.0 1 1 BLOWER WIPER SEAT GROUND
19J_B Or-0.8 2 2 FRONT WIPER WASHER FUSED POWER 24V 24V 24V 24V 24V 179F
63W_A Or-0.8 3 3 FRONT WASHER PUMP 24V 39.7 ohms at 20C (68F) 58_D W-1.0 AA 58_F W-1.0 BB
61 63C_A Or-0.8 4 4 FRONT WIPER PARK 24V PULSE 53S_D W-1.0 BB 58A_A W-1.0 AA
A A 63H Or-0.8 57 57 63H_A Or-0.8 63H_A Or-0.8 5 5 FRONT WIPER HIGH SPEED 24V 53S_C W-1.0 53S_C W-1.0 CC Normally Closed
B B 63L Or-0.8 58 58 63L_A Or-0.8 63L_A Or-0.8 6 6 FRONT WIPER LOW SPEED 24V PULSE 24V 272F Opens at 6.2 bar (90 psi)
74 M SPL_A5
C C 19J Or-0.8 60 60 19J_B Or-0.8 63H_B Or-0.8 202F 271M
63L_B Or-0.8 35F PINS 4 AND 6 ARE CONNECTED INTERNALLY
D D 63C Or-0.8 59 59 63C_A Or-0.8
61 61 0_DV Bk-0.8 SHEET 1 - 206F CAB GROUND WELD STUD BY THE LIMIT SWITCH INSIDE MOTOR 58A_A W-1.0 AA DIODE
1 1 0_KN Bk-0.8 BB
53S_E W-1.0 C C MODULE
60 13M 13F
PEDESTAL CAB 53S_A W-1.0 BB 273F
53P_D W-1.0 AA 64
HARNESS MAIN
HARNESS 178M ROLLBACK PRESSURE SWITCH
Normally Open JUMPER HARNESS FOR XT CHASSIS
Closes at 19 bar (275 psi)
1. 24V REMOTE RADIO (ALL CIRCUITS SHOWN INCLUDING BOX B BUT EXCLUDING BOXES A AND C (109M CONNECTED TO 110F)) AIR SEAT OPTION
2. 24V REMOTE RADIO WITH TAPE DECK (ALL CIRCUITS SHOWN INCLUDING BOXES B AND C BUT EXCLUDING BOX A (109M CONNECTED TO 110F)) 24 VOLT - 12 VOLT POWER CONVERTER OPTION
3. 24V RADIO READY (ALL CIRCUITS SHOWN EXCLUDING BOXES A, B, AND C (109M CONNECTED TO 110F))
4. 12V RADIO READY (ALL CIRCUITS SHOWN INCLUDING BOX A BUT EXCLUDING BOXES B AND C)
RADIO OPTIONS
SHEET 6 - OPTIONS
COMPONENTS
1. Batteries 11B. Grid Heater Temperature Sensor (Option) 22. Turbine Speed Sensor 34. FNR Switch 45. Program Reset Switch 57. Redundant Brake Pressure Switches 68. Secondary Steering Motor (Option) 79. Rear Wiper Motor 91. Cigar Lighter (Option) 103. Hazard Switch 114. Five Position Rotary Lamp
2. Master Disconnect Switch 11C. Grid Heater Controller (Option) 23. Filter Maintenance Switch 35. Backup Alarm Relay - Number 7 46. Parking Brake Switch 58. Relay Socket - Number 11 68A. Secondary Steering Solenoid (Option) 80. Horn Relay - Number 5 92. Power Converter - 24 volts to 12 volts (Option) 104. Turn Signal, Hi/Low Beam, and Horn Switch
3. Engine Fuel Solenoid 12. Neutral Start Relay - Number 8 24. Torque Converter Output Temperature Sender 36. Backup Alarm Disable Switch 47. Instrument Cluster 59. Detent Switch 69. Pin Engage Switch (Option) 81. Horn 93. Power Outlet (Option) Switch 115. High/Low Beam Relay -
4. Alternator 13. Ignition Switch 25. Transmission Solenoid Valve and Temperature Sensors (TUV road approved machines only) 48. Pilot Control Switch 60. Bucket Control Valve Electromagnetic Detents 70. Pin Engage Solenoid (Option) 82. Seat Compressor and Switch (Option) 94. Remote Radio or 24 Volt Radio (Option) 105. Flasher Module Number 13
5. Starter Motor 14. Ignition Relay - Number 1 26. Transmission Electronic Control Module 37. Backup Alarm 49. Up/Down Count Switch 61. Return-To-Travel/Float Switch 71. Ride Control Switch 83. Blower Switch 95. 12 Volt Radio (Option) 106. Left-Hand Rear Combination Lamp 116. License Plate Lamp
6. Starting Relay 15. Ignition Relay - Number 2 27. Transmission Shifter 38. Brake Warning Pressure Switch 50. Engine Oil Pressure Switch 62. Return-To-Dig Proximity Switch 72. Ride Control Relay - Number 4 84. Blower Motor Speed Resistors with Thermal Fuse 96. Radio Power Converter - 24 volts to 12 volts (Option) 107. Right-Hand Rear Combination Lamp 117. Dome Lamp
7. Fuel Filter Heater Relay - Number 16 16. Accessory Relay - Number 3 28. Diagnostic Connector 39. Coolant Level Sender 51. Pilot Control Relay - Number 10 63. Height Control/Return-To-Travel Proximity Switch 73. Ride Control Solenoid 85. Blower Motor 97. Left Speaker (Option) 108. Left-Hand Front Combination Lamp 118. Courtesy Lamp
8. Fuel Filter Heater Switch 17. Voltmeter Relay - Number 12 29. Transmission Kick-down Switch 40. Fuel Level Sender 52. Parking Brake Relay - Number 9 64. Float Pressure Switch 74. Front Wiper Motor 86. Air Conditioning Low Pressure Switch 98. Right Speaker (Option) 109. Right-Hand Front Combination Lamp
9. First Fuel Filter Heater 18. Time Delay Module 30. Transmission Auto Switch 41. Hydraulic Oil Temperature Sender 53. Parking Brake Solenoid 64A. Rollback Pressure Switch (Option) 75. Front Wiper and Washer Switch 87. Air Conditioning High Pressure Switch 99. Beacon Switch 110. Left-Hand Rear Work Lamp
10. Second Fuel Filter Heater 19. Output Speed Sensor 31. Declutch Switch 42. Hydraulic Filter Restriction Switch 54. Pilot Pressure Solenoid 65. Float Solenoid 76. Front Washer Pump Motor 88. Thermostat Switch 100. Rotating Beacon 111. Right-Hand Rear Work Lamp
11. Grid Heater Relay - Number 15 (Option) 20. Engine Speed Sensor 32. Brake Declutch Pressure Switch 43. Engine Coolant Temperature Sender 55. Fan Reversing Switch (Option) 66. Secondary Steering Module (Option) 77. Rear Wiper and Washer Switch 89. Compressor Clutch Lockout Relay - Number 14 101. Brake Lamp Pressure Switch 112. Left-Hand Front Work Lamp
11A. Grid Heater (Option) 21. Intermediate Speed Sensor 33. Transmission Enable Switch 44. Air Filter Restriction Switch 56. Fan Reversing Solenoid (Option) 67. Secondary Steering Pressure Switch (Option) 78. Rear Washer Pump Motor 90. Compressor Clutch 102. Brake Lamps Relay - Number 6 113. Right-Hand Front Work Lamp
WIRE IDENTIFICATION CIRCUIT LEGEND ACTUATOR SYMBOLS HOUSINGS CONTACT SYMBOLS FUSE AND CIRCUIT BREAKER NOTES
23F_A W-2.0 1 4 5 6
14
1 4 7 10
1. LEVER RELEASED
1 4
1. VACUUM SWITCH
1 4
1. SINGLE POLE,
1
1. FUSE 1. 209M and 209F disconnected when backup alarm disable switch is installed (TUV road approved machines only).
1. WIRE NUMBER 10
54 2. LEVER ACTUATED 2. PRESSURE SWITCH SINGLE THROW 2. CIRCUIT BREAKER, 2. Resistors part of ground wire assembly.
2. WIRE COLOR SYMBOL SPL_G2 V M A2 A1
3. 64M and 64F connected for North American machines, opposite side steady ON. 64M and 64F disconnected for European machines, opposite side OFF.
3. WIRE SIZE 1 2 3 21C_C W-1.0 A A 1 1 14_B LG-0.8 SHEET 6 - 253F (54) D+ 3. LIQUID LEVEL FLOAT 3. TEMPERATURE SWITCH 2. SINGLE POLE, AUTOMATIC RESET
0_GA Bk-2.0 B B 2 2
+ 4. PRESSURE 4. MOTOR DOUBLE THROW 3. CIRCUIT BREAKER, 4. 217F and 217M disconnected when engine shutdown relay special feature is installed.
9 R
Bk = BLACK LU = LIGHT BLUE S = GRAY 2 3 93M 93F 7 - 2 5 8 11 5. HAND OPERATED 2 5 5. LAMP 2 3. DOUBLE POLE, 2 MANUAL RESET 5. Used only on 621D.
21M 21F
DU = DARK BLUE N = BROWN T = TAN XXXX XXXX 8 11 12 13 6. TEMPERATURE SINGLE THROW
XXXX XXXX 15 6. On 521D connector 289 connected to fuel filter heater switch; on 621D connector 291 connected.
G = GREEN Or = ORANGE U = BLUE 7. COIL P 4. DOUBLE POLE, 7. Used only when grid heater option installed.
K = PINK P = PURPLE (VIOLET) W = WHITE 8. VARIABLE RESISTOR DOUBLE THROW
LG = LIGHT GREEN 1. SPLICE IDENTIFICATION 6. FEMALE CONNECTOR 11. SCHEMATIC SHEET NUMBER FOR CIRCUIT CONTINUATION 9. RESISTOR
R = RED Y = YELLOW
2. CIRCUIT CROSSING (NOT 7. CONNECTOR IDENTIFICATION 12. CONNECTION POINT ON SCHEMATIC 3 6 9 12 10. DIODE 3 3 3 ELECTRICAL SCHEMATIC P.I.N. JEE0135501 AND ABOVE
CONNECTED) 8. HARNESS IDENTIFICATION 13. COMPONENT NUMBER (IF ASSIGNED)
SHOWS POWER - MASTER DISCONNECT SWITCH IN ON POSITION 3. CIRCUIT CONNECTED 9. INDICATES PARTIAL CONNECTOR 14. COMPONENT NUMBER
A 11.
12A.
LIGHT EMITTING DIODE
MOMENTARY CONTACT T 521D Z-BAR, 521D XR, and 521D XT WHEEL LOADERS
4. WIRE IDENTIFICATION 10. CIRCUIT IDENTIFICATION 15. INDICATES INTERNALLY GROUNDED COMPONENT B
SHOWS POWER - KEY SWITCH IN ON POSITION 12B. MAINTAINED CONTACT Additional copies of this Hydraulic and Electrical Schematic can be ordered throughTechnical Publications Distribution System. The Part Number is 6-49280
BC02M037
Copyright
40 12
14
38
41 6
16
19 13 L
S3 S1 DS2
P
39
LS
BR3 7
P
18 R
T
32
20
BR1 31
17 T Pst P
LOCK
SX UNLOCK
241 BAR
(3495 PSI) 24
45 BAR 30 BAR
(653 PSI) (435 PSI)
35 LS
BR2
37 25
20
Z-BAR and
NOTE 3 XR MODELS
XT MODELS
b1 a1
290 BAR
(4206 PSI) A1
XY XY
XZ XZ
B1 5
22A P
M2
IN
22 2
T
3
b3 a3
33
290 BAR
(4206 PSI) A3
290 BAR B3
(4206 PSI)
4 1
SOLENOID
27 26 B X
2 VALVE A B
P T
FR1
NOTE 2 b4 a4 2
SEQUENCE
1 Y
290 BAR VALVE
FR2 (4206 PSI)
2 A4
LR B4
9 LS EF CF 290 BAR
(4206 PSI)
X Z1 Y X2
23 PP X1
LOGIC
240 BAR 1 VALVE
(3481 PSI) S2 S1 MP
MA MX 3
29 36 RELIEF
VALVE
8 T P
S L1 L
A T
M
28
42 42
40 12
14
38
16 6
19 13 L
S3 S1 DS2
P
39
LS
BR3 7
P
18 R
T
32
20
BR1 31
17 T Pst P
LOCK
SX UNLOCK
241 BAR
(3495 PSI) 24
45 BAR 30 BAR
(653 PSI) (435 PSI)
35 LS
BR2
37 25
20
Z-BAR and
NOTE 3 XR MODELS
XT MODELS
b1 a1
290 BAR
(4206 PSI) A1
XY XY
XZ XZ
B1 5
22A P
M2
IN
22 2
T
3
b3 a3
33
290 BAR
(4206 PSI) A3
290 BAR B3
(4206 PSI)
4 1
SOLENOID
27 26 B X
2 VALVE A B
P T
FR1
NOTE 2 b4 a4 2
SEQUENCE
1 Y
290 BAR VALVE
FR2 (4206 PSI)
2 A4
LR B4
9 LS EF CF 290 BAR
(4206 PSI)
X Z1 Y X2
23 PP X1
LOGIC
240 BAR 1 VALVE
(3481 PSI) S2 S1 MP
MA MX 3
29 36 RELIEF
VALVE
8 T P
S L1 L
A T
M
28
41 41