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921F
Tier 4
Wheel Loader
SERVICE MANUAL
TABLE OF CONTENTS
TORQUE SPECIFICATIONS - DECIMAL HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TORQUE SPECIFICATIONS - METRIC HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1001-3
Pound- Newton
Size Inches metres Pound- Newton
M4 24 to 36 3 to 4 Size Feet metres
M5 60 to 72 7 to 8 M10 54 to 64 73 to 87
Pound- Newton
Size Feet metres
1/2-13 55 to 65 74 to 88
5/8-11 140 to 150 190 to 203
1001-6
TABLE OF CONTENTS
821F - CAPACITIES AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
921F - CAPACITIES AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ENGINE OIL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TRANSMISSION TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DIESEL FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fuel Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Specifications for Acceptable No. 2 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
What is Selective Catalytic Reduction (SCR)? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Selective Catalytic Reduction (SCR) - Basic instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
MAINTENANCE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1002-3
Hydraulic System
Hydraulic Reservoir Refill Capacity ........................................................................... 110 liters (29.0 U.S. Gallons)
Total System Capacity............................................................................................... 200 liters (53.0 U.S. Gallons)
Type of Oil ..............................................................................................................Case AKCELA Hy-Tran Ultra®
Transmission
Refill Capacity with Filter Change ................................................................................ 34.1 liters (36 U.S. Quarts)
Type of Oil ....................................................................................................................................... Case Nexplore
Axles
Capacity
Front...................................................................................................................... 42.0 liters (44.4 U.S. Quarts)
Rear ...................................................................................................................... 40.0 liters (42.3 U.S. Quarts)
Type of Lubricant............................................................................................................................. Case Nexplore
NOTE: DO NOT use an alternate oil in the axles. The brake components in the axles could be damaged as a result
of using an alternate oil. Machines are shipped from the factory with break-in oil.
1002-5
BC02N250
1002-6
RCPH10WHL435BAH3
NOTE: The main factors taken into account to define Glossary Acronym Definition
the shelf life in the previous figures are the ambient DEF Diesel Exhaust Fluid
storage temperature and the initial alkalinity of ISO International Organization
DEF/AdBlue®. The difference in evaporation for Standardization
between vented and non-vented storage containers
is an additional factor. MSDS Material Safety Data Sheet
NOTE: The information in this table is for reference NOx Nitrogen Oxide
only and has been provided by the International
PPE Pe r s o n a l Protective
Organization for Standardization, Document number Equipment
ISO 22241-3 Diesel engines - NOx reduction agent
AUS 32 - Part 3: Handling, transportation and stor- SCR Selective Catalytic
Reduction
age.
Disposal ULSD Ultra Low Sulfur Diesel
• Dispose of DEF/AdBlue® and any filter
accumulations in accordance with all applicable
Federal, State, and local laws governing waste
disposal.
For machines sold in California CNH must warrant
the diesel emission control system in the application
for which it is sold or leased to be free from defects in
design, materials, workmanship, or operation of the
diesel emission control system which cause the
diesel emission control system to fail to conform to
the emission control performance level it was verified
to, or to the requirements in the California Code of
Regulations, Title 13, Sections 2700 to 2706, and
2710, for the periods of time listed below, provided
there has been no abuse, neglect, or improper
maintenance of your diesel emission control system,
vehicle or equipment, as specified in the owner’s
manuals. Where a warrantable condition exists, this
warranty also covers the engine from damage
caused by the diesel emission control system,
subject to the same exclusions for abuse, neglect or
improper maintenance of your vehicle or equipment.
Please review your owner’s manual for other
warranty information. The diesel emission control
system may include a core part (e.g., particulate
filter, diesel oxidation catalyst, selective catalytic
reduction converter) as well as hoses, connectors,
and other emission-related assemblies.
1002-9
MAINTENANCE SCHEDULE
FREQUENCY IN HOURS
Initial Service
LUBRICATE
SERVICE
REPLACE
NUMBER
CHANGE
SERVICE POINTS
ADJUST
INTERVAL
CHECK
CLEAN
DRAIN
ITEM
Every 100 Hours 9 Grease Front Drive Shaft Support Bearing 100
10 Lubricate Loader Lift & Cylinder Pivots (10) Z-bar 100
10 Lubricate Loader Lift & Cylinder Pivots (18) XT 100
11 Check Cab Air Filter 250
Every 3000
XX Replace DEF supply module filter 3000
Hours
MAINTENANCE POINTS
84397762
See your Operators manual for maintenance of If you operate the machine in severe conditions,
safety related items and for detailed information of lubricate and service the machine more frequently.
the ser vice items on this char t. Operators and
service manuals are available for this machine from
your dealer.
Section
1003
1003
METRIC CONVERSION CHART
1003-2
TABLE OF CONTENTS
CONVERSION FACTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Metric to U.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
U.S. to Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1003-3
CONVERSION FACTORS
Metric to U.S.
MULTIPLY BY TO OBTAIN
U.S. to Metric
MULTIPLY BY TO OBTAIN
* = exact
Section
2000
2000
2000-2
TABLE OF CONTENTS
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2000-3
ENGINE
Removal STEP 5
STEP 1
BD02N160
STEP 2 STEP 6
Stop engine. Actuate brake pedal several times to
discharge brake accumulators. Put key switch in ON
position and move loader control lever back and forth
at least 30 times to release any pressure from
hydraulic circuit. Put key switch in OFF position.
STEP 3
Slowly loosen the filler cap for hydraulic reservoir to
release air pressure in hydraulic reservoir.
STEP 4
BD02N160
BD06F108
BD03A231 BD06F109
Double up a nylon lifting strap (1) and slide through Tag and disconnect hood wiring harness connector
the exhaust stack (2) on the hood. from rear chassis wiring harness connector.
STEP 8 STEP 11
1
BD03A230 BD03A227
STEP 9
BD03A226
BD03A232 BD06F110
Carefully raise and remove hood from loader. Lower Loosen clamps on turbocharger and air cleaner,
hood onto suitable platform and disconnect lifting remove the intake hose.
equipment.
STEP 16
STEP 13
BD06F110
BD03A115
BD03A225 Loosen the clamp on the after cooler and remove the
Loosen clamp on air cleaner intake hose and remove after cooler inlet hose from the machine.
the crankcase ventilation hose.
2000-6
STEP 18 STEP 21
BD06F112
BD06F111
Loosen the clamp on the intake manifold for the after Remove the air cleaner and muffler from the bracket.
cooler output hose.
STEP 22
STEP 19
BD06F113
BD03A118
STEP 20
BD06F114
BD06F115 BD06F118
Remove the drive belt from the engine. Tag and disconnect the wiring from the alternator.
STEP 24 STEP 27
BD06F116 BD06F119
Loosen clamps and remove lower cooler hose from Remove bolt securing wiring harness clamp to
the engine. engine.
STEP 25 STEP 28
1
1
2
2
BD06F117 BD06F120
If loader is equipped with air conditioning, identify, Remove bolt securing wiring harness clamp (1) to the
tag, and disconnect the engine wiring harness engine. Remove ground wires (2) from the engine.
connectors from air compressor clutch connector (1).
Remove the thre e m oun tin g b olts (2) for the
compressor and set the compressor on the left
battery cover.
2000-8
STEP 29 STEP 32
2 3
BD06F121 BD06F111
Tag and remove the wires from the starter solenoid Tag and remove the grid heater cable.
(3), remove the ground cable (2), and ground strap
(1) from the starter. STEP 33
NOTE: Move the starter cables away from the
engine, move the wiring harness away from the
engine.
STEP 30
BD03A142
STEP 31
BD06F123
BD06F127
BD06F124
Tag and disconnect the fuel filter heater wires (1), Remove the lower cover for the drive shaft.
disconnect the fuel line (2) from the fuel filter head,
plug the line and cap the fitting. STEP 39
STEP 36
BD03A172
STEP 41
Slowly raise engine from rear chassis. Be sure all
h a r n e s s c o n n e c t i o n s a n d h o s e s h ave b e e n
disconnected and are clear of the engine. Remove
engine from machine.
BD06F126
Installation
1
2 1
3 2
3
1 4
4 5
2
5
3 6
6
7
7
8 4
5
6
7
BS03B035
STEP 42 STEP 47
If engine rubber isolators require replacement,
remove and discard isolators (3 and 4). Install new
rubber isolator (4), then rubber isolator (3).
STEP 43
Slowly raise engine and move into position over rear
chassis. Be sure all harness connections and hoses
are out of the way then lower engine. Put washer (5)
between front rubber isolator (4) and chassis. Install
washer (2), bolt (1), washer (6), and nut (7) in engine
isolators. Lower engine into position.
BD03A172
STEP 46
Connect engine oil drain hose to frame bracket.
2000-11
STEP 48 STEP 51
BD06F127 BD06F124
Install the lower cover for the drive shaft. Remove cap from fitting and plug from the hose,
connect fuel line (2). Connect fuel filter heater wires
STEP 49 (1). Remove and discard tag.
STEP 52
BD06F126
BD03A142
Install bolt and clamp for fuel return hose. NOTE: Start the connector on the EDC 7 with lever
straight out from EDC 7. Use lever to pull connector
into position.
2000-12
STEP 54 STEP 57
2 3
BD06F111 BD06F121
Connect grid heater cable to grid heater. Remove Install the wires to the starter solenoid (3), install the
and discard tag. ground cable (2), and ground strap (1) to the starter.
Remove and discard tags.
STEP 55
STEP 58
3
1
2
2
1
BD06F122
BD06F120
Install the heater hose (2) to the rear of the engine,
mount the clamps (3), install the radiator hose (1). Install bolt securing wiring harness (1) clamp to the
engine. Install ground wires (2) to the engine.
STEP 56
STEP 59
BD06F146
BD06F118 BD06F115
Connect the wiring to the alternator. Remove and Install the drive belt.
discard tags.
STEP 64
STEP 61
BD06F113
BD06F117
STEP 62
BD06F114
BD06F116
BD06F112 BD06F111
Place the muffler and air cleaner on the bracket. Tighten the clamp on the intake manifold for the after
Install mounting bolts in air cleaner and tighten, cooler output hose.
install the mounting bolts in the muffler and leave
loose at this time. STEP 69
STEP 66
BD03A115
BD06F110
BD06F110 BD03A232
Install the intake hose and tighten the clamps on Carefully raise and place hood over loader.
turbocharger and air cleaner.
NOTE: Refer to step 7 and 8 of removal for lifting
procedure.
STEP 72
STEP 75
BD03A225
1
Install the crankcase ventilation hose and tighten the
BD03A227
clamp on air cleaner intake hose.
STEP 73
BD03A226
BD03A221
BD03A228
Install the pin from the top of the lifting motor, lower NOTE: If hood strut is not adjusted properly the
and remove lifting equipment. hood will be damaged.
When a hood is removed and replaced an initial
STEP 77 adjustment on the strut is necessary. Adjust between
the top of the lift motor adjusting jam nut (1) to the top
of the threads (2) to 20 mm (X). With the motor down
to its lowest point take a measurement between the
left hand side hood bumper and the counter weight,
record this measurement (Y). Use the following table
to adjust the strut (X).
Hood Adjustment Table
Y X Y X Y X Y X
(MM) (MM) (MM) (MM) (MM) (MM) (MM) (MM)
1 19 21 14 41 9 61 5
2 19 22 14 42 9 62 5
BD06F109
3 18 23 14 43 9 63 4
Connect hood wiring harness connector to rear
chassis wiring harness connector. Remove and 4 18 24 13 44 9 64 4
discard tag. 5 25 45 65
18 13 9 4
6 18 26 13 46 8 66 4
7 17 27 13 47 8 67 3
8 17 28 12 48 8 68 3
9 17 29 12 49 8 69 3
10 17 30 12 50 7 70 3
11 16 31 12 51 7 71 2
12 16 32 12 52 7 72 2
13 16 33 11 53 7 73 2
14 16 34 11 54 6 74 2
15 16 35 11 55 6 75 2
16 15 36 11 56 6 76 1
17 15 37 10 57 6 77 1
18 15 38 10 58 6 78 1
19 15 39 10 59 5 79 1
20 14 40 10 60 5 80 0
2000-17
STEP 79 STEP 85
BD02N160 BD06F108
Check and make sure that drain caps are tight. Lower the hood with the hood lift motor.
STEP 80 STEP 86
Install a new oil filter on engine. Fill engine with 13.25 Put articulation lock in OPERATING position.
liters (14 U.S. quarts) of Case AKCELA Engine Oil
(SAE 15W-40).
STEP 81
If hydraulic reservoir was drained, fill reservoir of the
821F with 90.8 liters (24.0 U.S. gallons) of Case
AKCELA Hy-Tran Ultra® fluid. Fill the reservoir of the
921F with 110 liters (29.0 U.S. gallons) of Case
AKCELA Hy-Tran Ultra® fluid.
STEP 82
Fill engine coolant system with a solution of 50%
Ethylene Glycol and 50% water. Cooling system
capacity is 30 liters (32 U.S. quarts). Install the
radiator cap. Fill the coolant reservoir up to the FULL
mark on the reservoir.
STEP 83
Connect the batteries, install battery covers, put
master disconnect switch in ON position.
STEP 84
Start engine and run the engine at low idle. Run the
engine at operating temperature for approximately
five minutes to completely mix the Ethylene Glycol
an d wat er. Wh en the coo lan t is at o pe ra ting
temperature, stop the engine. When engine has
cooled, check the coolant level at the reservoir.
WARNING: Hot coolant can spray out if radiator cap
is removed. To remove radiator cap: Let system cool,
turn to first notch, then wait until all pressure is
released. Scalding can result from fast removal of
radiator cap.
2000-18
RADIATOR
Removal STEP 5
STEP 1
Park loader on level surface and lower bucket to
ground. Apply parking brake and shut down engine.
STEP 2
BD06F128
STEP 6
BD03A040
STEP 3
Put master disconnect switch in OFF position.
STEP 4
BD02N160
STEP 7
BD03A120
BD03A109
2 2
BD03A108 BD03A106
Loosen the upper radiator hose clamps, remove the Remove screws and install lifting eyes (1). Attach
hose. suitable lifting equipment to lifting eyes. Remove four
mounting bolts (2), remove radiator from machine.
STEP 9
BD06F129
STEP 10
BD03A113
Installation STEP 15
STEP 12
Move radiator into position above cooling frame.
Carefully lower radiator while guiding it into position
in cooling frame.
STEP 13
1
BD06F129
STEP 16
BD03A106
STEP 14
BD03A108
STEP 17
BD03A113
BD06F130
BD06F131 BD03A120
Align the whole in the fender on the bolt. Have another person raise and hold the side panel
up into position. Apply Loctite 242 to the threads,
STEP 19 install the two mounting screws for the side panel
and torque to 6.5 ± 3.0 Nm (57.5 ± 26.5
pound-inches).
NOTE: Photo is of the oil cooler side of the machine,
the procedure is the same.
STEP 22
BD06F132
Align the slots in the fender with the tabs on the body
of the machine.
STEP 20
BD02N160
STEP 23
Fill engine coolant system with a solution of 50%
Ethylene Glycol and 50% water. Cooling system
capacity is 30 liters (32.0 U.S. quarts). Install the
radiator cap. Fill the coolant reservoir up to the FULL
mark on the reservoir.
DSC00105.TIF
STALL TEST
2002-2
TABLE OF CONTENTS
821F SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
STALL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
921F SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
STALL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSTRUMENT CLUSTER DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
PROCEDURE TO HEAT THE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
POWER MODE SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PERFORMING STALL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Test No. 1 - Torque Converter and Hydraulic Stall Together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Understanding the Results of Test No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Test No. 2 - Torque Converter Stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Understanding the Results of Test No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Test No. 3 - Hydraulic Stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Understanding the Results of Test No. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2002-3
821F SPECIFICATIONS
Engine with 4 Speed Transmission
A. Low idle ..........................................................................................................................................870 to 930 rpm
Alternate low idle .................................................................................................................................570 to 630 rpm
Alternate Accelerated Idle ...............................................................................................................1170 to 1230 rpm
B. Maximum No Load RPM .............................................................................................................2100 to 2155 rpm
C. Converter Stall ............................................................................................................................1883 to 1963 rpm
D. Hydraulic Stall .............................................................................................................................1883 to 1963 rpm
E. Converter & Hydraulic Stall .........................................................................................................1497 to 1577 rpm
Temperature of the torque converter oil....................................................................... 82° to 104° C (180° to 220° F)
Temperature of the hydraulic oil....................................................................................... 54° to 57°C (129° to 134°F)
NOTE: Hydraulic Stall and Converter & Hydraulic Stall RPM values are read while the lift arms are rising with the
bucket held rolled back and the engine at WOT in max power mode with transmission in manual mode and in 3rd
gear.
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.
2002-4
921F SPECIFICATIONS
Engine with 4 Speed Transmission
A. Low idle ..........................................................................................................................................870 to 930 rpm
Alternate low idle .................................................................................................................................570 to 630 rpm
Alternate Accelerated Idle ...............................................................................................................1170 to 1230 rpm
B. Maximum No Load RPM .............................................................................................................2100 to 2155 rpm
C. Converter Stall ............................................................................................................................1900 to 1940 rpm
D. Hydraulic Stall .............................................................................................................................1860 to 1940 rpm
E. Converter & Hydraulic Stall .........................................................................................................1525 to 1605 rpm
Temperature of the torque converter oil....................................................................... 82° to 104° C (180° to 220° F)
Temperature of the hydraulic oil....................................................................................... 54° to 57°C (129° to 134°F)
NOTE: Hydraulic Stall and Converter & Hydraulic Stall RPM values are read while the lift arms are rising with the
bucket held rolled back and the engine at WOT in max power mode with transmission in manual mode and in 3rd
gear.
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.
2002-5
BD06F027
BD06F188
BD06F184
BD06F169
BD06F170
BD06H038
Test No. 1 - Torque Converter and Test No. 2 - Torque Converter Stall
Hydraulic Stall Together 1. Sit in the seat.
1. Sit in the seat.
2. Start the engine and run the engine at low idle.
2. Start the engine and run the engine at low idle.
3. Press the brake pedal, release the park brake,
3. Press the brake pedal, release the park brake, shift into Forward.
shift into Forward.
4. Run the engine at low idle.
4. Run engine at low idle. Push the clutch cutout
5. Push down and hold the brake pedal for the
switch to OFF. Put the transmission in manual
remainder of this test.
mode. Push down and hold the brake pedal for
the remainder of this procedure. 6. Turn the transmission control lever to third gear.
5. Turn the transmission control lever to third gear. 7. Increase the engine speed to full throttle.
6. Increase the engine speed to full throttle. 8. Check the engine speed.
7. Hold the bucket control lever in the ROLLBACK 9. Decrease the engine speed to low idle.
position and raise the lift arms.
10. Place the transmission in neutral and apply the
NOTE: The stall speed must be read while the lift parking brake.
arms are in motion.
11. Stop the engine.
8. Check the engine speed.
9. Release the bucket control lever. Understanding the Results of Test
No. 2
10. Decrease the engine speed to low idle.
1. If the engine speed was as specified, the engine,
11. Lower the bucket to the ground, place the torque converter and transmission are probably
transmission in neutral and apply the parking good.
brake.
2. If the engine speed was more than specified, the
12. Stop the engine. 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
Understanding the Results of Test troubleshooting information.
No. 1 3. If the engine speed was less than specified, do
1. If the engine speed was as specified, the engine, Test No. 3.
torque converter, transmission and hydraulic
system are probably good.
2. If the engine speed was not as specified, do Test
No. 2 and 3.
2002-10
2003
AFTER COOLER
2003-2
TABLE OF CONTENTS
TROUBLESHOOTING AFTER COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
AFTERCOOLER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2003-3
STEP 2
Raise hood. Install ‘T’ fitting in waste gate valve hose.
Attach pressure gauge. Install another pressure
gauge into the intake manifold port.
STEP 3
Have assistant start engine and run at 2000 r/min BD03A118
(rpm). Record pressure readings for both gauges. If Inspect the after cooler outlet flex hose for leaks or
the pressure difference is greater than 60 mbar holes and insure that the clamps are tight.
(0.87 psi), inspect cooler components for damaged
or missing parts.
STEP 6
STEP 4
BD03A119
BD03A109
AFTERCOOLER REMOVAL
Removal STEP 4
STEP 1
BD03A118
STEP 2
BD03112
BD03A111
BD03A119 Remove three cover mounting bolts and lift cover off.
Loosen clamps and remove Intake hose.
2003-5
STEP 7 STEP 10
BD03A109 BD03A113
Unlatch air conditioning condenser clamp. Remove two bolts, one from each side of the after
cooler mounting frame.
STEP 8
STEP 11
L i f t a i r c o o l e r a n d f ra m e f r o m m a c h i n e w i t h
appropriate lifting devise.
STEP 12
BD03A107
STEP 9 BD03A111
BD03A117
BD03A111
BD03A113
STEP 3
BD03A117
BD03A107 BD03A116
Position air conditioner condenser and install Install air cooler inlet hose. Tighten clamps at
mounting bolts. Rotate the condenser down and turbocharger outlet.
latch.
STEP 8
STEP 5
BD03A115
STEP 6
BD03A119
STEP 12
Have assistant start engine and run at 2000 r/min
(rpm). Record pressure readings for both gauges.
confirm that the pressure difference is less than 60
mBar (0.87 psi).
BD03A118
2010
2010-2
TABLE OF CONTENTS
Air Filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pre-cleaner Disassembly & Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Primary/Secondary Fillter Element Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Primary/Secondary Element Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2010-3
AIR FILTRATION
IMG_1682.AI.TIF
STEP 2
IMG_1680.AI.TIF
IMG_1683.AI.TIF
1 2
IMG_0115.PNGD
STEP 2
IMG_0142.PNG
STEP 5
IMG_0099.PNG
IMG_0143A.PNG
IMG_0144A.PNG IMG_0143A.PNG
Remove secondary filter element from right side of Install new primary filter element by sliding it down
housing. Remove debris from inside filter element into housing.
housing before installing new filter elements.
NOTE: Make sure primary and secondary filter
NOTE: Do not clean the seconday filter element. It elements form an effective seal.
must be replaced if damaged or clogged.
STEP 3
Primary/Secondary Element
Reassembly
STEP 1
IMG_0142.PNG
STEP 4
IMG_0144A.PNG
721F-8508.PNG
IMG_0099.PNG
2020
2020-2
TABLE OF CONTENTS
SCR System Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Upstream Exhaust Temperature Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Upstream Exhaust Temperature Sensor Reinstall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Downstream Exhaust Temperature Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Downstream Exhaust Temperature Sensor Reinstall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
NOx Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
NOx Sensor Reinstall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2020-3
STEP 1
IMG_0912.TIF
721F-8469.PNG STEP 4
Raise the hood using controls located behind the
access cover.
STEP 2
IMG_1507.TIF
STEP 1
IMG_1510.JPG
STEP 6
IMG_1510.TIF
STEP 2
IMG_1514.TIF
IMG_1507.TIF
IMG_0099.PNG IMG_0099.PNG
Turn master electric switch to “on” position. Clear any Turn master electric switch to the “off” position.
fault code. Start engine and check to see if problem
has been corrected. STEP 3
STEP 1
IMG_1465.TIF
STEP 4
721F-8469.PNG
GRAPHIC_ID
STEP 1
IMG_1524.TIF
STEP 6 IMG_1518.TIF
STEP 2
1528.TIF
STEP 7
IMG_1524.TIF
GRAPHIC_ID
R e m o ve s e n s o r a n d w i r i n g h a r n e s s a s o n e
component from machine.
2020-7
STEP 3 NOx Sensor Removal
NOTE: Do not use impact wrenches on the exhaust
system unless the sensors are removed.”
STEP 1
IMG_1528.TIF
STEP 4 721F-8469.PNG
STEP 2
IMG_0099.PNG
1
2
IMG_1465.TIF IMG_1535.TIF
Locate NOx sensor (1) on exhaust system down Loosen hex nut on NOx sensor.
stream of catalyst (2).
STEP 6
STEP 4
2
1
IMG_1536.TIF
IMG_1539.TIF
STEP 1
IMG_1585.TIF
STEP 9
IMG_1536.TIF
STEP 2
IMG_1584.TIF
STEP 10 IMG_1535.TIF
IMG_1544.TIF
1 2
IMG_1584.TIF IMG_1524.TIF
Install NOx sensor module and secure it to mounting Secure NOx sensor wire harness with P-clip (1) to
support bracket using hex bolts. NOx sensor module catalyst mounting support bracket (2) using hex
torque 10.5 to 14.5 Nm (8 to 10.5 lb ft.). bolts. Secure wire harness with wire ties where
appropriate.
STEP 4
STEP 6
IMG_0099.PNG
SCR CATALYST
2030
2030-2
TABLE OF CONTENTS
SCR Catalyst . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2030-3
SCR CATALYST
Removal STEP 3
NOTE: Do not use impact wrenches on the exhaust 2
system unless sensors are removed. 1
STEP 1
IMG_0912.TIF
STEP 2
IMG_1507.TIF
IMG_0099.PNG Loosen hex nut on sensor.
Turn the master electric switch to the “off” position.
2030-4
STEP 5 STEP 7
IMG_1510.TIF IMG_1518.TIF
Remove upstream exhaust gas temperature sensor. Loosen hex nut and remove downstream exhaust
temperature sensor.
STEP 6
STEP 8
1 2
IMG_1465.TIF
gas temperature sensor (2) after the SCR catalyst. Loosen hex nut on NOx sensor.
STEP 9
IMG_1536.TIF
IMG_1555.TIF IMG_1552.TIF
Attach a suitable lifting device and lift strap to the Remove hex bolts from mounting support brackets at
SCR catalyst. front of SCR catalyst.
STEP 11 STEP 13
IMG_1549.TIF IMG_1560.TIF
Remove clamp, gasket and gasket alignment sleeve Remove hex bolts that secure mounting support
at SCR catalyst and mixing pipe connection. Discard bracket to the rear of the SCR catalyst.
clamp and gasket.
NOTE: Gasket alignment sleeve may be attached to
mixing pipe. Gasket and clamp should be replaced
every time the connection is disassembled.
2030-6
STEP 14 Installation
NOTE: Do not use impact wrenches on the exhaust
system unless sensors are removed.
STEP 1
IMG_1560.TIF
STEP 15
IMG_1571.TIF
STEP 2
IMG_1571.TIF
IMG_1567.TIF
IMG_1560.TIF IMG_1549.TIF
Install hex bolts into SCR catalyst through rear Install new gasket and clamp on connection between
mounting support bracket. SCR catalyst and mixing pipe. Clamp torque 6 Nm
(53 lb in.). Tighten all hex bolts to secure SCR
NOTE: Leave hex bolts loose until final positioning of
catalyst to mounting support brackets.
SCR catalyst is completed.
NOTE: Gasket and clamp should be replaced every
STEP 4 time connection is disassembled. The gasket
alignment sleeve press fits into mixing pipe or
muffler, whichever fits better.
NOTE: It might be necessary to loosen the turbo
clamp, brackets and U-bolts to gain proper alignment
of components.
STEP 6
IMG_1552.TIF
IMG_1536.TIF
IMG_0099.PNG
STEP 8
IMG_1507.TIF
2040
2000-2
TABLE OF CONTENTS
Intake Temperature/Humidity Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2040-3
Removal STEP 3
STEP 1
IMG_1643.TIF
721F-8469.PNG
Raise the engine compartment hood using controls Locate the intake temperature/humidity sensor on air
located behind the access cover. intake pipe between the air filter housing and
turbocharger.
STEP 2
STEP 4
IMG_0099.PNG
IMG_1646.TIF
STEP 2
IMG_1648.TIF
Remove sensor.
NOTE: Cover hole in the intake pipe to prevent
debris from entering the system. IMG_1646.TIF
IMG_1645.TIF
STEP 4
IMG_0099.PNG
2050
2050-2
TABLE OF CONTENTS
DEF/ADBLUE Heater Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2050-3
Removal STEP 3
STEP 1
IMG_1693.TIF
721F-8469.PNG
Raise the hood using controls located behind the Place a suitable container below radiator drain
access cover. located behind access cover. Remove radiator cap.
Remove drain cap and drain engine coolant. Install
tank drain plug and radiator cap after coolant has
STEP 2
drained.
NOTE: Use compressed air and water to clean
debris from around drain plug area prior to draining
the system.
STEP 4
IMG_0099.PNG
IMG_0945.TIF
IMG_1477.TIF IMG_1484.TIF
Disconnect the machine wiring harness from the Remove hex bolts securing heater control valve to
DEF/AdBlue heater control valve. mounting support bracket.
STEP 6 STEP 8
IMG_1479.TIF 1486.TIF
Using a small flat blade screw driver, pull up on the Remove heater control valve from machine.
fitting retaining clip and disconnect the coolant
inlet/outlet lines from the heater control valve.
2050-5
Installation STEP 3
STEP 1
IMG_0099.PNG
STEP 2
IMG_1477.TIF
2060
2060-2
TABLE OF CONTENTS
DEF/ADBLUE DNOx Supply Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2060-3
Removal STEP 3
STEP 1
721F-8490.PNG
IMG_0099.PNG
IMG_1592.TIF
Turn the master electric switch to the “off” position.
Raise the right hand side engine compartment side
panel of the machine.
2060-4
STEP 5 STEP 7
IMG_1594.TIF IMG_1607.TIF
Remove thumb screw securing the right hand side Mark supply and return line connection locations for
inner fender panel. reference during reassembly.
STEP 6 STEP 8
IMG_1598.TIF GRAPHIC_ID
Remove right hand side inner fender panel. Disconnect DEF/AdBlue supply and return lines from
underneath DNOx supply module.
NOTE: To disconnect fittings, squirt water into the
fitting connection to lubricate the O-ring. Squeeze the
locking tabs together while slightly pushing the fitting
ends together and then pulling them apart. If the
fitting will not release, but is free to rotate, the O-ring
is likely stuck and additional water should be used.
NOTE: Use compressed air and water to clean
debris from supply and return line connections.
2060-5
STEP 9 STEP 11
IMG_1615.TIF IMG_1626.TIF
Remove hex bolts securing the DNOx supply module Remove DNOx supply module from the machine.
to the mounting support bracket.
Installation
STEP 10
STEP 1
1 2
1 2
IMG_1634.TIF
IMG_1615.TIF IMG_1600.TIF
Fit the DNOx supply module into mounting support Check wire harness and supply lines for proper
bracket and secure with hex bolts. positioning.
NOTE: Make sure wire harness and supply lines do
STEP 3 not contact anything that would cause damage.
STEP 5
IMG_1640.TIF
IMG_0099.PNG
Reconnect supply and return lines underneath DNOx Turn master switch to “on” position. Clear any fault
control module. To connect, push the two fitting ends codes. Start engine. Check for fluid leaks at
together until an audible snap is heard. connections. Confirm problem has been corrected.
NOTE: Test fitting connections to be sure they are
secure. Match supply and return markings to ensure
correct connections are made.
2060-7
STEP 6
IMG_1598.TIF
STEP 7
IMG_1592.TIF
2070
2070-2
TABLE OF CONTENTS
DEF/Adblue Dosing Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2070-3
Removal STEP 3
NOTE: Do not use impact wrenches on the exhaust
system unless the sensors are removed.
STEP 1
WHL011MM.PNG
1 2
WHL010MM.PNG
IMG_0099.PNG
Remove intake pipe (1) connecting turbocharger and
Turn master electric switch “off”. charge air cooler. Remove intake pipe (2) connecting
air filter housing inlet and support bracket.
NOTE: Cover openings to prevent debris entering
system.
2070-4
STEP 5 STEP 7
1 2
WHL026MM.PNG WHL021MM.PNG
Remove engine coolant line hold down bracket (1) for Mark location of DEF/AdBlue supply and return lines
easier access to dosing injector (2). fo r r e fe r e n c e d u r i n g r e a s s e m b l y. R e m o ve
DEF/AdBlue supply and return lines. Cap lines to
NOTE: Mark location and routing of coolant lines for
prevent debris from entering the system
reference during reassembly.
NOTE: To separate connections, squirt water into
STEP 6 fittings to lubricate O-rings. Squeeze fitting locking
tabs slightly and push fitting together then pull it
apart. If fitting will not release, but is free to rotate,
the O-ring is likely stuck and additional water should
be applied.
STEP 8
WHL001MM.PNG
WHL023MM.PNG
STEP 1
WHL025MM.PNG
STEP 10
WHL025MM.PNG
STEP 2
WHL027MM.PNG
WHL023MM.PNG
1 2
WHL022MM.PNG WHL011MM.PNG
Connect DEF/AdBlue supply and return lines and Remove covers from air intake pipe openings. Install
wiring harness to dosing injector. air intake pipe (1) connecting air filter housing inlet
and suppor t bracket. Install air intake pipe (2)
NOTE: Use marks made during disassembly to
connecting turbocharger inlet side and charge air
determine proper positioning.
cooler.
STEP 4 STEP 6
WHL026MM.PNG
IMG_0099.PNG
Secure engine coolant line hold down bracket.
Turn master electric switch to “on”. Clear any fault
code. Start machine. Check for leaks at DEF/AdBlue,
exhaust and intake system connections. Confirm
problem has been corrected.
Section
2080
2080
2080-2
TABLE OF CONTENTS
DEF/AdBlue Supply Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2080-3
Removal STEP 3
STEP 1
IMG_1693.TIF
721F-8469.PNG
Raise the hood using controls located behind the Place a suitable container below radiator drain
access cover. located beneath the access cover at rear left hand
side of machine. Remove radiator cap. Remove drain
cap. Drain coolant. Install tank drain plug and radiator
STEP 2
cap after coolant has drained.
NOTE: Use compressed air and water to clean
debris from around drain plug area.
STEP 4
IMG_0099.PNG
WHL024MM.PNG
WHL029MM.PNG
tank. Loosen drain plug and drain DEF/AdBlue. Remove filler neck/screen assembly and O-ring from
Install drain plug and access cover after DEF/AdBlue supply ta nk by pullin g upwa rd while twisting
has drained. assembly left and right.
STEP 6 STEP 8
PICT106.TIF WHL002MM.PNG
Remove bolts securing filler neck screen assembly. Remove hex bolts and panel to access supply tank.
NOTE: Place a plug in filler neck hole to prevent
loose screws from entering the supply tank.
2080-5
STEP 9 STEP 11
WHL005MM.PNG WHL007MM.PNG
Remove rubber boot cover from liquid level/temp Pull wire and hose harness up and off to the side out
sensor sending unit wires, DEF/AdBlue and engine of the way.
coolant supply lines. Mark wire and hose connection
NOTE: Plug all lines to prevent debris from entering
positions.
the system.
NOTE: Use compressed air and water to clean
debris from top of DEF/AdBlue supply tank around STEP 12
liquid level/temp sensor sending unit area.
STEP 10
WHL008MM.PNG
WHL009MM.PNG
STEP 2
WHL012MM.JPG
WHL008MM.PNG WHL002MM.PNG
Use reference marks from disassembly procedure to Replace access panel and secure using hex bolts.
position DEF/AdBlue level temp sensor and pick-up
unit. Secure by turning it clockwise. STEP 7
STEP 4
WHL006MM.PNG PICT119.TIF
Remove plugs from all lines. Reconnect DEF/AdBlue Reinstall the O-ring onto the DEF/AdBlue supply tank
supply/return and purge lines, engine coolant supply/ with the radius surface facing upward.
return lines and liquid level gage sensor wiring
NOTE: Lubricate O-ring with petroleum jelly.
harness. To connect, push connections together all
the way, and then pull back to lock.
STEP 8
STEP 5
WHL005MM.PNG
PICT109.TIF
Replace rubber boot protective cover.
Reinstall filler neck assembly onto supply tank.
2080-8
STEP 9
PICT106.TIF
STEP 10
IMG_0099.PNG
2090
2090-2
TABLE OF CONTENTS
DEF ADBLUE SUPPLY TANK LEVEL AND TEMPERATURE SENSOR PICKUP AND HEATER . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2090-3
Removal STEP 3
STEP 1
IMG_1693.TIF
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Raise the hood using controls located behind the Place a suitable container below the radiator drain
access cover. under the access cover at the left rear of the
machine. Remove radiator cap. Remove drain cap
and drain engine coolant. Install tank drain plug and
STEP 2
radiator cap after coolant has drained.
NOTE: Use compressed air and water to clean
debris from around drain plug area before draining
system.
STEP 4
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Use compressed air or water to clean dirt and debris Unplug wiring harness. Disconnect engine coolant
from DEF/AdBlue supply tank around filler cap/neck lines and DEF/AdBlue lines. Disconnect the lines by
(1) and level/temp sensor pickup heater element (2). pushing coupling together all the way to unlock.
Squeeze tabs and pull coupling apar t to break
STEP 6 connections.
STEP 8
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Mark hose and wire connection positioning. Move wiring harness, engine coolant/DEF/AdBlue
supply/return and purge line harness off to the side.
Plug all lines to prevent debris from entering the
system.
2090-5
STEP 9 Installation
STEP 1
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STEP 2
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Remove plugs from all lines. Reconnect DEF/AdBlue Turn master electric switch to the “on” position. Clear
purge and supply/return lines. Reconnect engine any fault codes. Start the machine and check for
coolant supply/return lines. Reconnect liquid level engine coolant and DEF/AdBlue leaks. Confirm that
and temperature sensor wiring har ness. Push problem has been corrected.
connections together all the way and then pull back
to lock. STEP 6
STEP 4
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2100
2100-2
TABLE OF CONTENTS
DEF/adblue supply filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal Supply Tank Filler Neck Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation Supply Tank Filler Neck Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal Supply Line Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation Supply Line Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal DNOx Supply Module Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation DNOx Supply Module Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2100-3
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STEP 4
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STEP 2
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Raise the hood using controls located behind the NOTE: Use compressed air and water, to clean
access cover. debris from around filler cap/neck area.
2100-4
STEP 5 STEP 7
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Remove bolts securing filler cap/neck screen Remove plug from filler neck. Rinse screen with
assembly. water to remove accumulated debris. Reinstall plug
into filler hole.
NOTE: Place a stopper into filler neck hole to
prevent loose screws and debris from entering NOTE: If the screen is damaged replace it. To
supply tank. replace, remove bolts and separate filler neck from
screen. Attach new screen to filler neck and secure
STEP 6 with bolts.
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Reinstall filler cap/neck screen assembly (1) into DEF/AdBlue supply line screen is located under the
supply tank (2). engine hood on the right side of engine at rear of
machine.
STEP 3
STEP 2
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1
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Locate supply line filter screen housing within supply Remove filter screen from housing with needle nose
line between supply tank (1) and DNOx supply pliers. Rinse filter screen with water to remove
module (2) mounted on right hand side of engine. accumulated debris.
NOTE: Use compressed air and water to clean NOTE: If filter screen is damaged, replace it.
debris from around screen assembly.
Installation Supply Line Screen
STEP 5
STEP 1
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Turn master electric switch to “on” position. Clear any Raise the hood using controls located behind the
fault codes. Start engine and check connections for access cover.
leaks. Confirm problem has been corrected.
STEP 3
Removal DNOx Supply Module
Filter
STEP 1
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STEP 4
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1
2
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Squirt water into fitting connections to lubricate Remove filter element (1) from housing (2) by turing it
O-r ings. Disconnect fittings by pushing them counter clockwise. Discard filter element following
together. Then squeeze locking tabs and pull fitting local environmental and waste regulations.
down and off.
NOTE: If the fitting will not release, but is free to Installation DNOx Supply Module
rotate, the O-ring is likely stuck and lubrication of the Filter
O-ring should be repeated.
STEP 1
STEP 6
2
1
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IMG_2001.PNG Lubricate filter element O-ring (1) on housing side.
Remove the DEF/AdBlue filter element assembly Lubricate housing O-ring (2). Install filter element on
from DNOx supply module by turning it counter housing by turing it clockwise.
clockwise. Pull straight down and away from module.
NOTE: Lubricate O-ring with petroleum jelly.
NOTE: Use a suitable container to catch any fluid
discharged during disassembly. NOTE: Hand tighten filter only.
2100-9
STEP 2 STEP 5
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Lubricate filter element O-ring on control module Turn master electric switch to “on” position. Clear any
side. fault codes. Start engine and check connections for
leaks. Confirm problem has been corrected.
NOTE: Lubricate O-ring with petroleum jelly.
STEP 3
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STEP 4
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TABLE OF CONTENTS
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
BELT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
With Out Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
With Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4001-3
STARTER
Removal STEP 4
STEP 1
Park machine on a level surface and lower bucket to
ground.
STEP 2
BD06F135
BD06F133
STEP 3
BD06F134
Installation STEP 7
STEP 5
1
BD06F134
2 Install and tighten the wires on the starter solenoid.
Remove and discard tags.
STEP 8
Place the master disconnect switch in the ON
BC05G047
1. STUDS position. Lower the engine compartment with lifting
2. NUTS motor.
Apply Loctite 747 primer to studs and holes, apply 2
drops of Loctite 271 to each hole and stud.
Immediately install and torque studs to 19 to 29 Nm
(14 to 21 pound-feet). Allow adhesive to cure for 20
minutes before installing starter.
STEP 6
BD06F135
ALTERNATOR
Removal STEP 4
STEP 1
Park machine on a level surface and lower bucket to
ground.
STEP 2
BD06F137
BD06F133
STEP 3 BD06F138
STEP 5
BD06F136
BD06F139
BD06F140
STEP 8
BD06F139
BD06F137 BD06F136
STEP 11
BD06F138
BD06F133
BELT INSTALLATION
BC05G045
WITH OUT AIR CONDITIONING
BC05G046
WITH AIR CONDITIONING
4002
Section
4002
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ELECTRICAL WIRE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
UNDERSTANDING THE TROUBLESHOOTING TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
LOCATING COMPONENTS ON THE SCHEMATIC POSTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
STARTING AND CHARGING SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Starting Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Crank Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Crank Request Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
..................................................................................... 50
Master Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Neutral Start Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
..................................................................................... 52
POWER RELAY MODULES AND COLD STARTING SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Power Relay Module A, Power converter F1, Secondary steering F2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Power Relay Module B, ACC Power F1, DNOX F2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Power Relay Module C, Ignition Power F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Grid Heater Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Grid Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Power Relay Module D, Fuel Filter Heater F1, Engine ECM F2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
..................................................................................... 55
Water Separator Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Fuel Filter Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
ENGINE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Water In Fuel Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Throttle Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Electronic Diesel Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
RETURN TO TRAVEL - RETURN TO DIG - PIN ENGAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Return-To-Travel/Float Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Height Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Electromagnetic Detents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Return-To-Dig Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Pilot Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Height Control/Return-To-Travel Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Return to Dig Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Pin Engage Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Pilot Pressure Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Pin Engage Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
PILOT CONTROL - RIDE CONTROL - FAN CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Ride Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Ride Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Fan Control Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Fan Reverse Relay (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Pilot Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Ride Control Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Rollback Pressure Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Rollback Jumper (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Fan PWM Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Fan Reversing Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4002-3
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Output Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Transmission Solenoid Valve and Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Filter Maintenance Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Torque Converter Output Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Engine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Intermediate Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Turbine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Transmission Shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Transmission Electronic Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Transmission Enable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
FNR Switch for Joystick Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Transmission Kick-down Switch (Located In Hydraulic Controller for Joystick Option; Next to Hydraulic Levers for
Single Axis Controls) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
FNR Switch for Single Axis Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Transmission Auto Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Brake Declutch Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Declutch Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Diagnostic Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
WARNING BUZZER, INSTRUMENT CLUSTER 1, PARK BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Instrument Cluster Connector 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Warning (AIC) Buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Parking Brake Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Air Filter Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Parking Brake Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Radiator Coolant Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Brake Warning Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
SWITCH PAD, INSTRUMENT CLUSTER 2, PARK BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Switch Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Instrument Cluster Connector 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Hydraulic Filter Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Hydraulic Oil Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Redundant Brake Pressure Switch 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Redundant Brake Pressure Switch 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
BACK UP ALARM CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Back-up Alarm Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Back-up Alarm Disable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
LIGHTS - 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Work Lamps Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Door Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Rotating Beacon (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Beacon Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Left Hand Front Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Right Hand Front Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Left Hand Rear Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Right Hand Rear Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Lights Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
LIGHTS - 02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Brake Lamp Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Brake Lamps Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Flasher Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Hazard Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
4002-4
Turn Signal, High-Low Beam, and Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Driving Lamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
LIGHTS - 03 AND HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Left Hand Front Combination Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Right Hand Front Combination Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Horn Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
LIGHTS - 04 AND BACK UP ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Right Hand Rear Combination Lamp (North America Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Right Hand Rear Combination Lamp (Europe Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Left Hand Rear Combination Lamp (North America Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Left Hand Rear Combination Lamp (Europe Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
License Plate Lamp (North America Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
License Plate Lamp (Europe Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Back-up Alarm (North America Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Back-up Alarm (Europe Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
CAB WINDOW WASHER AND WIPER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Front Wiper High Speed Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Front Wiper Cut Out Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Front Wiper Low Speed Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Rear Wiper and Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Front Wiper and Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Front Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Rear Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Rear Washer Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Front Washer Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Wiper Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
SECONDARY STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Secondary Steering Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Secondary Steering Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Secondary Steering Module (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Secondary Steering Motor (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Secondary Steering Pressure Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
CAN COMMUNICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
CAN Communication Diagnostics Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
RADIO AND POWER CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Power Converter 24 volts to 12 volts (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Power Outlet (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
12 Volt Radio Ready (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Right Speaker (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Left Speaker (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
AIR SEAT - CIGAR LIGHTER - AIR CONDITIONING COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Seat Compressor and Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Cigar Lighter (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Compressor Clutch Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
A/C High/Low Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Compressor Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
CLIMATE CONTROL - AUTOMATIC TEMPERATURE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Electronic Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
External Air Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Internal Air Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Sun Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Blower Motor Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Blower Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Thermocouple Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
4002-5
Mixed Air Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Compressor Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Recycling Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Electronic Water Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
24 to 12 Volt Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
STANDARD CLIMATE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Electronic Water Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Blower Motor Speed Resistors with Thermal Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Blower Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Air Conditioning Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Control Panel Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Water Valve Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Air Recirculating Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
HOOD RAISE AND LOWER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Hood Up Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Hood Down Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Hood Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Hood Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
STARTING / ignition SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
...................................................................................... 135
Ignition Power Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Ignition Power Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Start Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
SCR SYSTEM/ joystick steering/ misc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
NOX Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Humidity and ambient temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
NOX Sensor (NOXS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Tank heater control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
DEF Level and tank temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Upstream temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Downstream temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Doser metering valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
DNOX Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Rear View Camera / Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Differential Lock Switch (Manual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Differential Lock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Differential Lock Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Pilot Dump Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
JSS Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Load Sense Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Pilot Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Lockup Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Joystick PVRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Transmission Kick Down Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
ARM POS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
FNR Switch (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
FNR Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
JSS Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Joystick STR Switch (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
JSS Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
4002-6
4002-7
SPECIFICATIONS
Electrical System ............................................................ Two 12 volt batteries connected in series, negative ground
System Voltage................................................................................................................................................24 volts
Batteries
Group Size ..........................................................................................................................................................31
Reserve Capacity ................................................................................................................................ 170 minutes
Cold Cranking Capacity At -17° C (0° F) for 60 Seconds At 6.0 Volts................................................700 amperes
Load of Capacity (Load) Test .............................................................................................................400 amperes
Alternator ..................................................................................................................................... 24 volt, 65 amperes
Voltage Regulator ............................................................................................................. Solid State, Not Adjustable
Starter................................................................................................................................ 24 volt, Solenoid Actuated
Bucket Control Valve (Joystick) Detent Electromagnets Resistance at 20° C (68° F) (Nominal)................ 68.2 ohms
Bucket Control Valve (Single Axis) Detent Electromagnets Resistance at 20° C (68° F) (Nominal) ........... 305 ohms
Fuel Level Sender............................................................................................................................... 33 to 240 ohms
Coolant, Torque Converter, and Hydraulic Temperature Sender 20° C (68° F) ......................................... 3521 ohms
Transmission Filter Restriction Switch with 510 ohms Internal Resistor (Normally Open)
Closing Set point ............................................................................................................................ 2.8 Bar (40 psi)
Hydraulic Filter Restriction Switch (Normally Open) Closing Set point .............................................. 2.8 Bar (40 psi)
Air Filter Restriction Switch (Normally Open) Closing Set point ................................. -6.4 kPa (Gauge) (-0.928 psig)
A/C High Pressure Switch
Closed With Pressure .................................................................................. Above 27.6 ± 0.7 bar (400.3 ± 10.1 psi)
Opens With Pressure ..................................................................................Below 20.7 ± 0.7 bar (300.22 ± 10.1 psi)
A/C Low Pressure Switch
Closed With Pressure .......................................................................................Below 0.3 ± 0.1 bar (4.35 ± 1.45 psi)
Opens With Pressure ......................................................................................... Above 1.4 ± 0.2 bar (20.3 ± 2.9 psi)
Brake Declutch Pressure Switch (Normally Closed) Opening Set point............................................ 24 Bar (350 psi)
Brake Warning Pressure Switch (Normally Closed) Opening Set point ................. 106 to 115 bar (1530 to 1670 psi)
Brake Redundant Pressure Switches (Normally Open) Closing Set point 55 to 69 bar decreasing (800 to 1000 psi)
Brake Lamp Pressure Switch (Normally Open) Closing Set point.....................................................4.13 bar (60 psi)
Secondary Steering Pressure Switch (Form C) Closing Set point ..................................................... 2.4 Bar (35 psi)
Fuel Filters Heater Resistance At 20° C (68° F) (Nominal) .......................................................................... 1.9 ohms
Water Separator Heater At 20° C (68° F) (Nominal)..................................................................................... 1.9 ohms
Parking Brake Solenoid DC Resistance At 20° C (68° F) (Nominal) .......................................................... 40.3 ohms
Pilot Pressure Solenoid (Joystick) DC Resistance At 20° C (68° F) (Nominal) .......................................... 29.9 ohms
Pilot Pressure Solenoid (Single Axis) DC Resistance At 20° C (68° F) (Nominal) ..................................... 27.4 ohms
Ride Control Solenoid DC Resistance At 20° C (68° F) (Nominal)............................................................. 22.7 ohms
Pin Engage Solenoid DC Resistance At 20° C (68° F) (Nominal) .............................................................. 28.8 ohms
Secondary Steering Solenoid DC Resistance At 20° C (68° F) (Nominal) ................................................. 39.3 ohms
Fan Reversing Solenoid DC Resistance At 20° C (68° F) (Nominal).......................................................... 39.3 ohms
Fan PWM Solenoid DC Resistance At 20° C (68° F) (Nominal) ................................................................. 29.3 ohms
Rollback Pressure Switch (Normally Closed) Opening Set point ....................................................... 6.2 Bar (90 psi)
Fuel Temperature Sensor At 20° C (68° F) (Nominal) ............................................................................... 2500 ohms
Grid Heater .................................................................................................................................................. 500 ohms
Engine Control Unit ............................................................................................... Electronic Diesel Control (EDC 7)
Analog Throttle ..................................................................................Idle Validation Switch Closes At 0.775V ± 0.1V
Throttle Position Potentiometer.................................................................................................. 5V Reference ± 0.2V
Low Idle Position .............................................................................................................................. 0.4V ± 0.025V
High Idle Position ................................................................................................................................. 4.0V ± 0.1V
4002-8
SPL_BCK_LT_GD2, SPL_BACK
0_29 RTT/Float GND BK 0.8 GXL SFL, Return to Travel SW 4 K
LGT GRND
SPL-BCK-LT-GD2, Spl Back Lgt
0 29 RTT/Float Ground Bk 0.8 GXL SFL, Return To Travel Sw 4 K
Gnd
0 AA Proximity Switch Grnd Bk 1.0 SXL PXH, Height Control RTT B SPL-A2, Ultrasonic A
0 AB Proximity Switch Grnd Bk 1.0 SXL SPL-A2, Ultrasonic A GND-FC, Ground A 1
0 AC Proximity Switch Grnd Bk 1.0 SXL PXF, RTD B SPL-A2, Ultrasonic A
0 AD Ride Control Ground Bk 1.0 SXL YRC, Ride Control Option 2 SPL-A1, Ultrasonic A
0 AE Pin Engage Ground Bk 1.0 SXL SPL-A1, Ultrasonic A YPE, Pin Engage Jumper B
4002-9
SPL-HOOD-GRND, Hood
0 B10 Hood Ground Bk 1.0 GXL E GND-CAB2, Ground A 1
Grnd 6 Pck
4002-10
SPL-HOOD-GRND, Hood
0 B16 Hood Down Control Ground Bk 1.0 GXL B ECC, Elect CNTR C B4
Grnd 6 Pck
0 B17 Back Light Ground Bk 0.8 GXL STA, Trans Auto Switch 7 SPL-BCK-LT-GD, Spl Bk Lt Grnd E
0 B18 Back Light Ground Bk 0.8 GXL SDC, Declutch Switch 7 SPL-BCK-LT-GD, Spl Bk Lt Grnd F
0 B19 Back Light Ground Bk 0.8 GXL SDR, Driving Lights Switch 7 SPL-BCK-LT-GD, Spl Bk Lt Grnd G
SPL-BCK-LT-GD2, Spl Bk Lt
0 B20 Back Light Ground Bk 0.8 GXL SRC, Ride Control Switch 7 J
Grnd
0 B21 Back Light Ground Bk 0.8 GXL SBU, Backup Alarm Disc Sw 7 SPL-BCK-LT-GD, Spl Bk Lt Grnd J
SPL-HOOD-GRND, Hood
0 B22 Hood Up Relay Ground Bk 1.0 GXL C ECC, Elect CNTR C C2
Gnd 6 Pck
0 B23 Back Light Ground Bk 0.8 GXL SRWP, Rear Wiper Switch 7 SPL-BCK-LT-GD, Spl Bk Lt Grnd L
SPL-PED-BL-GD, Spl Bk Lt Grnd
0 B24 Back Light Ground Bk 0.8 GXL SHZ, Hazard Switch 7 C
6 Pck
SPL-HOOD-GRND, Hood
0 B25 Hood Up Control Ground Bk 1.0 GXL D ECC, Elect CNTR C B2
Gnd 6 Pck
0 B26 Buzzer/Switch Pad Ground Bk 0.8 GXL SPL-BUZ, Ultrasonic A GND_CAB2, Ground A 1
0 B27 Buzzer Ground Bk 0.8 GXL SPL-BUZ, Ultrasonic A BUZ, AIC Buzzer 2
0 B28 Switch Pad Ground Bk 0.8 TXL SW-PD, Switch Pad 10 SPL-BUZ, Ultrasonic A
Splice Pack GND-CAB-SPL2 GND-CAB-SPL2, Spl Back GND-CAB6, Start, FFH, Water
0 EQ Bk 0.8 GXL H 1
Grnd Light Ground Sep Htr
0 ER Power Converter Grnd Bk 1.0 GXL CNV, 24V to 12V Pwr Conv 6 GND-CAB4, Ground C 1
GND_CB, Ground, On
0G Bk 2.0 SXL 1 GND_GL, Ground, Rear Grill 1
Cooling Box
GND-ENG1, STRT, FFH, Water
0 GB Starter Relay Control Ground Bk 1.0 SXL SRC-1, Relay 2 1
Sep Htr
0 HD Speed Sensor Grounds Bk 1.0 SXL TRANS, Cab Transmission 11 SPL-H2, Ultrasonic A
0 HE Output Speed Sensor Grnd Bk 1.0 SXL TRANS, Cab Transmission 28 OSS, Out Speed Sensor 1
Bk 0.8 GXL
0 HF Engine Speed Sensor Grnd ESS, Engine Speed Sensor 2 SPL-H2, Ultrasonic A
Twist
Bk 0.8 GXL
0 HG Inter Speed Sensor Grnd ISS, Inter Speed Sensor 2 SPL-H2, Ultrasonic A
Twist
Bk 0.8 GXL
0 HH Turbine Speed Sensor Grnd TSS, Turbine Speed Sensor 2 SPL-H2, Ultrasonic A
Twist
0 HL Redundant Brake Switch Grnd Bk 1.0 SXL PRB2, Redundant Brake Sw B GND_TRANS, Ground_Trans 1
0 HM Redundant Brake Switch Grnd Bk 1.0 SXL PRB1, Redundant Brake Sw B GND_TRANS, Ground_Trans 1
0 HR HYD FLTR SW Grnd Bk 1.0 SXL PHF9, HYD_FLTR_RES_SW 1 GND_TRANS, Ground_Trans 1
YRC_J, Ride
0 RD Ride Control Grnd Bk 1.0 SXL 2 YRC_J2, Ride_Control_OPT 2
CNTRL_Jumper
JSS_ARM, JSS Armrest to
0 SC GRND, Joystick Bk 0.8 GXL 7 PVRES, JSS Joystick V
CAB
0 SD GRND, Joystick Bk 0.8 GXL SPL_JSS_14, Ultrasonic A CAB_ARM, CAB to Armrest 7
0 SE GRND Bk 0.8 TXL SPL_JSS_10, Ultrasonic A CAN_MOD_2, JSS can mod 10
0 SF GRND Bk 0.8 GXL SPL_JSS_14, Ultrasonic A Cab to JSS Frame G
0 SG Common Bk 0.8 GXL SPL_JSS_10, Ultrasonic A Arm_Pos, Arm position 1
DTLTS,
0 TA DEF Sensor GND LU 0.8 GXL UBJM, DEF Level Temp 2 2
DEF_Tank_Level_Temp_Sensor
0U EXHT Temp DWN GND Bk 0.8 SXL DNOX2, NOX Controller 25 DTS, Downstream Temp SENS 2
12ACC Ignition Switch ACC Power W 0.8 GXL S-KEY, Ignition Switch 4 SPL-ACC, Ultrasonic A
12ACC
ACC PRM Control Power W 0.8 GXL SPL-ACC, Ultrasonic A PRM-B1, PRM Signal A
B
4002-17
LRR-E, RH Rear
18G J RH Position/Tail Fused Power Or 1.0 SXL 3 SPL-POS, Ultrasonic A
Combination Light
18G
RH Position/Tail Fused Power Or 1.0 SXL HD-N, Hood to Engine 5 SPL-POS-NA, Ultrasonic A
JN
18G K RH Position/Tail Fused Power Or 1.0 SXL HD-9, Hood to Engine 5 SPL-P9, A
18G L LIC Plate Fused Power Or 1.0 SXL SPL-P9, A LPL, LIC_PLATE_LIGHT A
SPL-TRANS-PWR, Trans
19A K TECM Fused Power Or 0.8 TXL J TECM, Trans 45
Pwr
19A L Park Brake Switched Fused Pwr Or 0.8 GXL SPB, Parking Brake Switch 2 SPL-PBS, Ultrasonic A
19A M Output Speed Sensor Fused Pwr Or 0.8 TXL CAB-T, Cab Transmission 29 SPL-TRNS-PWR, Trans Power K
SPL-TRANS-PWR, Trans
19A N Trans Fused Power Or 1.0 GXL A ECA, Elect Center A A1
Pwr
19A T Brake Declutch Switch Fused Or 0.8 GXL CAB-T, Cab-Transmission 24 SPL-TRANS-PWR, Trans Pwr D
Power
19A U Trans Kick Down Switch Fused Or 0.8 GXL SPL-FNR, Ultrasonic A 20M, Trans Kick Down 1
Power
19A V FNR Switch Fused Power Or 0.8 GXL SFNR, FNR Switch 5 SPL-FNR, Ultrasonic A
19A W Diagnostic Conn. Fused Power Or 0.8 GXL 108F, Diagnostic Connector 1 SPL-TRANS-PWR, Trans Pwr E
4002-21
19M A Sec. Steering Accessory Fused Or 1.0 SXL TRANS, Cab Transmission 3 TR-SS, Sec. Steering Module Opt A
Pwr
19M C Sec. Steering Accessory Fused Or 1.0 SXL SSM, Sec. Steering Module 7 SS-TR, Sec. Steering Mod Trans A
Pwr
19N Seat Compressor Fused Pwr Or 1.0 GXL SC, Seat Compressor Motor A ECA, Elect Center A C6
19P Pin Engage/Fan Fused Pwr Or 0.8 GXL SPL-PIN, Spl Back Lgt Pwr B ECA, Elect Center A A7
19P A Pin Engage Sw Fused Pwr Or 0.8 GXL SPE, Pin Engage Sw 2 SPL-PIN, Spl Back Lgt Pwr A
19P C Fan Rev Sw Fused Pwr Or 0.8 GXL SFC, Fan Control Switch 5 SPL-PIN, Spl Back Lgt Pwr C
19P D Fan Rev Relay Fused Pwr Or 0.8 GXL SPL-PIN, Spl Back Lgt Pwr E ECB, Elect Center B D7
19P E Fan Rev Relay Fused Pwr Or 0.8 GXL SPL-PIN, Spl Back Lgt Pwr F ECB, Elect Center B B7
19R Sec. Steering Ign Fused Pwr Or 0.8 GXL DM, Diode OR C SPL-2 Ultrasonic A
19RR Sec. Steering Ign Fused Pwr Or 0.8 GXL DM, Diode OR A ECA, Elect Center A A4
19R A Sec. Steering Ign Fused Pwr Or 1.0 SXL TRANS, Cab Transmission 4 TR-SS, Sec. Steering Module Opt B
19R C Sec. Steering Ign Fused Pwr Or 1.0 SXL SSM, Sec. Steering Module 1 SS-TR, Sec. Steering Mod Trans B
19R D Alternator Resistor Fused Pwr Or 0.8 GXL SPL-2, Ultrasonic A 216F, Alternator Resistor 1
19R E Sec. Steering Ign Fused Pwr Or 0.8 GXL SPL-2, Ultrasonic A CAB-T, Cab Transmission 4
19S1 Sec. Steering Fused Pwr Or 3.0 GXL PRM_A1, PRM Output A SPL_19S, Ultrasonic A
19S2 Sec. Steering Fused Pw Or 1.0 GXL SPL_19S, Ultrasonic A CAB_T, Cab-Transmission 26
19S1 E Sec. Steering Fused Pwr Or 1.0 SXL TRANS, Cab Transmission 26 TR-SS, Sec. Steering Module Opt E
SPL-FLSHR-PWR,
1 DV Brake Lights/Flasher Bat Pwr R 2.0 GXL A ECC, Elec CNTR C A4
Ultrasonic
SPL-FLSHR-PWR,
1 DW Brake Lt Relay Bat Pwr R 1.0 GXL A ECD, Elec CNTR D A2
Ultrasonic
1E Grid heater Fuse Bat Power R 19.0 SXL P-C2, B+ Power from PRMD 1 GHF1, Grid Heater Fuse 1
1 GA Filter Htr Pwr R 3.0 SXL PRM-D1, PRM Output C SPL-HTR, Ultrasonic A
1 GB Fuel Filter Htr Pwr R 2.0 SXL SPL-HTR, Ultrasonic A FFH, Fuel Filter Heater A
1 GC Water Sep Htr Pwr R 2.0 SXL SPL-HTR, Ultrasonic A WSH, Water Separator Heater B
1 KA Hazard Switch Pwr R 1.0 GXL SHZ, Hazard Switch 2 SPL-FLSHR-PWR, Ultrasonic A
1 NA Battery Crossover R 62.0 SGR BT3, Starter Battery 1 BT2, Disconnect Battery 1
1 NB Battery Starter R 62.0 SGR BT1, Battery Starter 1 B3, Starter Battery 1
1 NC B+ Power PRMC R 19.0 SXL B1, Starter Power Stud 1 P-C1, B+ Power From PRMC 1
1 ND SSM Power R 62.0 SGR 244F Starter Sec. Strg Mtr 1 B4, Starter Power 1
1 NE Battery STRTR R 62.0 SGR B7, Starter-Battery 1 BT1, Battery_Starter 1
1 NF SSM PWR R 62.0 SGR B8, Starter_Power 1 244F, Starter-sec_STRG_MTR 1
1T EVGT_3 PWR R 1.0 SXL P_C6, B+ PWR FRM PRMD 1 EVGT_3, EVGT_FUSE A
1Y Grid Heater Fused Power R 19.0 SXL GHF3, Grid heater Fuse 1 GHF4, Grid Heater 1
1Z Starter Relay Battery Power R 8.0 SXL P-C4, B+, Power From PRMC 1 195, Starter Relay Power 1
20G A EDC7 ESO-K Interface W 0.8 TXL ENG, Engine Cab1 31 EDC7, Engine Controller 89
20G B EDC7 ESO-K Interface W 0.8 GXL CAB-E, Cab Engine 31 DIA, Diagnostic E
21C Neutral Start Relay Output W 0.8 GXL SPL-CR, Ultrasonic A ECB, Elect Center B D4
21C A Neutral Start Relay Output W 0.8 GXL SPL-CR, Ultrasonic A ECB, Elect Center B D5
4002-25
LU 0.8 GXL
25A Eng Speed Sig TRANS, Cab Transmission 7 ESS, Engine speed Sensor 1
Twist
25A A Eng Speed Sig LU 0.8 TXL TECM, Trans 19 Cab+T, Cab-Transmission 7
LU 0.8 GXL
25B Int Speed Sig TRANS, Cab Transmission 9 ISS, Int Speed Sensor 1
Twist
25B A Int Speed Sig LU 0.8 TXL TECM, Trans 42 Cab+T, Cab-Transmission 9
LU 0.8 GXL
25C Turbine Speed Sig TRANS, Cab Transmission 8 TSS, Turbine Speed Sensor 1
Twist
25C A Turbine Speed Sig LU 0.8 TXL TECM, Trans 41 Cab+T, Cab-Transmission 8
25D Output Speed Sig LU 1.0 SXL TRANS, Cab Transmission 10 OSS, Output Speed Sensor 2
25D A Output Speed Sig LU 0.8 TXL TECM, Trans 62 Cab+T, Cab-Transmission 10
25F Forward Signal LU 0.8 TXL TS1, Transmission Shifter B TECM, Trans 43
25G Brake Declutch Switch LU 1.0 SXL Trans, Transmission-Cab 14 PBD, Declutch Pressure Switch B
4002-27
33R A Redundant Brake Accumulator Y 1.0 SXL TRANS, Cab Transmission 1 SPL-RD, Ultrasonic A
Pressure Low
33R B Redundant Brake Accumulator Y 1.0 SXL SPL-RD, Ultrasonic A PRB2, Redundant Brake Switch A
Pressure Low
33R C Redundant Brake Accumulator Y 1.0 SXL SPL-RD, Ultrasonic A PRB1, Redundant Brake Switch A
Pressure Low
33U Parking Brake Switch Y 0.8 TXL SPB, Parking Brake Switch 3 AIC-2, Advance Instr Cluster 2 6
34A A Diff Lock SW B+ Or 0.8 GXL SDA, Diff Lock Switch 2 SPL_PBS, Ultrasonic A
34A B Diff Lock SW SIG B+ Or 0.8 GXL SDA, Diff Lock Switch 2 SPL_PBS, Ultrasonic A
34A C Diff Lock SOL B+ W 0.8 TXL SPL_D19, Ultrasonic A CAB_T, Cab-Transmission 2
34A D Diff Lock SOL B+ Or 1.0 SXL TRANS, Transmission-Cab 27 YDL, Diff Lock Solenoid 1
4002-30
36G A Torque Conv Output Temp P 0.8 TXL CAB-T, Cab Transmission 13 TECM, Trans 49
Signal
36H Hydraulic Oil Temp P 1.0 SXL TRANS, Cab Transmission 30 HOT, Hydraulic Oil Temp Sender A
36H A Hydraulic Oil Temp P 0.8 TXL CAB-T, Cab Transmission 30 AIC-1, Advance Instr Cluster 1 9
36J Fuel Level Analog P 1.0 SXL ENG, Engine-Cab1 1 RFL_23, Fuel_Level_Send A
36R A Trans Temps/Filter Return P 1.0 SXL TRANS, Cab Transmission 12 SPL H1, Ultrasonic A
36R B Trans Filter Maint Sw Return P 1.0 SXL SPL H1, Ultrasonic A FM, Filter Maint Switch 2
36R C Valve Body Temp Return P 0.8 TXL SPL H1, Ultrasonic A TRC, Trans Control 9
36R D TCO Temp Return P 1.0 SXL SPL H1, Ultrasonic A TCOT, TCO Sender 2
36R E Trans Temps/Filter Return P 0.8 TXL CAB-T, Cab Transmission 12 TECM, Trans 46
36T Valve Body Temp Sig P 0.8 TXL TRANS, Cab Transmission 5 TRC, Trans Control 8
36T A Valve Body Temp Sig P 0.8 TXL CAB-T, Cab Transmission 5 TECM, Trans 39
37D A Diagnostic Signal P 0.8 TXL 108F, Diagnostic Connector 2 TECM, Trans 15
37E Diagnostic Signal Switched P 0.8 TXL 108F, Diagnostic Connector 4 TECM, Trans 18
38A Doser Valve GND LU 0.8 GXL DNOX2, NOX Controller 11 DEFDM, Doser Metering VLV 2
38B DEF Level SIG Y 0.8 GXL UBJ, DEF Level Temp 1 DNOX2, Nox Controller 18
DTLTS,
38B A DEF Level SIG Y 0.8 GXL UBJM, DEF Level Temp 1 1
DEF_Tank_Level_Temp_Sensor
38C Tank Heat GND LU 0.8 TXL DNOX2, NOX Controller 23 THV, Tank Heater Control Valve 1
38D Tank Heat B+ Or 0.8 TXL DNOX2, NOX Controller 1 THV, Tank Heater Control Valve 2
4002-32
DTLTS,
38G A DEF Temp SIG Y 0.8 GXL UBJM, Def Level Temp 3 3
Def_Tank_Level_Temp_Sensor
38H DNOX2 K-Line W 0.8 TXL ENG, Engine-Cab1 18 DNOX2, NOX Controller 31
401B Pedal POS Signal Y 0.8 GXL BTM_C, Cab Bottom Bulkhd F BPP, Pedal Position 4
41H A High Beam Pwr Or 1.0 GXL SRHSTLK, RH Stalk Switch 56a SPL_HB, Ultrasonic A
41H B High Beam LH Pwr Or 0.8 GXL SPL_HB, Ultrasonic A ECB, Elect Center B A3
41H C High Beam RH Pwr Or 0.8 GXL SPL_HB, Ultrasonic A ECB, Elect Center B A4
41H D High Beam Pwr Or 0.8 TXL SW-PD, Switch Pad 1 SPL_HB, Ultrasonic A
41J Driving Light Power Or 1.0 GXL SDR, Driving Lights Switch 6 SRHSTLK, RH Stalk Switch 56
41L A Low Beam Power Or 1.0 GXL SRHSTLK, RH Stalk Switch 56b SPL-LB, Ultrasonic A
41L B Low Beam LH Power Or 0.8 GXL SPL-LB, Ultrasonic A ECB, Elect Center B A6
41L C Low Beam RH Power Or 0.8 GXL SPL-LB, Ultrasonic A ECB, Elect Center B A5
41T Position Lights Switched Pwr K 1.0 GXL SDR, Driving Lights Switch 3 SPL_PR, Ultrasonic A
41T A Position Lights RH Switched Pwr K 1.0 GXL SPL_PR, Ultrasonic A ECB, Elect Center B A8
41T B Position Lights LH Switched Pwr K 1.0 GXL SPL_PR, Ultrasonic A ECB, Elect Center B A7
41T C Position Lights Switched Pwr K 1.0 GXL D-OR, Diode OR B SPL_PR, Ultrasonic A
42C A Front Work Lights Fused Pwr DU 2.0 GXL CAB-RF, Cab to Roof Conn. H SPL_42C, Ultrasonic A
42C C Front Work Lights Fused Pwr DU 2.0 GXL SPL_42C, Ultrasonic A SWL, Work Lights SW 3
42C D Front Work Lights Fused Pwr DU 1.0 GXL SPL_42C, Ultrasonic A D-OR, Diode OR A
42C F Front Work Lights Fused Pwr DU 2.0 GXL ROOF, Roof to Cab Conn. H SPL-WRKF, Ultrasonic A
42C G RH Front Work Lights Fused Pwr DU 1.0 GXL SPL-WRKF, Ultrasonic A LRFW, RH Front Work Light 1
42C H LH Front Work Lights Fused Pwr DU 1.0 GXL SPL-WRKF, Ultrasonic A LLFW, LH Front Work Light 1
42R A RH Front Work Lights Fuse Pwr DU 1.0 GXL LRFS, Front_WK_LT_OPT 1 SPL_WRK1, Ultrasonic A
42R B RH Front Work Lights Fuse Pwr DU 1.0 GXL SPL_WRK1, Ultrasonic A LRFR, Front_WK_LT_OPT 1
42R C Rear Work Lights Fused Pwr DU 2.0 GXL CAB-RF, Cab to Roof Conn. S SWL, Work Lights SW 6
42R F Rear Work Lights Fused Pwr DU 2.0 GXL ROOF, Roof to Cab Conn. S SPL-WRKR, Ultrasonic A
42R G RH Rear Work Lt Fused Pwr DU 1.0 GXL SPL-WRKR, Ultrasonic A LRRW, RH Rear Work Light 1
42R H LH Rear Work Lt Fused Pwr DU 1.0 GXL SPL-WRKR, Ultrasonic A LLRW, LH Rear Work Light 1
4002-33
SPL_BCK_LGT2, Spl_Back
49 Z Back Light Power S 0.8 GXL J SDA, Diff Lock Switch 8
Lgt Pwr
51B A JSS ACT SW W 0.8 GXL SPL_JSS_2, Ultrasonic A SJS, Joystick_Control_SW 3
51B B JSS ACT SW W 0.8 GXL SJS, Joystick_Control_SW 6 SPL_JSS_2, Ultrasonic A
51B C JSS ACT SW W 0.8 GXL JSS_CAB, JSS Cab 5 SPL_JSS_2, Ultrasonic A
CAB_ARM_FRM, Cab to Arm
51B D JSS ACT SW W 1.0 SXL 5 SPL_JSS_7, Ultrasonic A
to Frm
51B E B+, JSS W 0.8 GXL JSS_RLY, Relay K2 86 SPL_JSS_7, Ultrasonic A
51B G B+, JSS W 0.8 GXL SPL_JSS_7, Ultrasonic A JSS_RLY, Relay K2 87
51B H JSS ACT SW W 0.8 GXL SPL_JSS_7, Ultrasonic A CAB_ARM, Cab to Armrest 6
4002-36
CANS
G 0.8 TXL CAB_ARM_FRM, Cab to Arm to
LB CAN LO, CAN MOD2 CAB_ARM, Cab to Armrest 12 1
twist Frm
Y 0.8 TXL
CAN H CAN High ENG, Engine-Cab1 14 SPL_CAN_DH, Ultrasonic A
TWIST
CAN Y 0.8 GXL TERM_CAN_2, Can Bulk
CAN2 HI, Term B SPL_CAN_HV, Ultrasonic A
H2 twist Head
CAN Y 0.8 GXL
CAN2 HI, NOX SPL_CAN_HT, Ultrasonic A EDC7, Engine Controller 53
H3 twist
CAN Y 0.8 TXL
CAN High SPL-CAN-JS_HI, Ultrasonic A SPL_CAN_GH, Ultrasonic A
HA TWIST
CAN Y 0.8 TXL
CAN High SPL-CAN-DIAG, Ultrasonic A DIA, Diagnostic C
HB TWIST
CAN Y 0.8 TXL
CAN High SPL-CAN-TRANS, Ultrasonic A SPL-CAN-DIAG, Ultrasonic A
HC TWIST
CAN Y 0.8 TXL
CAN High SPL-CAN-TRANS, Ultrasonic A TECM, Trans 25
HD TWIST
CAN Y 0.8 TXL
CAN High SPL-CAN, Ultrasonic A SPL-CAN-TRANS, Ultrasonic A
HE TWIST
CAN Y 0.8 TXL
CAN High SW-PD, Switch Pad 7 SPL-CAN, Ultrasonic A
HF TWIST
CAN Y 0.8 TXL
CAN High SPL-CAN, Ultrasonic A AIC-1, Adv Instrument Cluster 1 3
HG TWIST
CAN Y 0.8 TXL
CAN High SPL_CAN_TEL, Ultrasonic A TEL, Telematics M
HH TWIST
CAN Y 0.8 TXL
CAN High SPL_CAN_TEL, Ultrasonic A SPL_CAN_JS_H2, Ultrasonic A
HJ TWIST
CAN Y 0.8 GXL
CAN HI, EDC SPL-CAN-DH, Ultrasonic A EDC7, Engine Controller 35
HK twist
CAN Y 0.8 TXL
CAN High SPL_CAN_TEL, Ultrasonic A SPL_CAN_DIAG, Ultrasonic A
HL TWIST
4002-43
1 – Alternator 1
Correct
Check Points 2 Possible Cause of Bad Reading
Reading
3 4
Check the 10 ampere fuse at
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.
9
3
8
5
10
2
4 11
1
6
RCPH10WHL094FAH
1. STARTING RELAY 7.
2. RESISTOR 75 OHM 8. MASTER DISCONNECT SWITCH
3. ALTERNATOR 9. STARTER
4. CRANK CONTROL RELAY 10. IGNITION SWITCH
5. BATTERIES 11. NEUTRAL START RELAY
6. CRANK REQUEST RELAY 12.
NOTE: The battery must be at full charge and all connections clean and tight before doing any testing of the
electrical system. Use a Multimeter for the following tests.
4002-49
1 – Starting Relay
Located in the right side of the engine compartment on cooling fan housing, open engine compartment to gain access.
Correct
Check Points Possible Cause of Bad Reading
Reading
NOTE: Put the transmission in NEUTRAL. Have another person hold the ignition switch in the START position.
Terminal for wire 21D to ground 24 volts Check crank control relay (4), also check circuit 21D.
2 – Resistor
Located in the cab access panel for fuses and relays.
NOTE: Turn master disconnect switch off, disconnect terminals from resistor.
Correct
Check Points Possible Cause of Bad Reading
Reading
3 – Alternator
Located on left side of engine, open engine compartment to gain access.
Correct
Check Points Possible Cause of Bad Reading
Reading
Between the B+ terminal of Check circuit to positive post of left battery. Bad master
24 volts
alternator and ground disconnect switch.
Between terminal for wire 1-BA and 24 volts Bad wire 1-BA.
ground
Between the B+ 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 ECA-F4. Check power relay module A, and 105 ampere circuit
breaker in engine compartment of machine.
Terminal for wire 21H to ground Continuity Bad ground circuit or bad EDC7 (24).
NOTE: Put the master disconnect switch in the ON position. Put the transmission in NEUTRAL. Have another
person hold the ignition switch in the START position.
Terminal for wire 21C-B to ground 24 volts Bad neutral start relay (11), check wire circuit 21C.
Terminal for wire 21G to ground 24 volts Bad EDC7 (24), check wire circuit 21G.
Terminal for wire 21D-A to ground 24 volts Bad crank control relay.
5 – Batteries
Located on right and left rear sides of the machine.
NOTE: Put the master disconnect switch in the ON position. Have another person hold the ignition switch in the
START position.
Terminal for wire 21C-A to ground 24 volts Check circuit 21 to neutral start relay (11).
Terminal for wire 21E to ground 24 volts Bad crank request relay.
7 –
4002-51
NOTE: Disconnect cables from both terminals of master disconnect switch (main contact). Put master disconnect
switch in ON position.
Between terminals of master Continuity If there is no continuity, the master disconnect switch (2) is bad.
disconnect switch
Between terminals of master Open Circuit If there is continuity, the master disconnect switch is bad.
disconnect switch
NOTE: Use the same method to check the master disconnect switch (auxiliary contact).
9 – Starter Motor
Located on left side of engine, open engine compartment to gain access.
Correct
Check Points Possible Cause of Bad Reading
Reading
NOTE: Put the transmission in NEUTRAL. Have another person hold the ignition switch in the START position.
Bad starting relay (1). Also check wire 1-BB between starter
Terminal S to ground 24 volts
and starting relay (1).
10 – Ignition Switch
Located on steering column.
Correct
Check Points Possible Cause of Bad Reading
Reading
Terminal for wire 1DM to ground 24 volts Check circuit 1DM to ECC-F5 fuse.
NOTE: Disconnect the connector from the ignition switch. Turn the switch to ON.
NOTE: Put master disconnect switch and ignition switch in ON position. Make sure transmission is in NEUTRAL.
Terminal for wire 25T to ground 24 volts Check circuit 25T, check FNR switch (55).
NOTE: Have another person hold the ignition switch in the START position.
Terminal for wire 21K-B to ground 24 volts Check circuit 21K-B and ignition switch (10).
Terminal for wire 21C to ground 24 volts Bad neutral start relay.
12 –
4002-53
13 14
20
18 15
21 16
17
RCPH10WHL094
NOTE: Put the master disconnect switch in the ON position. Turn the ignition switch to the ON position.
Terminal for wire 12ACC-C to 24 volts Check circuit 12ACC and check ignition switch (10).
ground
Terminal for wire 19L to ground 24 volts Bad power relay module A.
NOTE: Put the master disconnect switch in the ON position. Turn the ignition switch to the ON position.
Terminal for wire 12ACC-B to 24 volts Check circuit 12ACC, check ignition switch (10).
ground
Terminal for wire PRM-B J11 BUSS 24 volts Bad power relay module B
to ground
Terminal for wire 13K-C to ground 24 volts Check 13K and check ignition switch (10).
Terminal for wire 0-BV to ground Continuity Bad ground circuit or bad EDC7 (24).
NOTE: Put the master disconnect switch in the ON position and the ignition switch in ON position.
Terminal for wire 1-Y to ground 24 volts Bad 150 ampere fuse. Check wires 1-Y and 1-E.
NOTE: Have an assistant put the transmission in neutral and the ignition switch in the START position. Make sure
engine temperature is below -0 ° C (32 ° F).
Terminal for wire 28G to ground 24 volts Bad EDC7 (24), also check circuit 28G.
Terminal for wire 1-BE to ground 24 volts Bad grid heater relay.
17 – Grid Heater
Located in the right side of the engine in intake manifold, open engine compartment to gain access.
Correct
Check Points Possible Cause of Bad Reading
Reading
Terminal for wire 1-BE of grid heater Resistance If an open or short circuit is obtained, replace the grid heater.
to ground
Correct
Check Points Possible Cause of Bad Reading
Reading
Terminal for wire 31B to ground Continuity Bad ground circuit or bad EDC7 (24).
Terminal for wire 1-GA to ground 24 volts Bad power relay module
19 –
4002-56
NOTE: If the readings are good, check circuit 1-GA between water separator heater connector WSH and power
relay module D connector PRM-D1.
NOTE: If the readings are good, check circuit 1-G between fuel filter heater connector FFH and power relay
module D connector PRM-D1.
4002-57
ENGINE CONTROLLER
24 22 23
RCPH10WHL094FAH
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Terminal for wire 18J-H to ground 24 volts Check power EDC7, also check circuit 18J.
Terminal for wire 35W to ground 24 volts Bad water separator sensor.
23 – Throttle Potentiometer
Located below cab under throttle pedal.
Correct
Check Points Possible Cause of Bad Reading
Reading
NOTE: Put the master disconnect switch in the ON position and the ignition switch in ON position.
Terminal for wire 24S to 24R 5 volts Bad EDC7 (24). Also check wire 24S.
Terminal for wire 24R to ground Continuity Bad EDC7 (24). Also check wire 24R.
0.4 ± 0.025
Terminal for wire 24B to 24R Bad potentiometer.
volts
Terminal for wire 24B to 24R 4.0 ± 0.1 volts Bad potentiometer.
NOTE: Put the ignition switch in OFF position and the master disconnect switch in the OFF position. Disconnect
connector RTHP. Throttle pedal in low idle position.
1000 ± 400
Between pin 1 and 6 at pedal ohms at 20° C Bad potentiometer.
(68° F)
1200 ± 400
Between pin 4 and 5 at pedal ohms at 20° C Bad potentiometer.
(68° F)
4002-59
NOTE: Put the master disconnect switch in the ON position. Put the ignition switch in the ON position.
Terminal for wire 18J-C pin 2 to 24 volts Bad fuse ECM-F2, bad wire 18J.
ground
Terminal for wire 18J-B pin 3 to 24 volts Bad fuse ECM-F2, bad wire 18J.
ground
Terminal for wire 18J-D pin 8 to 24 volts Bad fuse ECM-F2, bad wire 18J.
ground
Terminal for wire 18J-E pin 9 to 24 volts Bad fuse ECM-F2, bad wire 18J.
ground
NOTE: Use diagnostic service tool for additional tests on EDC7.
4002-60
28
30
25 26 31 32
27
29 33 34
RCPH10WHL094FAH
25. RETURN TO TRAVEL FLOAT SWITCH 30. HEIGHT CONTROL/RETURN TO TRAVEL PROXIMITY SWITCH
26. HEIGHT CONTROL SWITCH 31. RETRUN TO DIG SWITCH
27. ELETROMAGNETIC DETENTS 32. PIN ENGAGE SWITCH (OPTION)
28. RETURN TO DIG PROXIMITY SWITCH 33. PILOT PRESSURE SOLENOID
29. PILOT CONTROL RELAY ECD-K3 34. PIN ENGAGE SOLENOID (OPTION)
NOTE: The battery must be at full charge and all connections clean and tight before doing any testing of the
electrical system. Use a Multimeter for the following tests.
4002-61
25 – Return-To-Travel/Float Switch
Located on right side console.
Correct
Check Points Possible Cause of Bad Reading
Reading
NOTE: Disconnect the wiring harness connector from the return-to-travel/float switch. Put the return-to-
travel/float switch in FLOAT position.
NOTE: Put ignition switch in OFF position. Connect wiring harness connector to return-to-travel/float switch. Put
ignition switch in ON position. Put driving lamp switch (95) in position 3.
NOTE: Turn the master disconnect to the ON position, the ignition switch to the ON position and the pilot control
switch to the ON position.
Terminal for wire 53P-D to ground. 24 volts Bad pilot control relay (29), check fuse ECA-F5.
Terminal for wire 54A to ground. 24 volts Bad height control switch.
4002-62
27 – Electromagnetic Detents
Located under right side console.
Correct
Check Points Possible Cause of Bad Reading
Reading
74 ohms @
Between pins 3 and 4 Bad electromagnetic detent
20° C (68° F)
74 ohms @
Between pins 2 and 5 Bad electromagnetic detent
20° C (68° F)
74 ohms @
Between pins 1 and 6 Bad electromagnetic detent
20° C (68° F)
328 ohms @
Between pins 3 and 4 Bad electromagnetic detent
20° C (68° F)
328 ohms @
Between pins 2 and 5 Bad electromagnetic detent
20° C (68° F)
328 ohms @
Between pins 1 and 6 Bad electromagnetic detent
20° C (68° F)
NOTE: Put the master disconnect switch and ignition switch in ON position. Put pilot control switch (39) in OFF
position and return to travel/float switch (25) in ON position.
Wiring harness connector EM, pin 1 24 volts Bad return to travel/float switch (25). Also check wires 55A.
to ground
Wiring harness connector EM, pin 2 24 volts Bad height control switch (26). Also check wires 54A.
to ground
Wiring harness connector EM, pin 3 24 volts Bad return to dig switch (31). Also check wires 53A.
to ground
NOTE: Disconnect the connector from the return-to-dig proximity switch. Put the master disconnect switch and
the ignition switch in the ON position. Put the pilot control switch (39) in the OFF position and the return to dig
switch in the ON position.
Terminal C for wire 53P-I to ground 24 volts Bad pilot relay (29), also check circuit 53P.
NOTE: If the readings are good, replace the return-to-dig proximity switch.
4002-63
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure pilot control switch
(39) is OFF.
Terminal for wire 19C-C to ground 24 volts Bad fuse ECA-F5, also check circuit 19C.
Terminal for wire 53C-A to ground 0 volt Bad instrument cluster (62). Also check circuit 53C.
Terminal for wire 53P-A to ground 24 volts Bad pilot control relay.
Terminal for wire 53C-A to ground 24 volts Bad instrument cluster (62). Also check circuit 53C.
NOTE: Disconnect the connector from the height control/return-to-travel proximity switch. Put the master
disconnect switch and the ignition switch in the ON position. Put the pilot control switch (39) in the OFF position
and the return to travel switch in the ON position.
Terminal C for wire 53P-J to ground 24 volts Bad pilot relay (29), also check circuit 53P.
NOTE: If the readings are good, replace the height control/return-to-travel proximity switch.
NOTE: Turn the master disconnect to the ON position, the ignition switch to the ON position and the pilot control
switch to the ON position.
Terminal for wire 53P-E to ground. 24 volts Bad pilot control relay (29), check fuse ECA-F5.
Terminal for wire 53A to ground. 24 volts Bad return to dig switch.
4002-64
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put pin engage switch in OFF
position.
Terminal for wire 57-B to ground 0 volt Bad pin engage switch.
Terminal for wire 57-B to ground 24 volts Bad pin engage switch.
Check the driving lamp switch (95). Also check circuit 49. If
Terminal for wire 49-F to ground 24 volts 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. Make sure the pilot control
switch (39) is OFF.
Terminal A for wire 53P-A to ground 24 volts Bad pilot control relay (29), also check circuit 53P.
NOTE: If the readings are good, replace the pilot pressure solenoid.
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the pin engage switch
(32) in the ON position.
Terminal for wire 57-D to ground 24 volts Bad pin engage switch (32), also check circuit 57.
NOTE: If the readings are good, replace the pin engage solenoid.
4002-65
43 44
35 37 39
40
36 41
38 42
RCPH10WHL094FAH
35. RIDE CONTROL SWITCH (OPTION) 40. RIDE CONTROL SOLENOID (OPTION)
36. RIDE CONTROL RELAY (OPTION) 41. ROLLBACK PRESSURE SWITCH (OPTION)
37. FAN CONTROL SWITCH (OPTION) 42. ROLLBACK JUMPER
38. FAN REVERSE RELAY (OPTION) 43. FAN PWM SOLENOID
39. PILOT CONTROL SWITCH 44. FAN REVERSE SOLENOID (OPTION)
NOTE: The battery must be at full charge and all connections clean and tight before doing any testing of the
electrical system. Use a Multimeter for the following tests.
4002-66
NOTE: Connect connector SRC to ride control switch. Put master disconnect switch and ignition switch in ON
position. Put ride control switch in OFF position.
Terminal for wire 58C to ground 0 volt Bad ride control switch.
Terminal for wire 58C to ground 24 volts Bad ride control switch.
Check driving lamp switch (95). Also check circuit 49. If LED in
Terminal for wire 49-G to ground 24 volts 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 58T to ground 24 volts Bad ride control switch. Also check wire 58T.
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Terminal for wire 52AU to ground 24 volts Bad fan control switch.
Terminal for wire 52M to ground 24 volts Bad fan control switch.
Check driving lamp switch. If LEDs in fan control switch are not
Terminal for wire 49-Q to ground 24 volts
ON with 24 volts at check point, replace fan control switch.
Terminal for wire 19P-D and 19P-E 24 volts Check fuse ECA-F7 and circuit 19P.
to ground
NOTE: Put the fan control switch in the manual reverse position.
Bad fan reverse solenoid, bad fan control switch (37), bad
Terminals for wire 52A-A to ground 24 volts
advanced instrument cluster (62).
4002-68
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Terminal for wire 19C-F to ground 24 volts Bad fuse ECA-F5, also check circuit 19C.
Terminal for wire 31L to ground 24 volts Bad pilot control switch.
Check driving lamp switch (95) and fuse ECC-F3. Also check
Terminal for wire 49-N to ground 24 volts
circuit 49.
NOTE: If the readings are correct replace the pilot control switch.
NOTE: Switch opens at 6.2 bar (90 psi). Release all hydraulic pressure from the system, disconnect the wiring
harness from the rollback pressure switch.
Terminal for wire 58 to ground 37 to 43 ohms Bad ride control solenoid (40).
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the ride control switch
(35) in the ON position. Accelerate the machine to at least 5 km/hr (3 m.p.h.).
24 volts at
Bad ride control relay (36) or ride control switch (35). Also
Terminal for wire 58-B to ground 5 km/hr
check circuit 58.
(3 m.p.h.)
4002-69
NOTE: Disconnect wiring harness connector YFN from fan PWM solenoid.
Between pins A and B of fan PWM 26 to 32 ohms Bad fan reversing solenoid.
solenoid
NOTE: In the options menu of the instrument cluster select auto for the fan. Stall the transmission to raise
transmission temperature to high operating range.
Pin A of wiring harness connector 24 volts Bad instrument cluster. Also check wire 56.
YFN to ground
NOTE: Disconnect wiring harness connector YFR 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).
Pin 1 of wiring harness connector 24 volts Bad fan control switch. Also check wire 52-A.
YFR to ground
4002-70
TRANSMISSION
46 48
52
55 56 57 60
49 50 45 53 54
51 47 61 58
RCPH10WHL094FAH
45. OUTPUT SPEED SENSOR 54. TRANSMISSION ENABLE SWITCH
46. TRANSMISSION SOLENOID VALVE AND TEMPERATURE SENSORS 55. FNR SWITCH FOR JOYSTICK CONTROLS
47. FILTER MAINTENANCE SWITCH 56. TRANSMISSION KICK-DOWN SWITCH
48. TORQUE CONVERTER OUTPUT TEMPERATURE SENDER 57. FNR SWITCH FOR SINGLE AXIS CONTROLS
49. ENGINE SPEED SENSOR 58. TRANSMISSION AUTO SWITCH
50. INTERMEDIATE SPEED SENSOR 59. BRAKE DECLUTCH PRESSURE SWITCH
51. TURBINE SPEED SENSOR 60. DECLUTCH SWITCH
52. TRANSMISSION SHIFTER 61. DIAGNOSTIC CONNECTOR
53. TRANSMISSION ELECTRONIC CONTROL MODULE
NOTE: The battery must be at full charge and all connections clean and tight before doing any testing of the
electrical system. Use a Multimeter for the following tests.
4002-71
NOTE: If you have transmission shifting problems, see Section 6002 for complete troubleshooting information for
Items 45 through 61.
66
62 63
68
67
69
65 64
RCPH10WHL094FAH
NOTE: Disconnect the connector AIC-1 from the instrument cluster and SW-PD from the switch pad.
Connector terminal SW-PD 5 to Open Circuit Bad air filter restriction switch (66). Also check circuit 31F-A.
ground
Connector terminal SW-PD 4 to Bad hydraulic filter restriction switch (72). Also check circuit
Open Circuit
ground 31H-A.
Connector terminal AIC-1 6 and 12 Continuity Bad ground circuit. Check wires 0-DW and 0-DX.
to ground
Connector terminal AIC-1 11 to 130 to 9500 Bad engine coolant temperature sender (68). Also check circuit
ground ohms circuit 36C-A and ground circuit at sender.
Connector terminal AIC-1 2 to Bad fuel level sender (65). Also check circuit 36F-A and ground
33 to 240 ohms
ground circuit at sender.
Connector terminal AIC-1 9 to 130 to 9500 Bad hydraulic oil temperature sender (73). Also check circuit
ground ohms 36H-A and ground circuit at sender.
Connector terminal AIC-2 4 to Bad redundant brake switche(s) (75)(76). Also check circuit
Open Circuit
ground 33R.
Connector terminal AIC-1 14 to Bad parking brake switch (64). Also check fuse ECA-F6 and
24 volts
ground circuit 19D-B and 52C.
NOTE: Put the blower switch in any position other than OFF and thermostat switch fully clockwise.
NOTE: Put the driving lamp switch in position four or five. Put the high/low beam switch in HIGH BEAM position.
Connector terminal SW-PD 1 to Check high/low beam switch, driving lamp switch, and fuse
24 volts
ground ECB-F3 or F4. Also check circuit 41H-D.
Connector terminal AIC-1 14 to Bad parking brake relay or fuse ECA-F6. Also check circuits
24 volts
ground 52C and 19D-B.
Connector terminal AIC-1 20 to Bad pilot control relay or fuse ECA-F5. Also check circuits
24 volts
ground 53C-A and 19C-C.
4002-74
NOTE: Buzzer sounds for five seconds during self test when ignition switch is turned on.
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the parking brake
switch (74) is OFF.
Terminal for wire 19D-B and 19D-C 24 volts Bad fuse ECA-F6, also check circuit 19D.
to ground
Terminal for wire 52C to ground 0 volt Bad instrument cluster (62). Also check circuit 52C.
Terminal for wire 52P-B to ground 24 volts Bad parking brake relay.
Terminal for wire 52C to ground 24 volts Bad instrument cluster (62). Also check wire 52C.
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Approximately
Terminal for wire 36F to ground Check the instrument cluster (62).
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: 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 (62).
11.5 volts
NOTE: If the readings are correct replace the air filter restriction indicator switch.
NOTE: Put the master disconnect switch and ignition switch in ON position. Put parking brake switch in OFF
position.
Terminal 1 for wire 52P to ground 24 volts Bad parking brake relay (64). Also check circuit 52P
NOTE: If the readings are good, replace the parking brake solenoid.
NOTE: Disconnect the connector from the radiator 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 (62).
5 volts
4002-76
NOTE: Brake warning pressure switch opens at 110.3 bar (1600 psi).
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Approximately
Terminal 1 for wire 33P to ground Check circuit 33P.
11.5 volts
NOTE: With engine not running pump brakes at least 12 times. Disconnect the wires from the brake warning
pressure switch.
Between terminals 1 and 2 of the Continuity Bad brake warning pressure switch.
switch
70 71 74
75
76
72
73
RCPH10WHL094FAH
70 – Switch Pad
Located on steering column.
Correct
Check Points Possible Cause of Bad Reading
Reading
NOTE: Disconnect switch pad connector, put master disconnect switch and ignition switch in ON position.
Terminal for wire 17P-A to ground. 24 volts Bad instrument cluster (62).
NOTE: Disconnect the connector AIC-2 from the instrument cluster and SW-PD from the switch pad.
Connector terminal AIC-2 5 to Bad brake warning pressure switch (69). Also check circuit
Continuity
ground 33P-A and ground circuit at brake warning pressure switch.
Connector terminal AIC-2 11 to Bad secondary steering pressure switch (118). Also check
Continuity
ground circuit 35X and ground circuit at pressure switch.
Connector terminal SW-PD 5 to Open Circuit Bad air filter restriction switch (66). Also check circuit 31F-A.
ground
Connector terminal SW-PD 4 to Bad hydraulic filter restriction switch (72). Also check circuit
Open Circuit
ground 31H-A.
Connector terminal AIC-2 15 and 22 Continuity Bad ground circuit. Check wires 0-DB and 0-DA.
to ground.
Connector terminal AIC-2 4 to Bad redundant brake switche(s) (75)(76). Also check circuit
Open Circuit
ground 33R.
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Connector terminal AIC-2 14 and 20 24 volts Bad fuse ECD-F8. Also check circuit 19S-C and 19S-D.
to ground
Connector terminal AIC-2 21 to Bad fuse ECA-F3. Also check circuit 19E-A. Also check power
24 volts
ground relay module C (15).
NOTE: Put the blower switch in any position other than OFF and thermostat switch fully clockwise.
NOTE: Put the driving lamp switch in position four or five. Put the high/low beam switch in HIGH BEAM position.
Connector terminal SW-PD 1 to Check high/low beam switch, driving lamp switch, and fuse
24 volts
ground ECB-F3 and F4. Also check circuit 41H-D.
NOTE: Put the turn signal switch in the LEFT TURN position.
24 volts on and Check fuse ECA-F8, turn signal switch, and flasher module.
Connector terminal AIC-2 9 to off every 1-2 Also check circuit 45A-A to flasher module, and circuit 45L-D
ground seconds from flasher module to instrument cluster.
NOTE: Put the turn signal switch in the RIGHT TURN position.
24 volts on and Check fuse ECA-F8, turn signal switch, and flasher module.
Connector terminal AIC-2 10 to off every 1-2 Also check circuit 45B-A to flasher module, and circuit 45R-E
ground seconds from flasher module to instrument cluster.
Connector terminal AIC-2 18 to Bad pilot control switch or fuse ECA-F5. Also check wire 31L
24 volts
ground and circuit 19A.
4002-80
]
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 for wire 31H to ground. Check the instrument cluster (62).
11.5 volts
NOTE: If the readings are correct replace the hydraulic filter restriction switch.
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 (62).
5 volts
4002-81
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Terminal for wire 19A-L to ground 24 volts Check fuse ECA-F6, also check circuit 19A.
Terminal for wire 33U to ground 24 volts Bad parking brake switch.
Bad driving lamp switch. Also check fuse ECC-F3 and circuits
Terminal for wire 49-V to ground 24 volts
41 and 19Z.
NOTE: If 24 volts between wire 49 and ground and parking brake switch is not illuminated, replace parking brake
switch.
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Approximately
Terminal A for wire 33R-C to ground Bad instrument cluster (62), also check circuit 33R.
11.5 volts
NOTE: If the readings are good, replace the redundant brake pressure switch(es).
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
NOTE: If the readings are good, replace the redundant brake pressure switch(es).
4002-82
77 –
4002-83
79
78
RCPH10WHL094FAH
BS06H241 / BS06H242
NOTE: Disconnect the transmission electronic control module (53) connector TECM.
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Bad fuse ECA-F1, also check wires 19A-P, power relay module
Terminal for wire 19A-P to ground 24 volts
C, Ignition power (15).
Bad fuse ECA-F14, also check wires 19H, power relay module
Terminal for wire 19H to ground 24 volts
B, accessory power (14).
NOTE: Put parking brake switch in OFF position. Depress brake pedal once and put gear selector in REVERSE.
Terminal for wire 35A-A to ground 24 volts Bad back-up alarm relay.
NOTE: Put the master disconnect switch and the ignition switch in the ON position and the park brake to the OFF
position. Depress brake pedal once. Move the transmission shift lever to REVERSE.
Terminal for wire 35A-B to ground 24 volts Bad back-up alarm relay (78), also check circuit 35A-B.
NOTE: Wires 35A-E and 35A-D are connected together, connectors 209F and 209M, and switch is removed in
North American models. The connectors are disconnected and the switch is installed in TUV road approved
(Germany) models.
Terminal for wire 35R-C to ground 24 volts Bad back-up alarm disable switch.
4002-85
LIGHTS - 01
87
82 85
81
83 86
88
80 84
89
RCPH10WHL094FAH
80. WORK LIGHTS SWITCH 85. LEFT HAND FRONT WORK LAMP
81. DOOR SWITCH 86. RIGHT HAND FRONT WORK LAMP
82. ROTATING BEACON (OPTIONAL) 87. LEFT HAND REAR WORK LAMP
83. DOME LIGHT 88. RIGHT HAND REAR WORK LAMP
84. ROTATING BEACON SWITCH (OPTIONAL) 89. DIODES
NOTE: The battery must be at full charge and all connections clean and tight before doing any testing of the
electrical system. Use a Multimeter for the following tests.
4002-86
Terminal for wire 42-A and 42-B to 24 volts Bad fuse ECC-F2.
ground
NOTE: Put the work lamps switch in position 2 for front work lamps.
Terminal for wire 42C-C to ground 24 volts Bad work lamps switch.
NOTE: Put the wok lamps switch in position 3 for rear work lamps.
Terminal for wire 42R-C to ground 24 volts Bad work lamps switch.
81 – Door Switch
Located above door in cab.
Correct
Check Points Possible Cause of Bad Reading
Reading
Between pins on door switch with Open circuit Bad door switch
door closed
NOTE: Put master disconnect switch and beacon switch (84) in ON position.
Bad circuit between the beacon and the beacon switch (84).
Terminal for wire 46-D to ground 24 volts
Also check the beacon switch (84).
83 – Dome Lamp
Located in top of cab.
Correct
Check Points Possible Cause of Bad Reading
Reading
NOTE: Put master disconnect switch in ON position. Put dome lamp switch in ON position.
Terminal for wire 19U-C to ground 24 volts Check fuse ECC-F1, also check circuit 19U.
24 volts
Terminal for wire 43-B to ground Check circuit 43, also check advanced instrument cluster (62).
3 to 5 seconds
NOTE: Put master disconnect switch in ON position and driving lamp switch (95) in position 3.
Terminal for wire 19U-H to ground 24 volts Check fuse ECC-F1, also check circuit 19U.
NOTE: Disconnect wiring harness connector LLFW from LH front work lamp connector.
NOTE: Connect wiring harness connector LLFW to LH front work lamp connector.
NOTE: Put master disconnect switch in ON position. Put driving lamp switch (95) in position 3.
Check driving lamp switch (95). Also check circuit 42C from
Terminal for wire 42C-H to ground 24 volts
flood lamp to lamp switch (95) and wire 42-A to fuse ECC-F2.
4002-88
NOTE: Disconnect wiring harness connector LRFW from RH front work lamp connector.
NOTE: Connect wiring harness connector LRFW to RH front work lamp connector.
Terminal for wire 0-MJ to ground Continuity Bad ground circuit. (O-MJ, O-MG, O-MP, O-ML)
NOTE: Put master disconnect switch in ON position. Put driving lamp switch (95) in position 3.
Check driving lamp switch (95). Also check circuit 42C from
Terminal for wire 42C-G to ground 24 volts
flood lamp to lamp switch (95) and wire 42-A to fuse ECC-F2.
NOTE: Disconnect wiring harness connector LLRW from LH rear work lamp connector.
NOTE: Connect wiring harness connector LLRW to LH rear work lamp connector.
NOTE: Put master disconnect switch in ON position. Put driving lamp switch (95) in position 4 or 5.
Check driving lamp switch (95). Also check circuit 42R from
Terminal for wire 42R-H to ground 24 volts
flood lamp to lamp switch (95) and wire 42-B to fuse ECC-F2.
NOTE: Disconnect wiring harness connector LRRW from RH rear work lamp connector.
NOTE: Connect wiring harness connector LRRW to RH rear work lamp connector.
NOTE: Put master disconnect switch in ON position. Put driving lamp switch (95) in position 3.
Check driving lamp switch (95). Also check circuit 42R from
Terminal for wire 42R-G to ground 24 volts
flood lamp to lamp switch (95) and wire 42-B to fuse ECC-F2.
4002-89
89 – Lights Diodes
Located in the cab access panel for fuses and relays, rear of compartment.
Correct
Check Points Possible Cause of Bad Reading
Reading
LIGHTS - 02
93 94
95
90
92 91
RCPH10WHL094FAH
BS06H241 / BS06H242
Terminal for wire 1-AA to ground 24 volts Check fuse ECC-F4, also check wires 1-AA and 1-DR.
Terminal for wire 44 to ground 0 volt Bad brake lamp pressure switch.
NOTE: Put ignition switch in ON position. Have another person press and hold down brake pedal.
Terminal for wire 44 to ground 24 volts Bad brake lamp pressure switch.
Terminal for wire 1-DW to ground 24 volts Check fuse ECC-F4 and wires 1-DW and 1-DV.
Terminal for wire 44A to ground 0 volt Bad brake lamp pressure switch (90).
Terminal for wire 44A-A to ground 0 volt Bad brake lamps relay.
NOTE: Put ignition switch in ON position. Have another person press and hold down brake pedal.
Terminal for wire 44A to ground 24 volts Bad brake lamp pressure switch (90).
Terminal for wire 44A-A to ground 24 volts Bad brake lamps relay.
4002-92
92 – Flasher Module
Located in the cab access panel for fuses and relays, rear of compartment.
Correct
Check Points Possible Cause of Bad Reading
Reading
NOTE: Wiring harness connectors 64F and 64M must be connected for North American Machines for opposite
side steady on operation and disconnected for European machines for opposite side off operation.
Terminal for wire 1-DU to ground 24 volts Check fuse ECC-F4. Also check wires 1-DU and 1-DV.
NOTE: Put ignition switch in the ON position. Put the hazard switch (93) ON.
Terminal for wire 45H to ground 24 volts Bad hazard switch (93). Also check wire 45H.
Intermittent 24
Terminal for wire 45L-D to ground Bad flasher module.
volts
Intermittent 24
Terminal for wire 45R-E to ground Bad flasher module.
volts
NOTE: Put hazard switch (93) in OFF position. Put turn signal switch (94) in RIGHT turn position.
Bad turn signal switch (94) or fuse ECA-F8. Also check wires
Terminal for wire 45B-A to ground 24 volts
45B-A and 45B.
Intermittent 24
Terminal for wire 45R-E to ground Bad flasher module.
volts
Terminal for wire 45A-A to ground 24 volts Bad turn signal switch (94) . Also check wire 45A-A.
Intermittent 24
Terminal for wire 45L-D to ground Bad flasher module.
volts
4002-93
93 – Hazard Switch
Located on steering column.
Correct
Check Points Possible Cause of Bad Reading
Reading
Terminal for wire 1-KA to ground 24 volts Check fuse ECC-F4. Also check wires 1-KA and 1-DV.
HORN SWITCH
Check fuse ECC-F6 and horn relay (98). Also check wires 64C
Terminal for wire 64C to ground 24 volts
and circuit 19U.
TURN SIGNAL
Check fuse ECA-F8 and power relay module C(15). Also check
Terminal for wire 19B to ground 24 volts
wire 19B.
Terminal for wire 45B-A to ground 24 volts Bad turn signal switch.
Terminal for wire 45A-A to ground 24 volts Bad turn signal switch.
Terminal for wire 19Z-a to ground 24 volts Check fuse ECC-F3, also check circuit 19Z.
Terminal for wire 41T to ground 24 volts Bad driving lamp switch.
Terminal for wire 41J to ground 24 volts Bad driving lamp switch.
4002-95
96 99
97
98
RCPH10WHL094FAH
NOTE: Disconnect wiring harness connector LLF from LH front combination lamp connector.
Combination lamp connector pin 3 to Continuity Bad high beam lamp bulb.
pin 1
Combination lamp connector pin 2 to Continuity Bad low beam lamp bulb.
pin 1
Combination lamp connector pin 5 to Continuity Bad turn signal lamp bulb.
pin 1
NOTE: Connect wiring harness connector LLF to LH front combination lamp connector.
NOTE: Put master disconnect switch in ON position and driving lamp switch (95) in position 2.
Check fuse ECB-F7 and driving lamp switch (95). Also check
Terminal for wire 18F to ground 24 volts
circuit 18F.
NOTE: Put ignition switch in ON position. Put turn signal lever in LEFT turn position.
Intermittent 24 Check the turn signal switch (94) and flasher module (92). Also
Terminal for wire 45L to ground volts check circuit 45L to flasher module.
NOTE: If all readings are good, and lamps still do not turn ON replace the LH front combination lamp.
4002-97
NOTE: Disconnect wiring harness connector RF from RH front combination lamp connector.
Combination lamp connector pin 3 to Continuity Bad high beam lamp bulb.
pin 1
Combination lamp connector pin 2 to Continuity Bad low beam lamp bulb.
pin 1
Combination lamp connector pin 5 to Continuity Bad turn signal lamp bulb.
pin 1
NOTE: Put master disconnect switch in ON position and driving lamp switch (95) in position 3.
Check fuse ECB-F8 and driving lamp switch (95). Also check
Terminal for wire 18G-A to ground 24 volts
circuit 18G and wire 41T-A.
NOTE: Put ignition switch in ON position. Put turn signal lever in RIGHT turn position.
Intermittent 24 Check the turn signal switch (94) and flasher module (92). Also
Terminal for wire 45R to ground volts check circuit 45R to flasher module.
NOTE: If all readings are good, and lamps still do not turn ON replace the RH front combination lamp.
4002-98
98 – Horn Relay
Located in the cab access panel for fuses and relays.
Correct
Check Points Possible Cause of Bad Reading
Reading
Terminal for wire 19U-A to ground 24 volts Check fuse ECC-F6, also check wire 19U-A.
Terminal for wire 19U-E to ground 24 volts Check Fuse ECC-F6, also check wire 19U-E.
NOTE: Have another person push and hold the horn switch.
99 – Horn
Located on the left front of the machine with combination lamps.
Correct
Check Points Possible Cause of Bad Reading
Reading
NOTE: Disconnect the wire 64 from the horn. Have an assistant push and hold the horn switch.
Terminal for wire 64 to ground. 24 volts Check the horn relay (98). Also check wires 64 and 64-A.
101
103
100
102
RCPH10WHL094FAH
NOTE: Disconnect wiring harness connector LRR from RH rear combination lamp connector.
NOTE: Connect wiring harness connector LRR-N 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.
Intermittent 24 Check the turn signal switch (94) and flasher module (92). Also
Terminal for wire 45R-BN to ground volts check circuit 45R to flasher module.
Check fuse ECB-F8 and lamp switch (95). Also check circuit
Terminal for wire 18G-CN to ground 24 volts
18G.
NOTE: If all readings are good, and lamps still do not turn ON replace the RH rear combination lamp.
4002-101
NOTE: Disconnect wiring harness connector LRR-E from RH rear combination lamp connector.
NOTE: Connect wiring harness connector LRR-E 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 (94) and flasher module (92). Also
Terminal for wire 45R-A to ground volts check circuit 45R to flasher module.
Check fuse ECB-F8 and lamp switch (95). Also check circuit
Terminal for wire 18G-A to ground 24 volts
18G.
NOTE: If all readings are good, and lamps still do not turn ON replace the RH rear combination lamp.
4002-102
NOTE: Disconnect wiring harness connector LLR from LH rear combination lamp connector.
NOTE: Connect wiring harness connector LLR-N 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.
Intermittent 24 Check the turn signal switch (94) and flasher module (92). Also
Terminal for wire 45L-BN to ground volts check circuit 45L to flasher module.
Check fuse ECB-F7 and lamp switch (95). Also check circuit
Terminal for wire 18F-BN to ground 24 volts
18F.
NOTE: If all readings are good, and lamps still do not turn ON replace the LH rear combination lamp.
4002-103
NOTE: Disconnect wiring harness connector LLR-E from LH rear combination lamp connector.
NOTE: Connect wiring harness connector LLR-E 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 (94) and flasher module (92). Also
Terminal for wire 45L-A to ground volts check circuit 45L to flasher module.
NOTE: Put master disconnect switch in ON position. Put the driving lamp switch (95) in position 2.
Check fuse ECB-F8 and five driving lamp switch (95). Also
Terminal for wire 18G-E to ground 24 volts
check circuit 18G.
4002-104
NOTE: Put master disconnect switch in ON position. Put the driving lamp switch (95) in position 2.
Check fuse ECB-F8 and five driving lamp switch (95). Also
Terminal for wire 18G-E to ground 24 volts
check circuit 18G.
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: 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).
109 110
111
112
107 108
104 106
113
105
RCPH10WHL094FAH
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Terminal for wire 19J-D and 19J-E to Bad fuse ECA-F12, check circuit 19J, also check power relay
24 volts
ground module B (14).
Terminals for wire 63HC-B to ground Continuity Bad front wiper and washer switch (108).
Terminals for wire 63HC-B to ground 24 volts Bad wiper high speed relay.
Terminals for wire 63C2 to ground 24 volts Bad wiper high speed relay.
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Check fuse ECA-F12, check circuit 19J, also check power relay
Terminal for wire 19J-G to ground 24 volts
module B (14).
Terminal for wire 63L-B to ground 24 volts Bad wiper cut out relay.
Terminals for wire 63HC-A to ground Continuity Bad front wiper and washer switch (108).
Terminals for wire 63L-B to ground 0 volts Bad wiper cut out relay.
4002-107
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Bad fuse ECA-F12, check circuit 19J, also check power relay
Terminal for wire 19J-F to ground 24 volts
module B (14).
Terminals for wire 63C to ground 24 volts Bad wiper low speed relay.
Terminals for wire 63LC to ground Continuity Bad front wiper and washer switch (108).
Bad wiper low speed relay, also check high speed wiper relay
Terminals for wire 63C3 to ground 24 volts
(104).
NOTE: Put the rear wiper and washer switch in the ON position.
Terminal for wire 68L to ground 24 volts Bad rear wiper and washer switch.
NOTE: Press and hold the rear wiper and washer switch in the WASH position.
Terminal for wire 68W to ground 24 volts Bad rear wiper and washer switch.
Check rotary lamp switch (95) and circuit 49. If LEDs in rear
Terminal for wire 49-C to ground 24 volts wiper and washer switch are not ON with 24 volts at check
point, replace rear wiper and washer switch.
4002-108
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the front wiper and
washer switch is in the OFF position.
Check fuse ECA-F12, check circuit 19J, also check power relay
Terminal for wire 19J-B to ground 24 volts
module B (14).
NOTE: Put the front wiper and washer switch in the LOW position.
NOTE: Put the front wiper and washer switch in the HIGH position.
NOTE: Put the front wiper and washer switch in the wash position.
Terminal for wire 63W to ground 24 volts Bad front wiper and washer switch.
4002-109
NOTE: Make sure the front wiper and washer switch (108) is in the OFF position.
Between terminals B and D for wires Continuity Bad front wiper motor.
63C and 63L
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Terminal for wire 19J-A to ground 24 volts Check fuse ECA-F12, also check circuit 19J.
NOTE: Put the front wiper and washer switch (108) in the LOW position.
Check fuse ECA-F12, also check circuit 19J. Bad front wiper
Terminal for wire 63L-A to ground 24 volts
and washer switch (108), low speed relay or cut out relay.
Terminal for wire 63C to ground 0 volt Bad front wiper and washer switch (108)
NOTE: Put the front wiper and washer switch (108) in the HIGH position.
Check fuse ECA-F12, also check circuit 19J. Bad front wiper
Terminal for wire 63H-A to ground 24 volts
and washer switch (108), high speed relay or cut out relay.
Terminal for wire 63C to ground 0 volt Bad front wiper and washer switch (108).
NOTE: Put the front wiper and washer switch in the intermittent position.
Terminal for wire 63L-A to ground 24 volts pulse Bad front wiper and washer switch (108).
Terminal for wire 63C to ground 24 volts pulse Bad front wiper and washer switch (108).
NOTE: If the readings are good, replace the front wiper motor.
4002-110
NOTE: Make sure the rear wiper and washer switch (107) is in the OFF position.
Between terminals for wires 68C-A Continuity Bad rear wiper and washer switch (107).
and 68L-A
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Terminal for wire 19K-D to ground 24 volts Check fuse ECA-F13, also check circuit 19K.
NOTE: Put the rear wiper and washer switch (107) in the ON position.
Terminal for wire 68C-A to ground 24 volts Bad rear wiper and washer switch (107).
Terminal for wire 68L-A to ground 0 volt Bad rear wiper and washer switch (107).
NOTE: If the readings are good, replace the rear wiper motor.
NOTE: Put master disconnect switch and ignition switch in ON position. Depress and hold rear wiper and washer
switch (107) in WASH position.
Bad rear wiper and washer switch (107) Also check wires
Terminal for wire 68W-A to ground 24 volts
68W-A and 68W.
NOTE: If the readings are good, replace the rear washer pump motor.
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Connect volt meter to check
point then push down on front wiper and washer switch (108).
Bad front wiper and washer switch (108), also check circuit
Terminal for wire 63W-A to ground 24 volts
63W.
NOTE: If the readings are good, replace the front washer pump motor.
4002-111
SECONDARY STEERING
NOTE: Disconnect wire 51-B from secondary steering motor relay; make sure that wire does not touch any metal
part of machine during the remainder of this check. Put the master disconnect switch in ON position. Start and
run engine for two or three minutes while turning steering wheel left and right several times. DO NOT TURN
STEERING WHEEL TO STEERING STOPS. Turn ignition switch to OFF position to stop engine, then immediately
to ON position.
Between pin 1 of connector YSS and Check secondary steering module (116) and secondary
24 volts
ground steering pressure switch (118).
4002-114
NOTE: Disconnect the wiring harness connector SSM from the secondary steering module.
NOTE: Put the master disconnect switch and the ignition switch in ON position.
Pin 3 of connector SSM to ground 24 volts Bad wire 19S1-X to power relay module A fuse 2 (13).
Pin 7 of connector SSM to ground 24 volts Bad fuse ECA-F17 or ignition switch. Also check circuit 19M.
Pin 9 of connector SSM to ground Continuity Bad secondary steering pressure switch.
NOTE: Put ignition switch in OFF position to stop engine. Connect wiring harness connector SSM to secondary
steering module. Disconnect wire 51-B from secondary steering motor (117) relay terminal. Start and run engine
at idle speed. Disconnect wiring harness connector PSS from secondary steering pressure switch (118). Apply a
ground to pin C of connector PSS.
Terminal for wire 51-B to ground 24 volts Bad secondary steering module.
4002-115
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 wiring harness connector PSS from secondary steering pressure switch.
Pressure switch pin B to pin C Continuity Bad secondary steering pressure switch.
Pressure switch pin B to pin A Open Circuit Bad secondary steering pressure switch.
Pressure switch pin A to pin C Open Circuit Bad secondary steering pressure switch.
Pressure switch pin B to pin A Continuity Bad secondary steering pressure switch.
Pressure switch pin B to pin C Open Circuit Bad secondary steering pressure switch.
4002-116
CAN COMMUNICATION
119
RCPH10WHL094FAH
119.DIAGNOSTIC CONNECTOR
NOTE: The battery must be at full charge and all connections clean and tight before doing any testing of the
electrical system. Use a Multimeter for the following tests.
4002-117
Terminal B for wire 18K-D to ground 24 volts Check fuse ECC-F9, check circuit 18K.
4002-118
125
122 123
124
121
RCPH10WHL094FAH
120. 123.RADIO
121.POWER CONVERTER 24 TO 12 VOLT 124.RIGHT SPEAKER
122.12 VOLT POWER OUTLETS (OPTION) 125.LEFT SPEAKER
NOTE: The battery must be at full charge and all connections clean and tight before doing any testing of the
electrical system. Use a Multimeter for the following tests.
4002-119
120 –
Terminal for wire 19L-B and 19L-A to 24 volts Bad fuse F1 in power relay module A, also check circuit 19L.
ground
Terminal for wire 12V or 12V-A to Bad power converter (121), check fuse ECB-F1 and F2, also
12 volts
ground check wire 12V-A.
Terminal in radio connector for wire Check fuse ECB-F9, also check circuit 12V. Also check the
12 volts
12V-HA to ground remote radio power converter (121).
4002-120
NOTE: Disconnect connector from right speaker. Put master disconnect switch and ignition switch in ON position.
Turn radio (123) on. Put balance control for RH and LH speakers to center position.
Pin 1 in wiring harness connector Bad circuit between the right speaker and the radio or a bad
Voltage
RSPK to ground radio (123).
Pin 2 in wiring harness connector Continuity Bad circuit between the right speaker and the radio (123).
RSPK to ground
NOTE: Disconnect connector from left speaker. Put master disconnect switch and ignition switch in ON position.
Turn radio (123) on. Put balance control for RH and LH speakers to center position.
Pin 1 in wiring harness connector Bad circuit between the left speaker and the radio or a bad
Voltage
LSPK to ground radio (123).
Pin 2 in wiring harness connector Continuity Bad circuit between the left speaker and the radio (123).
LSPK to ground
126
130
129
127
128
RCPH10WHL094FAH
BS06H241 / BS06H242
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Terminal for wire from seat switch at Bad seat switch, also check circuit from seat switch to
24 volts
compressor compressor.
Terminal for wire 19W to ground 24 volts Check fuse ECA-F18, also check circuit 19W.
NOTE: Put master disconnect switch and ignition switch in ON position. Put fan speed switch (149) to HIGH and
thermostat switch to COLD.
Terminal for wire 61R-B to ground 24 volts Check thermostat switch, also check wire 61R-B.
Terminal for wire 61C to ground 24 volts Bad compressor clutch relay.
NOTE: Put ignition switch in OFF position. Disconnect wiring harness connector PR from A/C trinary pressure
switch. Connect a jumper wire between pins A and B of connector PR. Put ignition switch in ON position.
Terminal for wire 61R-C to ground 24 volts Check wires 61R-B and 61R.
4002-123
NOTE: Put master disconnect switch and ignition switch in ON position. Put the fan speed switch (149) to HIGH
and the thermostat switch to COLD.
Terminal B for wire 61A to ground 24 volts Check the thermostat switch, also check circuit 61A.
NOTE: Disconnect the wiring harness connector PR from the A/C trinary pressure switch. (Low and high
switches)
NOTE: Put master disconnect switch and ignition switch in ON position. Put fan speed switch (149) to HIGH and
thermostat switch to COLD.
131
RCPH10WHL094FAH
143 – Actuator
Correct
Check Points Possible Cause of Bad Reading
Reading
NOTE: Remove connectors from DNS Actuator and DNS Driver prior to testing.
144 – Driver
Correct
Check Points Possible Cause of Bad Reading
Reading
NOTE: Disconnect the wiring harness connector DNS RESISTOR from the resistor.
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Turn the fan speed switch
(149) to position 4.
Terminal for wire DNS65 to ground 24 volts Check the fan speed switch (149).
NOTE: If the readings are correct and the blower motor does not run, replace the blower motor. Turn the fan
speed switch (149) to position 1. If the blower motor ran in position 4 but not in position 1, 2,or 3, check the
blower fan resistor (146).
148 – Thermostat
Correct
Check Points Possible Cause of Bad Reading
Reading
Continuity
above 5C (41F)
Between terminals on thermostat +/-1C, open Bad thermostat.
below 0C
(32F)+/-1C.
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Continuity with
Between terminals 1 and 2. Bad recirculating switch.
switch on.
4002-131
157
156
154
155
RCPH10WHL094FAH
Terminal for wire 19Y-A 24 volts Check fuse ECC-F7, check circuit 19Y.
Terminal for wire 59U 24 volts Bad hood switch (156), check wire 59U.
Terminal for wire 19Y-B 24 volts Check fuse ECC-F7, check circuit 19Y.
Terminal for wire 59D 24 volts Bad hood switch (156), check wire 59D.
Terminal for wire 19Y-D to ground 24 volts Check fuse ECC-F7, check circuit 19Y.
Hold the hood switch in the raise Continuity Bad hood switch.
position, between pin C and B
Hold the hood switch in the lower Continuity Bad hood switch.
position, between pin A and B
4002-133
NOTE: Turn the master disconnect switch ON and disconnect connector HDM. Hold the hood switch (156) in the
raise position.
Bad hood up relay (154), bad hood switch (156), and check
Terminal for wire 60U-A 24 volts
fuse ECC-F7.
Bad hood down relay (155), bad hood switch (156), and check
Terminal for wire 60D-A 24 volts
fuse ECC-F7.
158
159
160
RCPH10WHL094FAH
158.IGNITION POWER LATCH 160.START LOCKOUT
159.IGNITION POWER CONTROL
NOTE: The battery must be at full charge and all connections clean and tight before doing any testing of the
electrical system. Use a Multimeter for the following tests.
4002-135
NOTE: Put master disconnect switch and ignition switch in ON position. Make sure transmission is in NEUTRAL.
Terminal for wire 13K to ground 24 volts Check circuit 13K, check Ignition switch (10).
NOTE: Put master disconnect switch and ignition switch in ON position. Make sure transmission is in NEUTRAL.
Terminal for wire 13K-A to ground 24 volts Check circuit 13K, check ignition switch (10).
Terminal for wire 0-EY to ground Continuity Bad ignition power control relay.
RCPH10WHL094FAH
161.NOX SENSOR 166.UPSTREAM TEMPERATURE SENSOR
162.HUMIDITY AND AMBIENT TEMPERATURE SENSOR 167.DOWNSTREAM TEMPERATURE SENSOR
163.NOX SENSOR (NOXS) 168.DOSER METERING VALVE
164.TANK HEATER CONTROL VALVE 169.DNOX CONTROLLER
165.DEF LEVEL AND TANK TEMPERATURE
NOTE: The battery must be at full charge and all connections clean and tight before doing any testing of the
electrical system. Use a Multimeter for the following tests.
4002-137
Normally
open,
Between terminals 2 and 3 Continuity Bad Lock Switch.
when switch is
closed
Normally
open,
Between terminals 2 and 3 Continuity Bad Lock Switch
when switch is
closed
NOTE: Put the master disconnect switch and ignition switch in ON position.
Terminal 1 for wire 34A-D to ground 24 volts Bad TECM module. Also check circuit 34C.
NOTE: If the readings are good, replace the differenital lock solenoid.
NOTE: Put the master disconnect switch and ignition switch in ON position.
Terminal 1 for wire 25R-B to ground 24 volts Bad TECM TRANS module. Also check circuit 25R.
CONNECTORS
CONNECTOR 108F - DIAGNOSTIC CONNECTOR
291663A1
245488C1
4002-142
CONNECTOR 197M - FNR-MAIN_CAB CONNECTOR 209F - BACKUP ALARM DISABLE
JUMPER
225351C1
245481C1
245480C1
245482C1
4002-143
CONNECTOR 20M - TRANSMISSION KICK-DOWN
SWITCH
225316C1
245481C1
199436A1
199436A1
245480C1
4002-144
CONNECTOR AIC2 - ADV INSTRUMENT
CLUSTER 2
8602417 87410948
222136A1
4002-147
4002-148
CONNECTOR CAB-RF - CAB TO ROOF CONNECTOR CAB-T - CAB TO TRANMISSION
CONNECTION
380839A1
388710A1
4002-149
CONNECTOR CL - CIGAR LIGHTER
3227856R1
225351C1
4002-150
CONNECTOR DM - DIODE OR
CONNECTOR D-OR - DIODE OR
245485C1
245485C1
245482C1
4002-151
CONNECTOR DNS-DRIVER
411311A1
4002-152
CONNECTOR DS - DOOR SWITCH
245482C1
225351C1
245485C1
4002-153
CONNECTOR ECA - ELECTRICAL CENTER A
87315248
4002-154
4002-155
CONNECTOR ECB - ELECTRICAL CENTER B
87312843
4002-156
4002-157
CONNECTOR ECC - WORK LIGHTS
87315249
4002-158
4002-159
CONNECTOR ECD - ELECTRICAL CENTER D
87312843
4002-160
4002-161
CONNECTOR EDC7 - ENGINE CONTROLLER
BOSCH-89-POLE
4002-162
CONNECTOR ENG-D - DISCONECT HARNESS CONNECTOR ESS - ENGINE SPEED SENSOR
245483C1
291718A1
225320C1
182069A1
4002-163
CONNECTOR FLSHR - FLASHER MODULE
225389C1
371614A1
245715C1
4002-164
CONNECTOR FWMG - FRONT WIPER MOTOR CONNECTOR GHC - GRID HEATER RELAY
GROUND
3227856R1
245480C1
3227856R1
4002-165
CONNECTOR - CAB GROUND SPLICE
87324393
87324393
4002-166
4002-167
CONNECTOR HD - HOOD SWITCH
245485C1
245484C1
4002-168
CONNECTOR HD-N - HOOD TO ENGINE
194788A1
225316C1
4002-169
CONNECTOR HVAC2 - HVAC2
87552622
291718A1
4002-170
4002-171
CONNECTOR LLF - LH FRONT LIGHTS CONNECTOR LLR-E - LH REAR COMBINATION
LAMP
225351C1
225351C1
245482C1
4002-172
CONNECTOR LRF - RH FRONT LAMP
225351C1
225351C1
195552A1
4002-173
CONNECTOR PAF - AIR FILTER RESTRICTION
SWITCH
291718A1
291719A1
CONNECTOR PBD - BRAKE DECLUTCH
PRESSURE SWITCH
245482C1
4002-174
CONNECTOR PBL - BRAKE LAMP PRESSURE CONNECTOR PO1 - POWER OUTLET
SWITCH
222136A1
12176446
12176446
4002-175
CONNECTOR PRB1 - REDUNDANT BRAKE
SWITCH
245483C1
4002-176
CONNECTOR PSS - SECONDARY STEERING CONNECTOR PXF - RTD
PRESSURE SWITCH
245485C1
245485C1
4002-177
CONNECTOR RAD - RADIO POWER CONNECTOR RAD-J2 - SPEAKER
292495A1 292501A1
411311A1
292497A1
4002-178
CONNECTOR RECT - ENGINE COOLANT CONNECTOR ROOF - ROOF TO CAB
TEMPERATURE CONNECTION
194788A1 388708A1
195552A1
4002-179
CONNECTOR RTHP - THROTTLE PEDAL CONNECTOR RWMG - REAR WIPER MOTOR
GROUND
225351C1
245480C1
3227856R1
245715C1
4002-180
CONNECTOR S-KEY - IGNITION SWITCH TO CONNECTOR SC - SEAT COMPRESSOR MOTOR
PEDESTAL HARNESS
245482C1
225253C1
382391A1
382391A1
4002-181
CONNECTOR SDR - DRIVING LIGHTS SWITCH CONNECTOR SFWW - REAR WIPER AND
WASHER SWITCH
382391A1 87345132
382391A1
4002-182
CONNECTOR SPK - SPEAKER
292494A1
CONNECTOR SPB - PARKING BRAKE SWITCH
382391A1
4002-183
CONNECTOR SPL-BCK-LGT - SPLICE BACK CONNECTOR SPL-BCK-LGT
LIGHT GD
87324393 87324393
4002-184
CONNECTOR SPL-PED-BL - SPL BACK LIGHT CONNECTOR SPL-PK1 - SPLICE 3 - 4 WAY
POWER 6 PACK
87324462
87324391
4002-185
CONNECTOR SPL-PK3 - SPLICE 3 - 4 WAY CONNECTOR SPL-TRNS-PWR - TRANSMISSION
POWER
87324462
87324393
382391A1
4002-186
CONNECTOR SRC-1 - STARTER RELAY CONNECTOR SRTD - DETENT SWITCH
225316C1
382391A1
87318288
4002-187
CONNECTOR SS-TR - SS-MOD-TRANS CONNECTOR STA - TRANSMISSION AUTO
SWITCH
245489C1
382391A1
225389C1
4002-188
CONNECTOR SWL - WORK LIGHTS SWITCH CONNECTOR TCOT - TORQUE CONVERTER
OUTPUT SENDER
382391A1
291718A1
4002-189
CONNECTOR TECM - TRANSMISSION
411398a1
4002-190
CONNECTOR TRANS - CAB TO TRANSMISSION
245488C1
4002-191
CONNECTOR TRC - TRANSMISSION CONTROL CONNECTOR TS2 - TRANSMISSION SHIFTER
245487C1
371566A1
291718A1
245486C1
4002-192
8602416
182069A1
4002-193
CONNECTOR YFR - FAN REVERSING SOLENOID
225316C1
245482C1
245482C1
291718A1
4002-194
225316C1
4002-195
NOTES
4002-196
ECD
INDEX OF FUNCTIONS SHT SHT SHT SHT
BACKUP ALARM 6
, 14
COLOR ABBREVIATIONS
70
62
SHT SHT SHT SHT SHT
SHT
71
SHT
CONNECTOR LIST 2
SHEET SHEET SHEET
CONNECTOR LIST 3
3 18
21 13 14 15
20
2
8
158
1
10
Relay in
4 location F5/F6
160
Relay in
location
F3\F4
6 11
16 17
159
162
161
Relay in
location F7\F8
CAN_L3 G-0.8
CAN_H3 Y-0.8
23
163
169
164
168
165
167
166
ENGINE CONTROL 5
92
90
Relay in
Relay in location
location
93 F9\F10
F1/F2
95
78
91
Turn
Signal
Driving
Lights
Light/
Horn
79
Horn
94
103
96 97
102
81
88
87
80
86
85
84
170
83
82
LIGHTING 2 7
172
54
173 171
57
55
59
56
174
46
47
45
61
48
58
49
50
51
52
53
60
TRANSMISSION CONTROLS 8
63
64
68
74
72
67
65
75
69
73
76
66
INSTRUMENT CLUSTER 9
25
35
36
26
29
33
31
32
98
27
37
99
39
28
40
38 34 30
41
42
44
43
MACHINE CONTROLS 10
113
155
154
104
108
105
114
106
115
107
117
109
156
111
116
BLUE BROWN
112
DOWN
LIMIT
UP
LIMIT 113
SWITCH SWITCH
157
110
NO
COM 118
NC
HOOD LIFT 11
121
122
129
122
126
128
130
125
124 123
119
127
R R
S S
177
175
8
8
185
176
179
178
181
182
180
183
186
144
143
146
147
148
153
149 150
152
151
STANDARD HVAC 14
721F, 821F, 921F Tier 4 Wheel Loader
ELECTRICAL SCHEMATIC
LEGEND
POWER RELAY A
POWER RELAY B
POWER RELAY C
POWER RELAY D
ILLUMINATION
4003
BATTERIES
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
Charging Guide For Batteries Other Than Maintenance Free Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PREPARING A DRY CHARGED BATTERY FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4003-3
SAFETY RULES
WARNING: Never try to charge the battery if WARNING: Battery acid causes severe
the electrolyte in the battery is frozen. burns. Batteries contain sulfuric acid. Avoid
47-83A contact with skin, eyes, or clothing. Antidote:
EXTERNAL-Flush with water.
WARNING: Never cause sparks to occur or
INTERNAL-Drink large quantities of water or
smoke near batteries that are charging or
milk. Follow with milk of magnesia, beaten
have been recently charged.
egg, or vegetable oil. Call physician
13-8A
immediately. Eyes: Flush with water for 15
WARNING: Disconnect the ground cable minutes and get prompt medical attention.
first when the battery cables are Batteries produce explosive gases. Keep
disconnected from the battery. sparks, flame, and cigarettes away. Ventilate
Connect the ground cable last when the when charging or using in enclosed area.
battery cables are connected to the battery. Always shield eyes when working near
47-55A batteries.
SPECIAL TOOLS
B795328
MAINTENANCE
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 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.
Capacity (Load) Test NOTE: Never apply a load for longer than 15
seconds. After each 15 seconds, turn the load control
This test can be done using a variable load tester knob to OFF for at least one minute.
s u c h a s t h e S u n E l e c t r i c VAT- 3 3 . O t h e r t e s t
equipment can be used. Connect the test equipment 4. Apply a 15 ampere load to the battery for 15
according to the instructions of the manufacturer of seconds. Wait at least three minutes before
the equipment. applying the load again.
1. The level of charge of the battery must be at 5. Check and make a record of the temperature of
least 75%. Do the Specific Gravity Check in this the electrolyte.
section. 6. Find the correct load for this test in Specifications
2. Prepare the tester (Sun Electric VAT-33 shown) in Section 4001.
for the test. NOTE: The correct load is half of the cold cranking
A. Select the voltmeter range that will measure 1 amperes at -17°C (0°F).
to 18 volts. 7. Turn the load control knob until the ammeter
B. Make sure the load control knob is in the OFF indicates the specified load. Keep the load for 15
position. seconds and read the voltmeter. Turn the load
control knob to OFF.
C. Select the ammeter range that will measure 0
to 1000 amperes. 8. Compare the test reading and the temperature of
the electrolyte to the chart below.
D. Move the volt lead switch to the NT. position. Temperature of . . . . . . . . . . . . . . . Minimum Voltage
3. Connect the tester to the battery as shown. electrolyte
21°C (70°F) and above . . . . . . . . . . . . . . . . . . . . 9.6
16°C (60°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
10°C (50°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
2
4°C (40°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
-1°C (30°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
-7°C (20°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9
-12°C (10°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7
1 -18°C (0°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
A. If the test result is equal to or more than the
vo l t a g e s h o w n , t h e b a t t e r y i s i n g o o d
condition.
B. If the test result is less than the voltage
shown, discard the battery.
B790499
CHARGING A BATTERY
The charging rate must be decreased if:
WARNING: Never try to charge the battery if
the electrolyte in the battery is frozen. 1. Too much gas causes the electrolyte to flow from
47-83
the cells.
Before you charge the battery, check the level of the 2. The temperature of the electrolyte rises above
electrolyte. 52°C (125°F).
It is difficult to give an exact charging rate because of NOTE: For the best charge, use the slow charging
the following variable conditions: (1) temperature of rates.
the electrolyte, (2) level of charge, and (3) condition
The battery is fully charged when, over a three hour
of the battery. Use the charging guide for the correct
period at a low charging rate, no cell is giving too
charging rate and time.
much gas, and the specific gravity does not change.
See Specifications in Section 4001 for the reserve
capacity of the battery in this machine.
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
4003a
4003a
TABLE OF CONTENTS
Jump Post Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4003-3
RCPH10WHL214AAH.PNG
INSTRUMENT CLUSTER
4005
4005-2
TABLE OF CONTENTS
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Self-Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Power Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
LCD Multi-function Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Navigating Through The LCD Multi-function Display Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Entering The Service Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Service screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Selecting Power Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Language Screen, Measurement Units, and Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
RETRIEVING FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
General Fault Code Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Fault Code Grouping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
VEHICLE FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
ENGINE FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
TRANSMISSION FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
INSTRUMENT CLUSTER FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
SELECTIVE CATALYTIC REDUCTION (SCR) FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
.
4005-3
INSTRUMENT CLUSTER
5
4 6
1 2 3 7 8 9 10
15 11
14 12
13
BD06H039
1. LOW BRAKE PRESSURE INDICATOR 9. LACK OF AUX STEER PRESSURE (OPTIONAL)
2. HIGH BEAM INDICATOR 10. PARKING BRAKE INDICATOR
3. TRANSMISSION OIL TEMPERATURE GAUGE 11. RIGHT TURN INDICATOR
4. CAUTION MASTER INDICATOR 12. FUEL LEVEL GAUGE
5. MULTI FUNCTION LCD DISPLAY 13. FUEL LEVEL AT MINIMUM
6. STOP MASTER INDICATOR 14. ENGINE COOLANT TEMPERATURE GAUGE
7. HYDRAULIC OIL TEMPERATURE GAUGE 15. LEFT TURN INDICATOR
8. WAIT TO START ENGINE PREHEAT
The instrument cluster monitors a number of functions and can be tailored to fit the operator’s preferences The
instrument cluster not only monitors machine functions, it warns the operator when caution is needed due to a
possible malfunction and when immediate action is needed due to a possible critical malfunction. When the
machine is started, the instrument cluster will perform the following self-test:
4005-4
B D
BD06F186
Located on the steering column, just to the left of the
Park Switch, is the key pad. Use this key pad to move
fr o m on e s c r e e n to a n o th e r, c h o o s e va r i o u s
selections, monitor the machine functions, and
retrieve information. All functions can be accessed in
the same basic manner.
A. Escape key: Use this key to exit and return to
BD06F188
the driving screen. Use this key anytime you
would like to start over and begin again, plus From the driving screen push the down arrow, as
use to check active, acknowledge errors. shown.
BD06F183
BD06F169
Press the down button again and the Trip 1 screen
BD06F027
will display. The LCD provides two trip computers.
Info 2 will be displayed next. The Info 2 screen will These will display since last reset the total time in
display coolant temperature, engine oil temperature h o u r s , t h e t o t a l f u e l , a n d t h e a ve r a g e f u e l
in either Fahrenheit or Celsius, DEF fluid level, as consumption per hour.
well as oil pressure PSI.
BD06F170
By continuing to scroll down, the fifth screen will
BD06F184
display the Trip 2 screen. Trip 1 and Trip 2 screens
Push the down button again and the Info 3 screen. can be reset independently. The previous screen can
This screen displays the temperature in Fahrenheit or be accessed by using the up arrow key.
Celsius of the transmission oil, hydraulic oil, sump oil,
and DEF fluid level.
4005-8
Reset The Trip Information
BD06F170
BD06F187
Press the confirm button to reset the trip selection to
zero.
BD06H038 / BD06F188
Press and hold the confirmation button for two seconds to arrive at the main menu screen. Use down arrow to
scroll through the menu’s.
Items and selections in this menu are:
1. Settings
2. Display
3. Diagnostics
4. Service
4005-10
RCPH10WHL060HAH
4005-11
Service screens
After the machine has been started or the key switch
has been turned to ON, the operator or service
technician may use the main menu to adjust machine
con figura tio ns to wor king c ond itio ns, to te st
components, view faults that may have occurred, or
to select preferences. Languages can be set at the
beginning of the menu configuration to allow the
operator to work in the language of choice.
RCPH10WHL367BAH
Engine selections
RCPH10WHL366AAH
Auto idle (Off, Low, Accelerated)
Settings
Power Mode (Max, Standard, Auto, Eco)
Selections at the setting menu include:
Engine options (fan auto, Work idle)
Engine
Auto Shutdown (optional) is used for interval settings
Transmission
Joystick steering (option will display only if machine
is joystick steering equipped).
RCPH10WHL369BAH
Transmission selections
Max gear
Min gear
POWERINCH (Optional 5-speed)
4005-12
Display Diagnostics
RCPH10WHL447AAH
RCPH10WHL376BAH
Service
Highlight the desired selection and press confirm.
The tests in the configuration menu should be
performed only by a qualified operator or technician.
Some test require the engine to be running at high
RPM’S.
Items and selections in this menu are: RCPH10WHL372BAH
● Calibration (Park brake and pedal calibration) At the screen shown above, highlight the power
mode and press the confirmation button to move to
● Select tires (tire size) the Power Mode Selection Menu.
4005-13
Auto idle shutoff (optional)
BD06F178
At the Power Mode Menu press the confirmation RCPH10WHL375BAH
RCPH10WHL358BAH RCPH10WHL363BAH
Language Screen, Measurement Units, To set hour and date, from the select screen choose
and Clock the clock designation and press the confirm key. Use
the arrow keys to show field for time and date by
The LCD screen can be set with language, units, and pressing the arrow key. When the correct time and
clock preferences. Use the arrow keys to scroll to the date have been entered by using the up and down
preferences menu. Press confirm. arrow keys (up increases numbers, down decreases
Choose the preferences desired, language in the numbers), press the confirm key to lock in correct
(English, Italian, Spanish, Portuguese, German, time. Press the escape key to return to the main
French, measurement units in English, Metric, or driving screen and lock selections into memory.
Imperial and clock units in either 12 or 24 hour).
Display backlight menu
Highlight the preference you wish to change and
press the confirm key. The preference will flash and
allow you to scroll through the choices. When the
correct preference is chosen, use the confirm key to
lock in the preference for the display. The escape key
will allow you to leave this application.
RCPH10WHL364BAH
RCPH10WHL361BAH
4005-15
RPM’S/Speedometer Fan auto (if equipped)
RCPH10WHL373BAH
RCPH10WHL371BAH
RCPH10WHL373BAH
setting, highlight the Eng Options selection and press Scroll to Calibration, high light and press the confirm
confirm. Select the Work idle selection and press key. always follow the prompts on the screen. Should
confirm. Increase or decrease the work idle speed an error occur, use the escape key to start over
using the arrow keys, then press confirm. Return to again.
the main driving screen by pressing the escape key.
.
NOTE: If the transmission is shifted into neutral, the
work idle feature will be deactivated.
BD06F195
BD06F186
A. Escape key
B. enter key
C. up key
D. down key
2. Yellow Faults, buzzer will beep once every 2
seconds:
A. Operator can acknowledge it by pressing the
enter key.
B. The message will disappear.
C. Buzzer will not beep anymore.
D. Yellow lamp will stay ON.
E. Fault will remain in Yellow list until it is closed.
3. Red Faults, buzzer will be continuous, alternating
sounds:
A. Operator can acknowledge it by pressing the
enter key.
B. Buzzer will change to a less stressing sound,
but will remain.
C. Message will remain on display with indication
of URGENT STOP.
4005-19
1816 Open circuit / JSS activation switch Check wiring, switch installation and proper
mechanical defect functioning of JSS activation switch.
Check wiring, installation, and proper functioning
Check JSS relay, JSS valve, JSS joystick
1820 of JSS components. See electrical schematics
power supply connections
and section 5009 for details.
Short to ground on JSS relay 85/AIC 1.21 or Check wiring, installation, and proper functioning
1821 short to power on relay 86/87a. Or activation of JSS components. See electrical schematics
switch failure and section 5009 for details.
JSS relay, ground connect., bad elec. Check wiring, installation, and proper functioning
1823 connect. Permanent ground at JSS relay (87) of JSS components. See electrical schematics
open circuit or short to power and section 5009 for details.
Check wiring, installation, and proper functioning
1824 Short to battery at activation button. Activation
of JSS components. See electrical schematics
switch failure
and section 5009 for details.
Check wiring, installation, and proper functioning
Open circuit between activation switch Pin 3
1830 of JSS components. See electrical schematics
and C5.E Pin 1
and section 5009 for details.
Check wiring, installation, and proper functioning
JSC controller, wrong operation. JSC
1831 of JSS controller. See electrical schematics and
controller internal fault
section 5009 for details.
Check wiring, installation, and proper functioning
JSC controller, JSC signal in, out of limits. of JSS components. See electrical schematics
1832 Input signal from JSS joystick to JSC and section 5009 for details. (Joystick Neutral:
controller out of limits. USignal>40%UBat+<60%Ubat;Joystick
actuated: USignal>20%UBat+<80%UBat)
Check connector of JSS valve and JSC
Output signal from JSC controller to valve out
1833 controller.
of limits.
JSS controller, JSC output, SC to BAT Power Check electrical connection for short to power. Or
1834
is applied to one of the JSC controller outputs. JSC internal relay is defective.
4005-21
1860 CAN timeout of C5.E detected by JSC No information available at time of print.
1861 CAN timeout of AIC detected by JSC controller No information available at time of print.
Internal malfunction transmission controller.
1863 TCU message JSS F-N-R disabled or JSS No information available at time of print.
F-N-R not activated.
1864 Test No information available at time of print.
NOTE: The following fault codes are for optional climate controlled heating and air conditioning system.
High pressure Pump relay - Short circuit to 1. Faulty reading from component.
3048
ground. 2. Wiring or circuits shorted.
Alternator voltage governor defect.
3051 Battery voltage to ECM too high
Replace alternator governor device or alternator.
Battery defect, alternator defect, wiring problems
(too high resistance) or ECU defect. Occurrence
3052 Battery voltage to ECM too low possible during cold start.
Replace battery or alternator. Check ECU and
wiring.
1. Faulty reading from component.
2. Connectors not mated fully, pins not pushed
into connector fully, bent pin or broken wire at
rear of connector.
3059 ECM afterrun was interrupted. 3. Wiring or circuits open.
4. Wiring or circuits shorted.
5. Connector pins corroded or dirty. When
removing connectors inspect and clean pins.
Clean female pins by installing and removing.
Depending on the pattern, various reasons can
cause the defect, internal ECU problems also
3060 Cylinder 1 unclassified error in injector possible.
Check the wiring and the injection signals,
replace ECU
Cylinder 1 injector cable short-circuit low side Short circuit in wiring with external source.
3061
to battery Check the wiring or replace injector
Check the wiring and the injection signals,
3062 Cylinder 1 signal low
replace ECU
Defective coil of injector.
3063 Cylinder 1 short-circuit high side to low side
Check the wiring and replace injector
Depending on the pattern, various reasons can
cause the defect, internal ECU problems also
3064 Cylinder 5 unclassified error in injector possible.
Check the wiring and the injection signals,
replace ECU
Cylinder 5 injector cable short-circuit low side Short circuit in wiring with external source.
3065
to battery Check the wiring or replace injector
Cylinder 3 injector cable short-circuit low side Short circuit in wiring with external source.
3069
to battery Check the wiring or replace injector
Check the wiring and the injection signals,
3070 Cylinder 3 signal low
replace ECU.
Defective coil of injector.
3071 Cylinder 3 short-circuit high side to low side
Check the wiring and replace injector
Depending on the pattern, various reasons can
cause the defect, internal ECU problems also
3072 Cylinder 6 unclassified error in injector possible.
Check the wiring and the injection signals,
replace ECU
Cylinder 6 injector cable short-circuit low side Short circuit in wiring with external source.
3073
to battery Check the wiring or replace injector
Check the wiring and the injection signals,
3074 Cylinder 6 signal low
replace ECU.
3075 Cylinder 6 injector cable short-circuit high side Defective coil of injector.
to low side Check the wiring and replace injector
Depending on the pattern, various reasons can
cause the defect, internal ECU problems also
3076 Cylinder 2 unclassified error in injector possible.
Check the wiring and the injection signals,
replace ECU
Cylinder 2 injector cable short-circuit low side Short circuit in wiring with external source.
3077
to battery Check the wiring or replace injector
3079 Cylinder 2 injector cable short-circuit high side Defective coil of injector.
to low side Check the wiring and replace injector
Depending on the pattern, various reasons can
cause the defect, internal ECU problems also
3080 Cylinder 4 unclassified error in injector possible.
Check the wiring and the injection signals,
replace ECU
Cylinder 4 injector cable short-circuit low side Short circuit in wiring with external source.
3081
to battery Check the wiring or replace injector
Check the wiring and the injection signals,
3082 Cylinder 4 signal low
replace ECU.
Cylinder 4 injector cable short-circuit high side Defective coil of injector.
3083
to low side Check the wiring and replace injector
Signal interrupted due to wiring problem,
defective or incorrectly installed crankshaft speed
sensor.
3088 Crankshaft sensor lost synchronization
Check wiring, sensor installation and proper
functioning of crankshaft sensor (evaluate raw
signals)
4005-28
Cause:
1. Faulty reading from component.
2. Connectors not mated fully, pins not pushed
3350 Terminal 50 - Always On
into connector fully, bent pin or broken wire at
rear of connector.
3. Wiring or circuits open.
4. Wiring or circuits shorted.
5. Connector pins corroded or dirty. When
removing connectors inspect and clean pins.
Clean female pins by installing
and removing.
Main Relay 4 (Engine brake exhaust valve) -
3354 See engine manual for details.
Short circuit to ground.
Main Relay 4 (Engine brake exhaust valve) -
3355 See engine manual for details.
Short circuit to battery or open load.
3358 CAN Transmit timeout See engine manual for details.
NOTE: See engine repair manual for electrical
Atmospheric pressure sensor - signal not schematic information.
3363
plausible. Cause:
1. ECU internal error
3367 Coolant temperature test failure. See engine manual for details.
4005-41
Short circuit to battery voltage or open circuit 1. Check the cables from TCU to the sensor.
4133 at transmission sump temperature sensor 2. Check the connectors.
input 3. Check the temperature sensor.
Short circuit to battery voltage or open circuit 1. Check the cables from TCU to the sensor.
4154
at output speed input 2. Check the connectors.
4155 3. Check the speed sensor.
Short circuit to ground at output speed input
1. Check the cables from TCU to the sensor.
2. Check the connectors.
4156 Logical error at output speed input 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, doesn’t fit to other speed speed.
4158
signals. 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.
4180 Vehicle controller time-out (CAN) 2. Check wire of CAN-Bus
3. Check the cable to the cluster controller
1. Check Joystick steering controller.
4181 JSS timeout 2. Check wire of CAN-Bus.
3. Check cable to Joystick steering controller.
1. Check engine controller
4182 Engine CONF timeout 2. Check wire of CAN-Bus
3. Check cable to engine controller
1. Check EEC controller
4183 EEC1 timeout 2. Check wire of CAN-Bus
3. Check cable to EEC controller
1. Check EEC controller
4184 EEC3 timeout 2. Check wire of CAN-Bus
3. Check cable to EEC controller
1. Check the cluster controller.
4185 Invalid test mode signal (CAN) 2. Check wire of CAN-Bus
3. Check the cable to the cluster controller
1. Check I/O controller
4193 AEB Request signal 2. Check wire of CAN-Bus
3. Check cable to I/O controller
1. Check engine controller
4197 Engine torque signal 2. Check wire of CAN-Bus
3. Check cable to engine controller
1. Check engine controller
4201 Reference engine torque signal 2. Check wire of CAN-Bus
3. Check cable to engine controller
1. Check engine controller
4202 Actual engine torque signal 2. Check wire of CAN-Bus
3. Check cable to engine controller
1. Check engine controller
4203 NOM friction torque signal 2. Check wire of CAN-Bus
3. Check cable to engine controller
4005-46
9176 AddMsg DM1 BAM (SCR controller) No information available at time of print.
9177 AddMsg DM1 PCK (SCR controller) No information available at time of print.
9178 TimeOut Packet (SCR controller) No information available at time of print.
CreateMbx 20ms DM1 Packets (SCR
9179 No information available at time of print.
controller)
9180 VCM controller CAN timeout No information available at time of print.
9181 VCM controller CAN did not start No information available at time of print.
Wheel Loader Configuration Plausibility
9182 No information available at time of print.
Failure - Wrong engine type
4005-54
CAN receive frame E2SCR (Dosing status not Possible failure modes:
19578
in range). 1. Controller communication error
CAN receive frame EEC1 (Engine torque not Possible failure modes:
19595
in range). 1. Controller communication error
CAN receive frame EEC1 (Engine speed not in Possible failure modes:
19596
range). 1. Controller communication error
CAN receive frame ET1 (Oil temperature not Possible failure modes:
19604
in range). 1. Controller communication error
Cause:
There was an open circuit detected in the
DEF/AdBlue® level sensor circuit.
19649 UREA Tank level sensor - open circuit Possible failure modes:
1. Faulty Sensor.
2. Faulty electrical wiring or connection.
3. Faulty DCU.
Cause:
There was a short to power detected in the
DEF/AdBlue® level sensor circuit.
19650 UREA Tank level sensor - Short circuit high Possible failure modes:
1. Faulty Sensor.
2. Faulty electrical wiring or connection.
3. Faulty DCU.
Cause:
There was a short to ground detected in the
DEF/AdBlue® level sensor circuit.
19651 UREA Tank level senor - Short circuit low Possible failure modes:
1. Faulty Sensor.
2. Faulty electrical wiring or connection.
3. Faulty DCU.
UREA Tank level error (CAN message or
19652 No information available at time of print.
electrical with real sensor) - (timeout))
UREA Tank level error (too many CAN
19653 No information available at time of print.
messages)
19654 UREA Tank level error - Open circuit No information available at time of print.
4005-70
Cause:
Switched power relay control circuit high.
ECM/PCM Power relay control circuit/open - Possible failure modes:
19741
main relay open circuit 1. Faulty relay
2. Faulty electrical wiring or connection
3. Denox module/supply module error
Cause:
Switched power relay control circuit open.
ECM/PCM Power relay control circuit/open - Possible failure modes:
19742
main relay shut off too early 1. Faulty relay
2. Faulty electrical wiring or connection
3. Denox module/supply module error
Cause:
High urea temperature in pump module.
UREA Temperature sensor of pump module - Possible failure modes:
19748
Out of range 1. Tank heating valve stuck open.
2. Check for other tank heating valve/coolant flow
solenoid related error codes.
Cause:
High urea temperature in pump module.
Dynamic UREA leakage test - Leakage Possible failure modes:
19749
detected 1. Tank heating valve stuck open.
2. Check for other tank heating valve/coolant flow
solenoid related error codes.
The dosing control unit (DCU) has activated this
fault due to other fault codes associated with the
DEF / AdBlue® injection control being active.
19757 Reagent - pump - Not delivering Diagnose those fault codes to clear this fault. If
this fault is active without any other codes active,
reload the software in the DCU or replace the
DCU.
The dosing control unit (DCU) has activated this
fault due to other fault codes associated with the
DEF / AdBlue® injection control being active.
19766 Compressed air regulation valve Diagnose those fault codes to clear this fault. If
this fault is active without any other codes active,
reload the software in the DCU or replace the
DCU
The dosing control unit (DCU) has activated this
fault due to other fault codes associated with the
DEF / AdBlue® injection temperature being
Plausibility of catalyst temperature sensors -
19775 active. Diagnose those fault codes to clear this
Plausibility error
fault. If this fault is active without any other codes
active, reload the software in the DCU or replace
the DCU.
4005-73
Context:
The denox module/supply module has detected the
urea tank temperature and denox module/supply
UREA Tank temperature - SRC Low: Short
19806 module temperature are not in agreement.
circuit low.
Possible failure modes:
1. Extreme cold ambient conditions.
2. DEF/AdBlue® tank temperature sensor is faulty.
Context:
The denox module/supply module has detected the
urea tank temperature and denox module/supply
UREA Tank temperature - SRC High: UREA
19807 module temperature are not in agreement.
temperature too high - Out of range
Possible failure modes:
1. Extreme hot ambient conditions.
2. DEF/AdBlue® tank temperature sensor is faulty.
Context:
The denox module/supply module has detected the
urea tank temperature and denox module/supply
19808 UREA Tank temperature - SRC Low: UREA
temperature too low - Out of range module temperature are not in agreement.
Possible failure modes:
1. Extreme cold ambient conditions.
2. DEF/AdBlue® tank temperature sensor is faulty.
Context:
During operation, the ventilation valve is fully
opened, the pump is then set to 100 % operation
until DEF/AdBlue® pressure has reached 500 kPa.
The ventilation valve is then closed. If DEF/AdBlue®
pressure does not reach 500kPa within 2.5 min,
this error occurs.
19813 Reagent - pump - Not delivering Cause:
The denox module/supply module has detected the
pump motor is not delivering.
Possible failure modes:
1. No DEF/AdBlue® in tank
2. System was empty, needs primed
3. Faulty pump
4. Faulty feeding line
4005-75
TABLE OF CONTENTS
STEERING CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
AUXILIARY STEERING PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
STEERING PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
AUXILIARY STEERING PUMP AND MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
STEERING BACK PRESSURE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5001-3
Removal STEP 7
STEP 1
Remove the cab skirts from the cab or canopy.
STEP 2
Remove all dirt and grease from steering control
valve.
STEP 3
Remove hydraulic reservoir fill cap, attach a vacuum
pump to the reservoir, start the pump.
BD06G245
STEP 4 Remove the mounting nut and washers from the
Tag hoses connected to steering control valve. steering shaft.
STEP 5 STEP 8
BD06G262 BD06G246
Disconnect hoses from steering control valve, cap or Remove the steering wheel from the shaft.
plug the fittings and hoses, turn off the vacuum
pump.
STEP 9
STEP 6
BD06G247
BD06G248 BD06G258
Remove the five mounting screws for the left and Remove the two mounting screws from the lower
right hand trim. trim.
STEP 11 STEP 14
BD06G249 BD06G259
Disconnect the ignition switch, remove the right and Pull floor mat away from the column and remove the
left hand trim pieces from the column. lower trim from the column.
STEP 12 STEP 15
BD06G257 BD06G260
Remove the screw from the brace. Remove the two lower mounting screws from the
front vent.
5001-5
STEP 16 Installation
STEP 18
BD06G261
STEP 20
BD06G263
BD06G263
BD06G261 BD06G257
Install the front trim, install and tighten the three Install the screw into the brace.
mounting bolts inside of the vent holes, install three
vents into the front trim. STEP 25
STEP 22
BD06G249
STEP 23
BD06G248
BD06G247 BD06G262
Install and tighten the six mounting screws for the Start the vacuum pump, remove the caps and plugs
instrument cover. the fittings and hoses. Connect hoses to steering
control valve according to the tags installed during
STEP 28 removal, remove and discard the tags.
STEP 31
Remove the vacuum pump from the reservoir, install
and tighten the reservoir fill cap.
STEP 32
Start and run the machine at low idle, turn the wheel
to full left and then to full right, stop the machine and
check for leaks.
STEP 33
BD06G245
Install the skirts onto the cab or canopy.
Install the steering wheel, install and tighten the
mounting nut and washers. STEP 34
Check fluid level in hydraulic reservoir. Add oil as
STEP 29 required. See Section 1002 for specifications.
BD06G244
1
2
10
4
9
5
6
8 7
BC05M084
1. STEERING LOAD SENSING HOSE TO PRIORITY VALVE 6. CAP SCREWS AND NUTS
2. STEERING LOAD SENSING HOSE TO STEERING VALVE 7. PRESSURE HOSE
3. PRESSURE SWITCH 8. STEERING SOLENOID
4. SUCTION PORT 9. STEERING PRESSURE HOSE
5. PUMP OUT PRESSURE TUBE FITTING 10. TANK RETURN TUBE
AUXILIARY STEERING PRIORITY VALVE ILLUSTRATION
5001-10
4
5
4
3 8
BC05M087
7. Connect a vacuum pump to hydraulic reservoir. IMPORTANT: In following Step, do not run auxiliary
steering pump and motor continuously for more than
8. Start vacuum pump. 20 seconds at a time without a two minute cool down.
9. Disconnect suction hose (4) from auxiliary 12. With engine at low idle and machine steering
steering pump and motor (7). Install a plug in straight ahead, turn key switch to OFF position to
suction hose and cap on fitting. stop engine and then immediately back to ON
10. Stop vacuum pump. position (not START position). Auxiliary steering
pump and motor should star t operating
11. Loosen fittings on pressure tube (5). immediately. Check that auxiliary steering light
12. Support auxiliary steering pump and motor (7). on infor mation center is ON and auxiliar y
Remove nuts (3), cap screws, and washers steering pump and motor is operating.
securing auxiliary steering pump and motor (7). 13. Turn steering wheel all the way to left and right to
13. Remove pressure tube (5) and auxiliary steering make sure that auxiliary steering pump and
pump and motor (7). motor operates correctly.
14. Restart engine. Check that auxiliary steering
light on information center stays ON and auxiliary
steering pump and motor is operating. After
Installation about three seconds motor should stop operating
1. Position auxiliary steering pump and motor (7) on and auxiliary steering light should go out.
its mounting plate while connecting and hand 15. Let engine run and allow batteries to recharge for
tightening pressure tube (5) to auxiliary steering a minimum of 10 minutes.
priority valve (6). See illustration on page 13.
2. While supporting auxiliary steering pump and
motor (7) have an assistant install cap screws,
washers, and nuts (3) to secure auxiliary steering
pump and motor (7), tighten the nuts.
3. Tighten pressure tube (5) fittings securely.
4. Start vacuum pump.
5. Remove plug from suction hose (4) and cap from
elbow. Connect suction hose to elbow installed in
auxiliary steering pump and motor (7).
6. Stop and disconnect vacuum pump. Install fill
cap in hydraulic reservoir.
5001-13
4
5
BC05M085
STEERING CYLINDER
Removal Installation
1. Loosen the fill cap for the hydraulic reservoir to 1. Put steering cylinders (11) in position in machine.
release pressure in the reservoir, then tighten the Make sure that washers (4) are installed between
fill cap. steering cylinder (11) and rear frame. See
illustration on page 15.
2. Disconnect grease hoses (1 and 16) from
steering cylinders (11). See illustration on page NOTE: Install a washer (4) on top and bottom of
15. steering cylinders (11) if possible. If only one washer
(4) can be installed, place washer (4) at bottom of
3. Disconnect hydraulic hoses (2, 3, 9, and 10) from
steering cylinders (11).
steering cylinders (11).
2. Make sure washers (14) are installed between
4. Install a plug in each hose (2, 3, 9, and 10) to
steer ing cylinders (11) and front frame of
prevent entry of foreign matter.
machine.
5. Remove locknut (15).
3. Install the pivot pin (5) to secure rear of steering
6. Remove cap screw (13). cylinders (11) to machine frame. Install spacer
(6), washer (7), and cap screw (8) to secure pivot
7. Remove pin (12).
pin (5).
8. Remove washers (14).
4. Tighten cap screw (8).
9. Remove cap screw (8), washer (7), and spacer
5. Install pin (12) in front of steering cylinders (11).
(6) securing pivot pin (5) at rear of steering
Make sure that washers (14) are installed in
cylinders (11).
correct position.
10. Use a suitable driver and drive pivot pin (5) out of
6. Install cap screw (13) and new locknut (15) in
steering cylinder (11).
steering cylinders (11) rod end and pin (12).
11. Remove washer(s) (4) from between steering Tighten locknut (15).
cylinders (11) and rear frame of machine.
NOTE: Cap screw (13) should turn freely in hole
12. Remove steering cylinders (11). after tightening.
7. Connect hose assemblies (2, 3, 9, and 10) to
steering cylinders (11).
8. Connect grease hoses (1 and 16) to steering
cylinders (11).
9. Tighten hydraulic reservoir fill cap.
10. Start engine.
11. Turn steering wheel all the way to right and then
to the left several times.
12. Stop the engine. Check fluid level in hydraulic
reservoir. Add oil as required. See Section 1002
for specifications.
5001-15
9 10
8
6
5
3 11
2
1 1 12
13
14
15
11
16
BS03B141
Removal Installation
1. Remove the fill cap for the hydraulic reservoir to 1. Install the valve, bolts, spacers and nuts onto the
release pressure in the reser voir, attach a machine, tighten the bolts.
vacuum pump to the reservoir, start the pump.
2. Install new O-rings onto the fittings of the hoses,
2. Disconnect hoses 2 and 6 from the pressure install and tighten the hoses.
valve.
3. Stop the vacuum pump, install and tighten the
3. Remove the nuts, bolts and spacers from the reservoir filler cap.
pressure vale, remove the valve from the
4. Start and run the machine at low idle, turn the
machine.
steering wheel from full left lock to full right lock
holding the steering over relief.
5. Stop the machine and check for leaks.
6. Check fluid level in hydraulic reservoir. Add oil as
required. See Section 1002 for specifications.
5001-17
BS06G529
TABLE OF CONTENTS
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
STEERING PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pressure Setting Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pressure Setting Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
STEERING CYLINDER LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
STEERING BACK PRESSURE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5002-3
SPECIAL TOOLS
B785789 B009638
B797157
Equipment Required
6. Connect the ammeter clamp (1) to the cable as
1. CAS- 10280 Flowmeter in illustration.
2. CAS-1808 Flowmeter fitting kit
Test Procedure
1. Install articulation lock.
BB830300
1. AMMETER CLAMP
7. Make sure that the parking brake is applied and
1 the bucket is on the floor.
BD03A040
8. Make sure that the oil is at operating
temperature.
1. ARTICULATION LOCK
NOTE: When performing this pressure check, 9. Make sure that the load valve for the flowmeter is
always be sure the articulation lock is in place, open (zero pressure).
especially when working in the articulation joint 10. Start and run the engine.
areas.
11. Stop the engine and turn the key back to the On
2. Loosen and remove the outlet hose to the position.
Auxiliary Steering Pump from the Auxiliar y
Steering Priority Valve. 12. Turn the steering wheel, this will activate the
auxiliary steering pump.
3. Install a plug into the Auxiliary Steering Priority
Valve. 13. Turn the load valve on the flowmeter towards
CLOSED until the pressure is 104 bar (1500 psi).
4. Connect the inlet of the flowmeter to the outlet
line of the Auxiliary Steering Pump. 14. Read the flowmeter and ammeter gauges and
record the readings.
5. Install the outlet hose of the flowmeter in the
hydraulic reservoir and hold in place with wire. 15. The flowmeter reading must not be less than
24.6 L/min, (6.5 U.S. gpm). The ammeter reading
must be 315 amps.
16. Turn the key switch to the OFF position. If the
flow was less than the specification, or if the
amperage was more than 315 amperes, remove
the auxiliary steering motor and pump. Test the
auxiliary steering motor. If the motor is good,
make repairs to the pump.
5002-5
Test Equipment 5. Push the button on the remote starter switch (1)
and look at the voltmeter in the tester.
1. A 24 volt battery that is fully charged.
6. Turn the load control (8) until the voltmeter (7)
NOTE: A 24 volt battery system (two 12 volt indicates 24 volts. Look at the ammeter (6) in the
batteries in a series) is used for this test. A 12 volt tester. Make a record of the ammeter indication.
battery system will cause damage to the auxiliary
steering motor.
2. A remote starter switch. 6 7
3. A tachometer to check the armature speed.
4. A Sun Electric VAT-33 Starting and Charging
System Tester.
8
Test Procedure
1. Remove the connector that is between the
ter minals on the magnetic switch and the
auxiliary steering motor.
B795328
2. Remove the auxiliary steering motor from the
auxiliary steering pump. 6. AMMETER
7. VOLTMETER
3. Remove the drive coupling from the auxiliary 8. LOAD CONTROL
steering motor (3).
7. Hold the tachometer against the armature shaft.
4. Connect the auxiliary steering motor (3), remote Look at the tachometer. Make a record of the
starter switch (1) and tester (2) to the 24 volt indication.
battery system (5) as illustrated.
8. Release the button on the remote starter
switch (1).
2
1
Understanding The Results Of The
Test
4 1. If the ammeter indication in step 6 was 30
3 amperes or less and the tachometer indication in
step 7 was 6950 r/min (r pm) or more, the
auxiliary steering motor is good.
2. If the armature speed was less than 6950 r/min
(rpm) and the ammeter indication was higher
5 than 30 amperes, replace the motor.
B790852
Pressure Setting Test 4. Make sure that the temperature of the hydraulic
oil is at least 54° C (129° F).
1. Install articulation lock (1). 5. To measure the temperature of the oil using the
instrument panel:
A. Press the up or down arrow key.
B. Stop at the info screen with the temperatures
that need to be monitored.
6. Apply the parking brake.
7. Start and run the engine at full throttle.
8. Lower the lift arms and hold the control lever in
the FLOAT position.
BD06F148
1. G1 TEST PORT
2. G2 TEST PORT
3. Connect a 345 bar (5000 psi) pressure gauge to
the test port (2).
NOTE: Make sure when you connect the pressure
gauge that you do so in a manner that you can read
the pressure gauge while sitting in the operators
seat.
5002-7
BD06F147
BS06G529
STEERING CYLINDERS
5005
5005-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5005-3
SPECIFICATIONS
Torque for piston cap screw........................................................................ 810 to 925 Nm (597.5 to 682 pound feet)
Torque for gland............................................................................................. 339 to 475 Nm (250 to 350 pound feet)
STEERING CYLINDER
Disassembly Inspection
1. Fasten tube (18) in a vise. Be careful not to 1. Clean all parts in cleaning solvent.
damage the tube. See illustration on page 4.
2. Check to be sure that piston rod (14) is straight. If
2. Remove gland (1) from tube (18). piston rod is bent, install a new piston rod.
3. Pull piston rod (14) and piston (9) straight out of 3. Inspect inside of tube (18) for deep grooves and
tube (18). other damage. If there is any damage to tube, a
new tube must be used.
4. Fasten piston rod (14) yoke in vise and put a
support below piston rod near piston (9). Put a 4. Remove small scratches on piston rod (14) or
shop cloth between support and piston rod to inside tube (18) with emery cloth of medium grit.
prevent damage to piston rod. Use emery cloth with a rotary motion.
5. Loosen and remove bolt and washer (8) that hold 5. Inspect bushing (17). If bushing requires
piston (9). replacement, remove grease fitting (15) and
retaining rings (16) then press bushing from tube
6. Remove piston (9) from piston rod (14).
end.
7. Remove and discard seal (13), loader ring (12),
wear ring (11), and cast iron ring (10) from piston
(9).
8. Remove gland (1) from piston rod (14).
9. Remove and discard O-ring (7), backup ring (6),
rod wiper (2), rod seal (3), buffer seal (4), and
bearing (5) from gland (1).
5005-4
16 15
17
16
18
8
9
19
13
12
11
10
5
4
3
7
6
14
BC05M089
Assembly 17. Install bolt and hardened washer (8) in piston (9).
1. Install bearing (5) in gland (1). 18. Install piston (9) on piston rod (14) and start bolt
(8) into piston rod.
2. Install buffer seal (4) in gland (1) so that lips of
seal are toward small end of gland. 19. Tighten bolt (8) to a torque of 810 to 925 Nm
(597.5 to 682 pound feet).
3. Install rod seal (3) in gland (1). Rod seal must be
installed so that lips of seal are toward small end 20. Fasten tube (18) in vise. Be careful not to
of gland. Seal can be difficult to install. Use tools damage tube.
that will not damage seal. See illustration on 21. Apply petroleum jelly to O-rings (7) and backup
page 4. ring (6) on gland (1) and to sealing surface in
4. Install rod wiper (2) in gland (1) with wiper lips tube (18).
toward large end of gland. 22. Lubricate piston (9) and inside of tube (18) with
5. clean hydraulic oil.
6. Install O-ring (7) on gland (1). 23. Push the piston (9) straight into tube (18). Be
careful not to damage cast iron ring (10), wear
7. Install backup ring (6) on gland (1). The backup ring (11), and seal (13) on piston (9).
ring must be toward large end of gland. If backup
ring is not flat on both sides, the side that is not 24. When piston (9) is in smooth part of tube (18),
flat must be toward O-ring (7). start gland (1) into tube (18).
8. Fasten piston rod (14) yoke in vise. 25. If the original parts are being assembled:
9. Lubricate piston rod (15) and bore in gland (1) A. Tighten gland to a torque of 339 to 475 Nm
with clean hydraulic oil. (250 to 350 pound-feet).
NOTE: If a new gland (1) is being installed, write B. Install and tighten self-tapping screw (19) to a
part number of cylinder on gland. torque of 2.3 Nm (20 inch-pounds).
10. Push gland (1) onto piston rod (14) large end C. If, after tightening gland, the self-tapping
first. If necessary, use a soft hammer to drive the screw (19) holes are not aligned, a new hole
gland onto piston rod. for self-tapping screw must be drilled. See
Step 26.
11. Put a support below and near the end of piston
rod (14). Put a cloth between support and piston 26. If a new gland (1) or a new tube (18) are being
rod to prevent damaging piston rod. assembled:
12. Install new cast iron ring (10) on piston (9). A. Tighten gland (1) to a torque of 339 to 475 Nm
(250 to 350 pound-feet).
13. Install new wear ring (11) on piston (9).
B. Use a No. 27 drill bit and drill a hole half in
14. Install a new loader ring (12) on piston (9). gland (1) and half in tube (18). Drill to a depth
15. Install a new seal (13) over loader ring (12). of 11 mm (7/16 inch). Do not drill within 13 mm
(1/2 inch) of a hole for gland wrench.
16. Clean the threads on the end of piston rod (14)
and threads of bolt (8) using Loctite cleaning C. Install and tighten self-tapping screw (19) to a
solvent. Allow to dry. Apply Loctite 243 to piston torque of 2.3 Nm (20 inch-pounds).
rod threads 6.4 mm (1/4 inch) from open end of 27. If hoses were removed with cylinder, install new
piston rod so that there is 12.7 mm (1/2 inch) of O-rings, if equipped, on hose fittings. Lubricate
Loctite 243 on piston rod threads. DO NOT apply O-rings with clean oil. Install hoses.
Loctite to first 6.4 mm (1/4/inch) of piston rod
threads.
5005-6
NOTES
Section
5006
CENTER PIVOT
5006
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
5006-3
SPECIFICATIONS
SPECIAL TORQUES
M16 bolt for upper pivot pin .......................................................................220 to 250 Nm (162 to 184 pound-feet)
M12 bolts for bearing retainers and lower pivot pin...........................................................124 Nm (91 pound-feet)
M12 bolts for lower pin plate .......................................................................128 to 136 Nm (94 to 100 pound-feet)
Ferry head screws for the drive shaft ................................................................61 to 81 Nm (45 to 60 pound-feet)
LUBRICANT
Pivot bearings and seals ............................................................................... Case AKCELA molydisulfide grease
Steering cylinder rod eyes............................................................................. Case AKCELA molydisulfide grease
SPECIAL TOOLS
CAS10219 ....................................................................................................................... Hand pump (hydraulic ram)
CAS10600 ................................................................................ Bearing cup and seal puller, includes 24850 adapter
CAS2029 ................................................................................... *Top bearing driver, bottom bearing driver and plate
* (Requires screw, two nuts, and two washers from CAS10592)
BC06A174
CAS2029 DRIVER SET
5006-4
CENTER PIVOT
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 rod
3. Stop the engine and apply the parking brake. 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 cap 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).
13. Disconnect the hoses for the steering cylinder. 31. Use a prybar to remove the upper pivot pin (4).
14. Install caps on the fittings and plugs in the hoses. 32. Loosen and remove the bolts (1) and washers (2)
15. Loosen and remove the bolts, lock washers, and that fasten the lower pin plate (15) to the lower
self-locking nuts that fasten the mounting bracket pivot pin (10).
for the hoses to the bracket on the front frame. 33. Loosen and remove the bolts (1) and washers (2)
16. Loosen and remove the bolts, flat washers, and that fasten the lower pin plate (15) to the bottom
self-locking nuts that fasten the bracket for the 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.
5006-5
1 2
3
4
5
1
6
2
7
5
8
10
6 9
16 12 11
6
8
13
6
2
14
1
8
15 2
2
1
1
BS03B152
44. Remove the bearing retainer (7) and shims (8). 17. BEARING DRIVER 20. BEARING CUP
18. NUT 21. PLATE
45. Use the puller to remove the seal (6) from the top 19. SREW 22. TOP PIVOT
of the bottom pivot.
5. Tighten a nut (18) on the screw (19) until the
46. Use the puller to remove the seal (6) from the bearing cup (20) is seated in the bore of the top
bottom of the top pivot. pivot (22). Remove the bearing driver (17) and
plate (21) from the top pivot (22).
47. Use an acceptable driver, the hydraulic ram, and
the hand pump to remove the upper pivot 6. Install a bearing cone (25), spacer (24), the other
bearing (9) from the top pivot. See Special Tools bearing cone (23), and the remaining bearing
in this section. cup (26) in the top pivot (22).
NOTE: The spacers are matched to the bearing 7. Install the bearing driver (17) and plate (21).
sets. Do not mix the spacers. Do not use the old
8. Tighten a nut (18) on the screw (19) until the
spacers if new bearing sets are being installed.
bearing cup (26) is seated against the spacer
48. Use an acceptable driver, the hydraulic ram, and (24). Remove the bearing driver (17) and plate
the hand pump to remove the lower pivot bearing (21) from the top pivot (22).
(12) from the bottom pivot. See Special Tools in
this section. 17 18 19
23
NOTE: The spacers are matched to the bearing 26
sets. Do not mix the spacers. Do not use the old 24
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).
25
21 22
BC06A119
17 18 19 27
7
BC06A125.
17
BC06A123
29
23 26
17
BC06A124
41. Install the other seal (6) in the bottom pivot. The
31. Remove the bearing driver (17) and plate (21)
top of the seal (6) must be even with the top of
from the bottom pivot (29).
the bottom pivot.
32. Put the bearing retainer (13) in place on the
lower pivot bearing (12).
33. Install the bearing driver and plate.
21 18 19
29
12 30
BC06A121
5008
5008-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
AUXILIARY STEERING MOTOR AND PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5008-3
SPECIFICATIONS
Auxiliary steering motor
Maximum amperes...............................................................................................................................30 amperes
Minimum armature speed ............................................................................................................ 6950 r/min (rpm)
Motor ...........................................................................................................................................................24 volts
Auxiliary steering pump
Minimum flow ..............................................................................................24.6 L/min at 104 bar at 315 amperes
(6.5 U.S. gpm at 1500 psi at 315 amperes)
5008-4
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.
5008-5
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
5009
5009-2
TABLE OF CONTENTS
SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
JOYSTICK STEERING SYSTEM (JSS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Description of the JSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F-N-R Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Procedures for Turning the JSS On and Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Kick-down Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Illustration of the valve PVFC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Illustration of the valve PVG32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Exploded view of the valve PVG32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
STEERING VALVES PVG32 AND PVFC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
JOYSTICK STEERING SYSTEM ARMREST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
JSS HYDRAULIC PRESSURE ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Pressure Setting Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Pressure Setting Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Steering Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
STEERING SPEED CALIBRATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5009-3
SAFETY RULES
WARNING
This safety alert symbol indicates important safety messages in this manual. When you see this symbol, carefully
read the message that follows and be alert to the possibility of machine damage, serious injury, or death.
M171C
WARNING
Be cautious when turning with joystick steering. Abrupt movements of the joystick to the left or right could cause
the machine to turn more sharply than acceptable. Take necessary precautions. Do not use the joystick for primary
steering. It is intended for short repetitive operations. Failure to comply could result in machine damage, death or
serious injury.
M1336
WARNING
If hydraulic pilots are disengaged, the joystick steering still remains active. Always disengage joystick steering
when not in use. Failure to comply could result in machine damage, death or serious injury.
M1348
WARNING
Do not use joystick steering when loading or unloading the machine from a truck or trailer. Always use the primary
steering wheel when loading or unloading the machine from transport. Failure to comply could result in machine
damage, death or serious injury.
M1345
WARNING
Use caution when moving about in the operator’s compartment when joystick steering is active. An inadvertent
movement against the joystick steering control could cause the machine to turn or move abruptly. Failure to
comply could result in machine damage, death or serious injury.
M1347
WARNING
Do not use joystick steering when traveling on a public road or highway. The left arm rest must be raised and in a
locked position. Use the primary steering wheel if travel on a public road or highway is required. Failure to comply
could result in machine damage, death or serious injury.
M1346
WARNING
Do not use joystick steering if operating at speeds over 20 km/h (12.4 mph). Always use the primary steering
wheel at higher speeds for optimum control of the machine. Failure to comply could result in machine damage,
death or serious injury.
M1349
5009-4
The JSS is mounted in parallel with the standard Preset condtion must be met by:
steering system. The standard steering system ● left armrest completely lowered
always has priority. If during joystick operation, the ● gear lever in neutral
primary steering wheel is moved, steering will revert
● equipment locking switch disenabled
to primary steering. Joystick steering is designed for
short, repetitive machine operations. ● pilot pressure switch on
● joystick steering switch in neutral
WARNING ● machine is stationary.
Do not use joystick steering if operating at speeds
over 20 km/h (12.4 mph). Always use the primary System efficiency check
steering wheel at higher speeds for optimum control
● with the JSS off, the pilot pressure must be less
of the machine. Failure to comply could result in
than or equal to 8 bar (115 psi).
machine damage, death or serious injury.
● the software monitors the armrest position switch.
M1349
When the JSS is turned on and during operation,
the switch position is checked. If the position of the
3 armrest is raised or the switch is shorted, the
system will deactivate.
JSS / AUX F-N-R (JSS) AUX F-N-R JSS / AUX F-N-R JSS (AUX) F-N-R
disabled enabled disabled enabled
Activation JSS activation signal JSS activation signal Auxiliary F-N-R F-N-R enable signal
signal enabling signal or JSS enable signal
Resulting JSS F-N-R Enabled JSS F-N-R Enabled AUX F-N-R JSS F-N-R
F-N-R Stays enabled. Stays enabled. Enabled Enabled
within 8 seconds
status
release parking
brake and engage
F or R to maintain
enabling.
F-N-R If JSS F-N-R not in If JSS F-N-R not in If AUX F-N-R not in
conditions neutral. neutral. neutral.
not met
F-N-R JSS / AUX F-N-R JSS / AUX F-N-R JSS / AUX F-N-R
alternative disabled. disabled. disabled.
status
5009-7
ERROR CODES
Errors for the JSS will only be displayed if the switch is in the ON position.
The errors can be reset by turning the JSS system OFF and On. The following two errors will not reset:
● 1821r Power Supply Failure ● 1830y Activation Switch failure.
The errors will always be shown on the display once they are present. To reset these errors the engine must be
turned off.
ERROR CODES TABLE
Error
Item Error Message
1 1812 JSS Failure Armrest Switch- short to battery or ground
2 1816 JSS Activation Button Failure – mechanical defect
3 1820 JSS Power Supply Failure – check JSS relay, valve, or joystick
4 1821 JSS Short to ground or power on relay, or activation switch
failure
5 1823 JSS Relay Ground Failure
6 1824 JSS Activation Switch Short to Battery
7 1830 JSS Activation Switch failure
8 1831 JSS Error JSC – wrong operation, controller internal fault
9 1832 JSS Signal Input Error JSC – controller out of limits
10 1833 JSS Signal Output Error JSC – controller out of limits
11 1834 JSS JSS controller, JSC output, short to BAT power
12 1835 JSS Valve Failure Power Supply
13 1836 JSS JSS controller, board temperature out of limts
14 1837 JSS JSS controller, switched power out of limits
15 1838 JSS Neutral switch out of range
16 1839 JSS Joystick steering is not calibrated
17 1841 JSS Valve Alarm
18 1842 JSS Valve Alarm Open Circuit
19 1843 JSS Pilot Pressure is High
20 1844 JSS Pilot Pressure Switch Short to Ground
21 1845 JSS Pilot Pressure is Low
22 1846 JSS Failure on LS Pressure Switch
23 1847 JSS JSC model type not available
24 1850 JSS Joystick Failure - Neutral Switch / Power Supply
25 1852 JSS Error in Ground Connection
26 1860 JSS CAN timeout of C5.E detected by JSC
27 1861 JSS CAN timeout of AIC detected by JSC controller
28 1863 JSS Internal malfunction transmission controller
29 9134 JSS CAN communication failed
30 9135 JSS CAN communication failed
5009-8
210 bar
3
211.6 bar
1
210 bar
2
W190-4R091
ILLUSTRATION OF THE VALVE PVFC
Connections
Port 1 - to the steering priority valve
Port 2 - to the auxiliary steering valve
Port 3 - to the LS port of the valve PVG32
5009-9
TO
T
LX
PP
A T2
B
P
W190-4R092
ILLUSTRATION OF THE VALVE PVG32
Connections
Ports A / B to the steering cylinder on the stem Port PP pilot pressure switch 8 bar
side and bottom side 350 bar, 65 l/min Port T outlet 25/40 bar
LS port to port 3 of the valve PVFC Port T2 not used
Port P to the steering priority valve 350 bar, 65 Port TO LX not used
l/min
5009-10
2
6
9
11
4
3
8
10
1
5
W190-4R099
EXPLODED VIEW OF THE VALVE PVG32
ELECTRICAL SYSTEM
Removal STEP 4
STEP 1
Park loader on level ground and lower bucket to 1
ground. Put transmission in NEUTRAL, apply parking
brake, and shut down engine. Put the master
disconnect switch in the OFF position.
STEP 2 11
Remove all dirt and grease from the steering system
valves and adjacent area.
IMPORTANT: Tag all connections prior to
disassembly. 9
10
STEP 3
1
W190-4R072
3 Remove nut (11) from the stud (9) to release the
chassis grounding cable (1).
2
STEP 5
4
7
2
8
5
6
W190-4R071
W190-4R073
Open the access panel on the right-hand side of the
cab to access the fuse and relay compartment.
Disconnect the connector from the chassis harness
(1) from the joystick cable (2). Remove the chassis
frame cable (1).
5009-12
STEP 6 STEP 8
5
2
3 8
2
W190-4R074
Disconnect the joystick harness (2) from the cab
wiring harness (3). W190-4R076
3 STEP 9
1
10
2
W190-4R075
9
Disconnect the connector (1) from the joystick 5
harness (2). Disconnect the armrest harness (3) from
the six-position connector (4). 12
11
W190-4R077
6 2
3
4
W190-4R078
Detach the joystick harness (1) from the mounting
brackets on the fuse and relay panel (2). Remove the
two connectors (3) by removing the two nuts (4),
washers (5) and capscrews (6). Remove the joystick
harness (1).
STEP 11
W190-4R080
To remove the armrest harness (9), see page 33.
5009-14
Installation STEP 14
STEP 12
1
3
4 12
7
14
13
16
15
8 W190-4R083
5 Open the access panel on the right-hand side of the
cab to access the fuse and relay compartment. Install
6
the steering control module (12) on the supporting
W190-4R071
plate (13) by installing the three nuts (14), capscrews
Connect the chassis harness (1) to PVG32 valve (2),
(15) and washers (16). Tighten the capscrews.
connect connector (3) to the pilot pressure switch
connector (4). Connect connector (5) to the solenoid
valve. Connect connector (7) to the pressure switch
on valve PVFC (6) and secure the harness with strap STEP 15
(8) on the valve.
4
STEP 13 1
5
1
11 6
7
10
W190-4R088
Connect the chassis harness (1) to the grounding
stud (9), install and tighten the nut (11).
W190-4R084
Connect the joystick harness (1) to the steering
control module (4) with connector (5). Connect
connector (6) to the cab harness connector (7).
5009-15
STEP 16 STEP 18
12 9
8 10
11
2
W190-4R085
Mount the joystick cable (1) to the fuse and relay
panel (9) by installing the two nuts (10), washers (11)
and capscrews (12). Tighten the capscrews.
1
STEP 17
W190-4R073
Connect connector (1) to the joystick harness (2).
14 STEP 19
13
1
W190-4R086
3
Connect the joystick harness (1) to the cab harness
(13) with connector (14).
W190-4R082
To install the armrest cable (3), see page 39.
5009-16
STEP 20
3 4
W190-4R087
8
14
D
C 20
12 11 10 19
27
28
15 29
F
E
Detail E
Detail C 16 view from F
13 view from D
721E-4R001
20
21
21
19 27
8
88
22
22
88
29 22
22
22
21
21
28
13
13
26
24
24
25
16
23
23 22
84419913sht
84419913 sht13
13
WIRING DIAGRAM
WIRING DIAGRAM OF
OF THE
THE JOYSTICK
JOYSTICK STEERING
STEERING SYSTEM
SYSTEM
5009-19
Removal STEP 3
STEP 1
Clean all dirt and grease from the steering valves
and adjacent areas.
STEP 2
4
2
3
W190-4R003
1 Tag and disconnect the hose (4) and (5) from valve
PVFC (2). Plug hoses and cap fittings.
2
STEP 4
W190-4R002
Loosen and remove the LS (3) tube from valve
PVG32 (1) and valve PVFC (2).
W190-4R004
Tag and disconnect the hose from the steering
priority valve to valve PVG32.
5009-20
STEP 5 STEP 8
W190-4R005
Tag and disconnect the outlet hose.
STEP 6
1 4
3
W190-4R008
Remove the steering valve PVG32 (2) from the
support bracket (1) by removing the four capscrews
(3) and washers (4).
W190-4R006
Tag and disconnect the supply hose to the steering STEP 9
cylinder line.
STEP 7 1
3
2
5
4
W190-4R009
Remove the mounting bracket (1) from the rear
chassis removing three nuts (2), washers (3),
W190-4R007 capscrews (4) and washers (5).
Tag and disconnect the supply hose to the steering
cylinder line.
5009-21
STEP 10 STEP 13
1
14
14
2
W190-4R010
Remove the mounting bracket (1).
W190-4R013
Unscrew the fittings (14) from the steering valve
STEP 11 PVFC (2).
1 8
STEP 14
7
1
9
10
6
2
W190-4R011
Remove the steering valve PVFC (6) from the
mounting bracket (1) by removing the two nuts (7),
W190-4R014
washers (8), capscrews (9) and washers (10). Remove the pilot pressure switch (1) with seal (2)
from the steering valve PVG32.
STEP 12
STEP 15
12
13
3
11
2 W190-4R015
Remove the reduction fitting (3).
W190-4R012
Unscrew the pressure switch (12) with seal (13) from
the “T” fitting (11).
5009-22
STEP 16 STEP 19
4
W190-4R016
Unscrew the union (4) from the “LS” port of the
steering valve PVG32.
W190-4R019
STEP 17 Remove joint (7) from port “T”.
W190-4R017
Remove the two fittings (5) from ports “A” and “B”.
STEP 18
W190-4R018
Remove the fitting (6) from the port “P”.
5009-23
Installation STEP 22
NOTE: Before assembling the steering valves, clean
the parts using solvent and dry them. 3
1. Inspect each part for defects.
2. Replace all damaged or deformed parts with new
ones.
STEP 20
1
W190-4R022
Install the two fittings (3) into ports “A” and “B”.
Tighten the fittings to 100 N m (75 pound feet).
STEP 23
W190-4R020
Install the joint (1) into port “T” of the steering valve
PVG32. Tighten the joint to 310 N m (230 pound
feet).
1
STEP 21
W190-4R023
2 Install the firing (1) into port “LS”. Tighten the fitting to
45 N m (33 pound feet).
STEP 24
W190-4R021
Install fitting (2) into port “P”. Tighten the fitting to 170 2
N m (125 pound feet).
W190-4R024
Install the reducer (2) for the pilot pressure switch on
the port “Pp”. Tighten the reducer to 45 N m (33
pound feet).
5009-24
STEP 25 STEP 27
3 10
2 11
4
9
W190-4R025
Install the pilot pressure switch (3) with seal (4) into
the reducer (2).
W190-4R027
STEP 26 Install the pressure switch (10) with seal (11) into the
“T” fitting (9).
STEP 28
6 1 4
3
7
8
5
5 6
2
W190-4R026
Install fitting (6) into port “1” of the steering valve W190-4R028
PVFC (5), “T” fitting (7) into port “2” and fitting (8) into Mount the steering valve PVFC (2) onto the mounting
the port “3”. Tighten all the fittings to 45 N m bracket (1) using two capscrews (3), washers (4),
(33 pound feet). nuts (5) and washers (6).
STEP 29
W190-4R010
Position the mounting bracket (1) for the steering
valves into the LH side rear chassis.
5009-25
STEP 30 STEP 32
9
1
11 10
7 8
W190-4R029 W190-4R007
Install three capscrews (7), washers (8), nuts (10) Connect the stem side steering cylinder supply hose
and washers (11). Tighten the nuts to 110 N m onto the fitting. Tighten the hose to 60 N m (44 pound
(80 pound feet). feet).
STEP 31 STEP 33
12
W190-4R006
Connect the bottom side steering cylinder hose.
Tighten to a torque of 60 N m (44 pound feet).
STEP 34
1 14
13
W190-4R030
Install the steering valve PVG32 (12) onto the
mounting bracket (1) using the four capscrews (13)
and washers (14). Tighten the screws to a torque of
30 N m (22 pound feet).
W190-4R005
Connect and tighten the outlet hose to 125 N m (92
pound feet).
5009-26
STEP 35 STEP 37
W190-4R004
Connect the suction hose of the steering priority
valve. Tighten the pipe to a torque of 60 N m
(44 pound feet). 5
STEP 36 4
W190-4R032
Connect the line for the “LS” (5) on the valve PVG32
(4) and on the valve PVFC (1). Tighten the line
14 N m (10 pound feet).
2
1
W190-4R031
Connect the hose (2) and hose (3) to valve PVFC (1).
Tighten to 14 N m (10 pound feet).
5009-27
26 10
30 16
View from “B” 27 13 10
E 33
See table 2
18 31
25 C
12 8
6 8
27 2
5 23 22
22 24
17
1
15
20 19
19 21
Detail “A”
B 34
F 3 4
W190-4R033
HYDRAULIC COMPONENTS OF THE JOYSTICK STEERING SYSTEM WITH AUXILIARY STEERINGSYSTEM - Table 1
5009-28
9
28
29
11
10
10
13
Detail J
35
J
11
13
36
16 D
30
9. Joint
30 10. Steering cylinder line pipes
Detail D view from H 11. Joint
14 13. Outlet pipe of valve PVG32
14. Joint
16. Priority valve suction pipe
28. Steering cylinder line pipe (bottom side)
Detail E 29. Steering cylinder line pipe (stem side)
30. LS priority steering valve pipe
Detail F view from G 35. Hydraulic pump
36. Steering priority valve
W190-4R034
HYDRAULIC COMPONENTS OF THE JOYSTICK STEERING SYSTEM WITH AUXILIARY STEERINGSYSTEM - Table 2
5009-29
26 13
34 10 10
27
30
* E 33 16
View from B
18
* D
7
31
25 C 12 8
22 24
8
6
2
5 23
17 27
* 22
G
1
15
20 19
21 19
F *
1. Steering valve support 22. Washer
2. Steering valve PVG32 23. Nut
3. Washer 24. Screw
4. Screw 25. 60 bar pressure switch
B 5. Steering valve PVFC 26. 8 bar pressure switch
6. Joint 27. Seal
7. Steering LS pipe 30. LS priority steering valve pipe
8. Joint 31. Joint
10. Steering cylinder line pipes 33. Reduction
12. Joint 34. Power steering valve
13. Outlet pipe of valve PVG32
15. Joint
16. Priority valve suction pipe
A 17. Joint
7 6
18. Flexible pipe LS of power steering line
19. Washer
4 20. Nut
View from C
3 21. Screw
* See table 2
W190-4R119
HYDRAULIC COMPONENTS OF THE JOYSTICK STEERING SYSTEM WITHOUT AUXILIARY STEERINGSYSTEM - Table 1
5009-30
34
Detail J
9
28
29
18
11
32
13
10 Detail D
36
11 J
Detail E 32
16
9. Joint
10. Steering cylinder line pipes
11. Joint
13. Outlet pipe of valve PVG32
30 14. Joint
14 16. Priority valve suction pipe
18. Flexible pipe LS of power steering line
28. Steering cylinder line pipe (bottom side)
Detail F 29. Steering cylinder line pipe (stem side)
view from G 30. LS priority steering valve pipe
32. Flexible hose feed of power steering valve
34. Power steering valve
36. Steering priority valve
W190-4R120
HYDRAULIC COMPONENTS OF THE JOYSTICK STEERING SYSTEM WITHOUT AUXILIARY STEERINGSYSTEM - Table 2
5009-31
9
1 2 19
15 18
16
21
11 YPP
A1
UNLOCK
20
P
T X1
LOCK
8 16B
MX
16A B1
20D
12 T 20A
280 bar
14
16C
20C
R R1 F
4 13A 13
2 20B
X 13F
16D
3
1
13E
5 P
2 B A
3 13D 16E
13B 1
T1
T1'
N B
240±8% L/min
240±8% L/min
280±8% L/min
20±8% L/min
B1 280±8% L/min
OPTION
22K
BOOM
BUCKET
22K
a3
a2
6 13C
T2
868050
868050
ø0.8
ø2.0
ø2.0
ø0.8
pst
22A
0.6
R2
a1
A1
A3
A2
B3
B2
P
17
765876
LS
Mp
1.2
Pst
22F
11
R901075585
898999
7
528789
528789
528789
30 bar
22C
T
22C )( 22H
22C
22G
847160
TP11: REAR BRAKE TO AXLE 10
224±3 bar
R901007569
R901075587
859551
TP10: FRONT BRAKE TO AXLE 22J
22D
8-10.8 bar
329140
TP6: FRONT BRAKE ACCUMULATOR
MT1
22B
S1
TP7: REAR BRAKE ACCUMULATOR
737012
290 bar
290 bar
936718
936718
290 bar
290 bar
936718
936718
TP2: IMPLEMENT LOAD SENSE
936725
TP5: STEERING PUMP PRESSURE
22D
TP1: UNLOADING PUMP PRESSURE 22E 22E 22D 22E
22E
S2
TP9: PILOT PRESSURE SUPPLY
22
A2
280±8% A1
b1
B2
899039
868050
ø2.0
ø2.0
ø0.8
ø0.8
L/min
45C
M2 P
22K 22K
b2
b3
45B
44 45A
45
43
42 234
M2 162 bar IN bar
35 LS EF LS IMPL 24
23cc 234
M1 TANK CF
bar .64
L
.8 24A
P 24B
46
45B 45D
Note 2 T 24C
35A T 30 LS 23
M1 LS SLS ST CF 32
G1
0.7
35B 35C 27
G2 X2
R
34 X1 30A 2
33 T
240 bar 0.31 1 46
0.31
34A 33A 30B
36 29
R L
34B 33B 3
30C
40 28
Note 1 0.75 LS
23cc 34C 33C T P
P T
28A
41 P
34D 33D
1.8
28B 28C
L1 L2 S1 S2 L4 L3 p
31 26
39 11 cc
T
25
38
37 37
HYDRAULIC COMPONENTS OF THE JOYSTICK STEERING SYSTEM - 821F (Note: Joystick steering section the same for 921F)
5009-32
Removal STEP 3
STEP 1
3
1 6
4
W190-4R037
STEP 2 8
7
4
W190-4R101
W190-4R035
Disconnect connector (7) from the “Kick-Down”
Remove the cover (3), support (4) from the armrest button (8) from the armrest cable connector (9).
adjustment (5).
5009-34
STEP 5 STEP 7
3
8 7 12
1
9 10
W190-4R102 11
From the inside and bottom of the armrest cover (1)
unscrew the threaded washer (2) and remove the W190-4R038
“Kick-Down” button (3). Remove the two nuts (8), washers (9), screws (10)
and washers (11) from the PVRES joystick (7).
STEP 6 Disconnect the connector (12) from the valve (7).
STEP 8
5
5 4 6 7
1
3
1
2
6
W190-4R040
W190-4R103
12
1
10
2
W190-4R039
STEP 10
13
11
9
W190-4R041
W190-4R042
STEP 12
Disconnect the connector (9) from the armrest
positioning switch. Remove the armrest cable. 1
3 5
4 4
2 6
W190-4R043
10 8 2
7 11
3
4
9
2 7
5 6
W190-4R104
W190-4R044
Remove the locking bracket (7) with pin (8) from the Unscrew the knob (2) from the suppor t (1) and
armrest height/angle adjustment (2). Unscrew the extract the armrest height/angle adjustment pin (3).
two nuts (9), capscrews (10) and the washers (11). Remove the plate (4) from the suppor t (1) by
Remove the pin (8) from inside the seat of the removing the four capscrews (5) with washers.
bracket (7). Remove the armrest position switch (6) from the
inside of the support (1) by removing the two screws
(7) and washers.
STEP 15
8 9
W190-4R045
Disconnect the wiring harness from the operator’s
seat (if equipped with air seat). Remove the four
capscrews (8), washers (9) from the base of the seat.
Remove the seat.
5009-37
STEP 16 STEP 19
13
12
10 11
1
W190-4R046 W190-4R049
Remove the suppor t fastening the seat belt by
Raise while slowly rotating the seat cushion
removing nut (10), washer (11), capscrew (12) and
support plate (1).
washer (13).
STEP 20
STEP 17
4
14
3
W190-4R050
W190-4R047
Unhook the rod (4) from the support (3) and remove
Remove the four screws (14) and washers from the
the seat cushion plate (1).
seat cushion.
STEP 21
STEP 18
1 5
7
2
6
W190-4R051
W190-4R048
Turn the knob of the support (3) clockwise and move
Pressing down on the seat cushion support plate (1), plate (5) forward until the four sliding blocks (6) are in
slightly tilt the aluminium tongue (2) to release the slots (7). Remove the plate (5).
support (1) and allow raising/rotating the front. Use
caution when releasing aluminium tongue (2) to
avoid breaking it.
5009-38
STEP 22 STEP 23
2 3
4 5
8
W190-4R052
Installation STEP 26
STEP 24
8
6
3 4
8
W190-4R054
STEP 25 5 6
W190-4R056
2 Push the seat plate (1) forward. From the top, insert
1 the two front capscrews (3) and washers (4). From
the seat runners (7) install nuts (5) and washers (6).
Tighten the nuts to a torque of 32 Nm. Repeat the
W190-4R055
procedure for the two rear capscrews.
Position the seat plate (1) on the seat support plate
(2).
5009-40
STEP 27 STEP 30
9 10
4
3
1
W190-4R057 W190-4R059
Install the seat plate (9). Turn the locking support (10) Install the seat cushion (3) onto plate (1) and secure
clockwise and at the same time push the plate (9) it with four screws (4) and washers.
toward the rear of the seat to locking it.
STEP 31
STEP 28
13 11 6
5
9 7 8
12
W190-4R060
Install the seat belt, install capscrew (5) and washer
W190-4R058
(6), nut (7) and washer (8). Tighten the nut to a
Insert the two lugs for the seat cushion plate (11) torque of between 47 and 68 Nm. Check that the
inside the two openings on the seat plate (9). Hook seat belt mounting hardware is tight and the seat belt
the rod (13) to the catch (12). Slowly lower the seat is not cut or frayed.
cushion support plate (11).
STEP 32
STEP 29
9 10
2
W190-4R061
W190-4R048
Lock the seat cushion support plate (1) by bending Put the seat in the cab. Connect the wiring harness
the aluminium tongue (2) into position. Use caution to the operator’s seat (if equipped with air seat).
when bending the aluminium tongue (2) to avoid Install the seat on the base and secure it with the four
breaking it. capscrews (9) and washers (10). Tighten the screws
to a torque of between 73 and 87 Nm.
5009-41
STEP 33 STEP 34
5 11 8
9 12
4
6
13
3 10
7 2
W190-4R105
W190-4R062
Install the armrest position switch (2) on the support Insert the armrest locking pin (8) in the bracket (9).
(1) using the two screws (3) and washers. Insert the install it on the armrest height/angle adjustment (10)
adjuster pin (4) inside the support (1) and screw the using the two capscrews (11), washers (12) and nuts
knob (5) on it. Install the plate (6) on support (1), (13). Tighten the nuts to 7 Nm.
secure it using four capscrews (7) and washers.
STEP 35
W190-4R106
Insert, rotate and secure the armrest locking pin (8)
as shown.
5009-42
STEP 36 STEP 38
1
11
6 4
5 5
2 3 W190-4R065
STEP 37
1
7
2
9 W190-4R066
Install the CAN module (1) in the seat (2) on the
armrest.
STEP 40
8 7 5 6
8 1
10
W190-4R064
2
14 9 10
12
11 1
13 3
W190-4R068
W190-4R108
STEP 42
Connect connector (1) of the “Kick-Down” button (2)
to the cable (3).
16
STEP 44
15
5
17
4
W190-4R107
W190-4R109
Insert the “F-N-R” switch (5) in the armrest (4),
connect connector (6) to the cable (7).
5009-44
STEP 45 STEP 46
4 1
2
4
9
8
3
W190-4R069
W190-4R070
Pressure Setting Test 4. Make sure that the temperature of the hydraulic
oil is at least 54° C (129° F).
1. Install articulation lock (1). 5. To measure the temperature of the oil using the
instrument panel:
A. Press the up or down arrow key.
DANGER
2 15. With the engine at low idle, with all the controls in
neutral, JSS NOT active, a differential reading of
28 to 30 bar (405 to 435 psi) should be obtained.
1 16. With the engine at low idle, with all the controls in
neutral, JSS ON and joystick in neutral, a
BD06F148
differential reading of 28 to 30 bar
1. G1 TEST PORT (405 to 435 psi) should be obtained.
2. G2 TEST PORT
17. With the engine at low idle, with all the controls in
3. Connect a 345 bar (5000 psi) pressure gauge to neutral, JSS ON and joystick in full left or right
the test port (2). turn, a differential reading of 28 to 30 bar
NOTE: Make sure when you connect the pressure (405 to 435 psi) should be obtained.
gauge that you do so in a manner that you can read NOTE: If the setting is not correct, verify that the
the pressure gauge while sitting in the operators hydraulic connection from the hydraulic steering
seat. valve PVFC that manages the LS signals connected
or is not kinked.
5009-46
STEP 2
1
521E-4R005
STEP 5
2
521E-4R003
STEP 3
521E-4R006
521E-4R004
521E-4R010
521E-4R007
The display will show a screen with the wording Afterwards, the display will automatically read “Joyst
“Steer. Straight?” Press the enter button to confirm. Full Right” “Release when WL starts moving”.
Move the Joystick lever completely to the right. As
STEP 7 soon as machine movement is noticed release the
lever.
STEP 10
521E-4R008
STEP 11
521E-4R009
After this operation, the display will read “O. K.” The
display will automatically read “Joyst Full Left”
“Release when WL starts moving”. Move the 521E-4R011
Joystick lever completely to the left. As soon as The display will read “Calibration Successful”
mahcine movement is noticed release the lever. indicating calibration is complete.
6001
Section
6001
TABLE OF CONTENTS
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Transmission Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Front Axle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Rear Axle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6001-3
TRANSMISSION
Removal STEP 7
STEP 1
Park the machine on a level surface and lower the
bucket to the ground. Stop the engine and apply the
parking brake.
STEP 2
Place the master disconnect switch in the OFF
position.
STEP 3
Refer to Section 9007 and remove ROPS cab or BD01D315
STEP 6
BD01D317
STEP 9
BD01D306
BD01D310
BD01D312 BD03A165
Identify, tag, and disconnect transmission wiring Identify, tag, and disconnect parking brake hose from
harness connectors from engine speed sensor, parking brake. Plug hose and cap fitting to prevent
intermediate speed sensor, and turbine speed entry of foreign matter into hydraulic system. Move
sensor. Move transmission wiring harness away from hose away from transmission. Remove four bolts and
transmission. two straps securing center drive shaft to transmission
output flange. Disconnect center drive shaft from
STEP 11 transmission.
STEP 14
BD01D316
BD01D314
BD03A160 BD01D342
Remove two bolts. Remove fill tube, with cap and oil In area between the transmission and the engine,
gauge assembled, two seals, and metal strainer. remove four bolts and two straps. Use pry bar to
Discard seals. disconnect engine drive shaft from transmission.
Using 3/4 inch drive socket, extensions, and impact
STEP 16 wrench, remove four bolts and washers securing
transmission to top mounting bracket.
STEP 19
IMG_2114.PNG
hoses. Remove and discard O-ring face seals from Remove bolts and washers securing RH and LH
fittings. mounting brackets to rear chassis.
STEP 17
BD01D343
BD01D361
BD03A164
If top mounting bracket requires removal, remove bolt
Raise transmission just enough to enable removal of
and washer then remove bracket.
RH and LH mounting brackets. Remove two bolts
and washers securing RH and LH mounting brackets
to transmission. Remove RH and LH mounting
brackets.
STEP 21
BD01D345
Transmission Mounting
3 4
C 1
1
4
3
2
2
2
1 1 5
5 5
7
1 6
5 1
2
BS03B153
Installation STEP 26
STEP 23
Check isolators for deterioration, tears, deformation,
or other damage. Replace as necessary: refer to
mounting illustration.
STEP 24
BD03A164
STEP 27
BD01D361
STEP 25
BD03A163
BD01D345
BD01D343
BD01D342
STEP 31
Using 3/4 inch drive socket, extensions, and impact Remove plugs in thermo bypass valve ports.
wrench, install four washers and bolts to secure top
mounting bracket to transmission. Then tighten bolts STEP 32
to a torque of 251 to 319 Nm (185 to 235 pound feet).
If bracket had been removed, tighten bolt to a torque
of 890 to 1000 Nm (655 to 735 pound feet). Connect
engine drive shaft to transmission. Install two new
straps and four new bolts. Tighten bolts to a torque of
61 to 81 Nm (45 to 60 pound feet).
STEP 29
IMG_2114.PNG
BD03A163
BD03A160 BD01D314
Position fill tube, two new seals, and metal strainer Connect transmission wiring harness connectors to
on transmission; metal strainer is installed between output speed sensor and filter maintenance switch
seals. Secure using two bolts. Tighten bolts to a following tags installed during removal. Remove and
torque of 17 to 33 Nm (12 to 24 pound feet). discard tags.
STEP 34 STEP 37
BD03A161 BD01D316
Connect rear drive shaft to transmission then install Install socket head bolt to secure wiring harness
two straps and four bolts. Tighten bolts to a torque of clamp.
61 to 81 Nm (45 to 60 pound feet).
STEP 38
STEP 35
BD01D312
BD01D310 BD01D306
Install two socket head bolts to secure transmission At brake valve, install new O-ring face seals in
wiring harness clamps. fittings. Connect brake to hydraulic reservoir hose
and brake pump pressure hose following tags
STEP 40 installed during removal. Remove and discard tags.
STEP 43
BD01D317
STEP 41 STEP 44
Fill transmission with Standard Multi-G Hydraulic oil
until oil level is up to the arrow in sight glass.
STEP 45
Refer to Section 8001 and install the hydraulic pump.
STEP 46
Refer to Section 9007 and install ROPS cab or ROPS
canopy.
STEP 47
BD01D315
Start and run engine at idle speed with transmission
Install socket head bolt to secure wiring harness in neutral. If transmission oil level is at or below
clamp. Connect transmission wir ing har ness bottom of crosshatch region, put articulation lock in
connector to control valve connector. LO CKED po sition a nd ad d Stan da rd M ulti- G
Hydraulic oil until oil level is up to crosshatch region.
Shut down engine and put ar ticulation lock in
OPERATING position.
6001-12
FRONT AXLE
Removal STEP 4
STEP 1
BD03A167
STEP 2
BD03A166
STEP 3
Stop engine. Actuate brake pedal several times to
discharge brake accumulators. Put key switch in ON
position and move loader control lever back and forth
at least 30 times to release any pressure from
hydraulic circuit. Put key switch in OFF position.
6001-13
STEP 6 STEP 8
For machines without brake damping accumulators, Disconnect differential lock hose.
disconnect brake hose from elbow. Remove and
NOTE: Locking front differential is available on 721F,
discard O-ring face seal from elbow.
821F and 921F machines equipped with heavy duty
NOTE: 721F machines with heavy duty axles and all axles.
821F/921F machines are equipped with brake
damping accumulators. STEP 9
STEP 7
BD01F298
100_0174 RESIZED.JPG
BD01D392
STEP 10
Repeat Step 9 to raise other front axle tire from
ground.
6001-14
STEP 11 STEP 13
IMG_2121.PNG BD01F296
Use an acceptable jack to hold front axle. Remove eight nuts bolts, and washers securing front
axle to machine.
STEP 12
STEP 14
Carefully lower front axle and remove from under
machine.
821FXR-8818.PNG
1. BOLT 4. NUT
2. WASHER 5. FRONT AXLE
3. WASHER
6001-16
Installation
STEP 15
Carefully move front axle under machine and raise
against mounting pads on machine.
STEP 16
84324413205.TIF
BD01F296
STEP 17
0R0R201007RCIL10WHL288BAL[1].TIF
IMG_2121.PNG
100_0174 RESIZED.JPG
BD01D298
For machines with brake damping accumulators,
install a new O-ring face seal and connect brake line
to elbow at axle connection. If accumulator has been
removed, bolt accumulator to machine frame and
connect brake line and hose to accumulator.
STEP 23
BD01D392
STEP 20
Repeat Step 19 to remove other jack stand from
under machine. IMG_1998 RESIZED.JPG
BD03A168
STEP 27
Refer to Section 7002 and bleed brakes.
STEP 28
Star t engine and raise bucket. Have assistant
remove safety link. Lower bucket to ground and stop
engine.
BD03A166 STEP 29
Position and support center bearing and front drive Put articulation lock in OPERATING position.
shaft and install eight washers and four bolts and
nuts. Tighten bolts to a torque of 99 to 128 Nm (73 to
94 pound feet). Install two straps and four bolts.
Tighten bolts to a torque of 61 to 81 Nm (45 to 60
pound feet). Secure lubrication hose to machine
using clamp; secure opposite end of hose using nut.
STEP 25
BD03A167
REAR AXLE
Removal STEP 5
STEP 1
Park machine on a level surface; be sure to allow
adequate space at side of machine for removal of
rear axle. Stop engine. Actuate brake pedal several
times to discharge brake accumulators. Put key
switch in ON position and move loader control lever
back and for th at least 30 times to release any
pressure from hydraulic circuit.
STEP 2
BD03A169
STEP 6
BD03A040
STEP 3
Install wood blocks between rear axle and chassis to
prevent rear axle from pivoting. BD01F299
STEP 7
BD03A162
821FXR-8818.PNG IMG_2133.PNG
Remove nuts/bolts and washers from rear wheels. At front of trunnion, remove three Allen head bolts
Remove both wheels from rear axle. and washers. Remove front cap: if necessary use
two M12 by 32 mm (1.25 inches) bolts in puller holes
NOTE: 721F and 821F (pictured) heavy duty axles
(A); tighten bolts evenly to pull cap from axle and
and all 921F axles have wheel studs on the axles and
trunnion. Remove and discard O-ring from cap.
use wheel nuts.
Repeat this step at rear of trunnion except remove
and retain shim(s) after removal of rear cap. Remove
pivot shaft using acce ptable sle eve or rod if
necessary.
6001-21
5
4
3
2
1
5 7
1
2 8
7 9
6
4
Installation STEP 13
NOTE: If shim(s) (7) have been lost or pivot pin (8)
has been replaced, do Step 12 to determine required
shim(s) otherwise go to Step 13. A
STEP 12
5 5
B
8
3
6
A B
STEP 15
Carefully move rear axle under machine. Raise axle
into position in trunnion and align pivot holes in
trunnion with pivot holes in axle.
6001-23
STEP 16
7
A 4 5
5 6
8 B
INSTALL PIVOT PIN 2.PNG
STEP 17
821FXR-8818.PNG
821FXR-8818.PNG BD03A162
Remove hydraulic jack supporting rear axle and jack Connect rear drive shaft to rear axle. Install two
stands supporting loader. straps and four bolts. Tighten bolts to a torque of 61
to 81 Nm (45 to 60 pound feet).
STEP 19
STEP 21
If necessary, fill axle with Standard Multi-G Hydraulic
oil.
STEP 22
Refer to Section 7002 and bleed brakes.
STEP 23
Place articulation lock in OPERATING position.
BD03A169
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TRANSMISSION OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Transmission ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electrical Shift Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Transmission ECM Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Transmission Sensor Data Collection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Automatic Problem Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Clutch Modulation Substitute Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Limp-Home Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Transmission/Transmission ECM Shutdown Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Transmission Clutch Calibration (4-Speed Transmission Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Gear Selections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Automatic/Manual Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Upshifting in Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Downshifting in Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Upshifting in Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Downshifting in Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Downshift Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Cold Start Protection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Brake Pedal Transmission Declutch (4-Speed Transmissions Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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 PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
TRANSMISSION OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
TRANSMISSION SHIFTER LOGIC INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
RELATIONSHIP BETWEEN TRANSMISSION ECM, VALVES, AND CLUTCHES . . . . . . . . . . . . . . . . . . . . . . 20
6002-3
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.....................................................................................................3.5 to 6.5 bar (51 to 96 psi)
Lubrication pressure ...........................................................................................................0.2 to 1.2 bar (3 to 18 psi)
Minimum pump output (at 2000 rpm) .....................................................................................80 L/min (21 U.S. gpm)
Transmission oil operating temperature..........................................................................80 to 120 °C (176 to 248 °F)
Clutch KV........................................................................................................................16 to 18 bar (232 to 261 psi)
Clutch KR .......................................................................................................................16 to 18 bar (232 to 261 psi)
Clutch K1 ........................................................................................................................16 to 18 bar (232 to 261 psi)
Clutch K2 ........................................................................................................................16 to 18 bar (232 to 261 psi)
Clutch K3 ........................................................................................................................16 to 18 bar (232 to 261 psi)
Clutch K4 ........................................................................................................................16 to 18 bar (232 to 261 psi)
6002-4
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 (APPLIES TO 4-SPEED
TRANSMISSION ONLY)
7. TRANSMISSION 14. PLUG
12
11
1
2
10
9
4
5
15
6
14
8
13 7
BS03A262
1. CLUTCH SHAFT KR 9. TRANSMISSION PUMP
2. POWER TAKE OFF 10. INPUT FLANGE
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
Modulation and shifting are controlled by the E. Provides various diagnostic messages to the
Tr a n s m i s s i o n E l e c t r o n i c C o n t r o l M o d u l e Information Center.
(Transmission ECM). This module replaces the oil F. Provides other information to the information
and springs that are found in hydraulically modulated center, which in turn displays engine speed,
transmissions. wheel speed, gear shift selection, and actual
T h e Tr a n s m i s s i o n E C M c o n t r o l s t h e c l u t c h gear selection.
e n g a g e m e n t , p r ov i d i n g s m o o t h e r s h i f t s a n d G. Provides a method to calibrate the
enhanced clutch life, whether the transmission is set transmission clutch control.
to the automatic or manual shift mode.
H. Establishes clutch modulation pressure during
The Transmission ECM also informs the Information transmission shifts.
Center, by the use of diagnostic codes, of any
transmission error and the hours of operation that the
error occurred.
D. Monitor will state “CALIB G/B” “CONFIRM As the operator depresses the accelerator and the
PLEASE”, press the enter key. torque on the transmission is lowered, the
transmission will upshift.
E. If the conditions are not correct for clutch
calibration the monitor will display the problem
that needs to be corrected.
Downshifting in Automatic Mode
F. Clutch calibration status will be displayed on Downshifting is determined directly by machine
the monitor, “ADJUST K1, K2, K3, K4, KV, speed and transmission torque. The transmission will
KR”. downshift to first or second gear as machine speed
decreases and transmission torque increases. For
G. After completing the Clutch Calibration example, if the unit begins to climb a hill in forth gear
procedure, turn the machine OFF for 15 and the machine speed decreases, as the torque
seconds. This sets the calibration in the requirement increases, the transmission will
controller. downshift into third, then second, and down to first
gear, if necessary.
6002-12
Upshifting in Manual Mode B. The shifter is moved into neutral and then into
forward or reverse.
In the manual mode, the transmission starts out in
the selected gear and stays in that gear until the C. The autoshift switch is recycled.
operator selects another gear or direction. The
transmission can be upshifted without reducing Manual Mode
engine speed or machine speed.
In the manual mode, the downshift button toggles
If the gear selected is two or more gears higher than between 1st and 2nd gear. The manual mode is
the present gear, the transmission will shift up useful in short haul operations. In this mode, the
through the gears at 2.5 second intervals until the downshift button functions in two ways in 1st and 2nd
selected gear has been reached. gear.
When the operator is in 2nd gear and pushes the
Downshifting in Manual Mode downshift button, the transmission instantly shifts into
The transmission can be downshifted in the manual 1st gear. When the operator pushes the downshift
mode without reducing engine speed or machine button again, the transmission upshifts into 2nd gear.
speed. If the machine is in 2nd gear and the downshift
If 1st gear is selected from 3rd or 4th gear, the button is pushed, the transmission instantly shifts into
transmission will downshift into 2nd gear for 1.2 1st gear. When the operator shuttles the shifter, the
seconds and then will shift into 1st gear. transmission upshifts back into 2nd gear.
With the number of different ways the downshift When the transmission sump temperature warms up
button functions, the operator can tailor the use of the to minus 10° C (14°F) (within approximately one
machine to the application at hand. minute), the machine will operate in all gears.
Automatic Mode
In the Automatic Mode, the downshift button only
shifts down. The downshift button allows the operator
to downshift through the entire range of gears. This is
useful in long haul applications or roading.
Each time the button is pushed the transmission will
instantly downshift one gear from 4th to 3rd, then
from 3rd to 2nd, and then from 2nd to 1st.
The transmission will automatically downshift and
then upshift, as needed, to the last gear that was
selected with the downshift button.
Example: If the downshift button was used to shift
from 4th to 3rd gear, the transmission will
automatically shift from 3rd down and then back up to
3rd again. It will not shift into 4th until the
transmission has been returned to the full range
automatic mode.
The transmission will retur n to the full range
automatic mode when:
A. Another gear is selected.
6002-13
NOTE: See next page for Measuring Point, Transmitter, Sensor and Connection locations.
6002-15
4-SPEED TRANS. ͻPRESSURE REGULATOR UNDER VOLTAGE 5-SPEED TRANS. ͻPRESSURE REGULATOR UNDER VOLTAGE
FORWARD REVERSE NEUTRAL FORWARD REVERSE NEUTRAL
CLUTCH PRESSURE REGULATOR 1 2 3 4 1 2 3 CLUTCH PRESSURE REGULATOR 1 2 3 4 5 1 2 3
KV Y5 ͻ ͻ ͻ KV Y5 ͻ ͻ ͻ
KR Y2 ͻ ͻ ͻ KR Y2 ͻ ͻ ͻ
K1 Y3 ͻ ͻ K1 Y3 ͻ ͻ
K2 Y6 ͻ ͻ K2 Y6 ͻ ͻ ͻ
K3 Y4 ͻ ͻ ͻ K3 Y4 ͻ ͻ ͻ
K4 Y1 ͻ K4 Y1 ͻ ͻ
BC01B047
MEASURING POINTS AND CONNECTIONS
6002-16
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 4. Heat the oil to an operating temperature of 80 to
take readings in the cab and CAS-2324 Special 100° C (176 to 212° F).
Adapter. 5. While in the cab, put the transmission in
NEUTRAL. Run the engine at full throttle. Record
Test Procedure the reading in the chart on page 16. Pressure
must be a minimum of 3.5 to 6.5 bar
1. Block the machine tires. (51 to 96 psi).
2. Apply the parking brakes.
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 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 56°C (100°F) above the
ambient temperatures.
B. Use a stop watch to establish the exact length of time required to reach the overheating condition.
C. Observe engine temperature, does the engine overheat? Which overheats first - engine or transmission?
2. When the transmission reaches overheated condition, shift to Neutral and maintain engine RPM at a fast idle
(1250 to 1450 RPM).
A. Oil temperature returns to Normal - establish length of time.
1. Check oil level, type and grade is correct (See Section 1002).
2. Check operator’s gear selection is correct for conditions.
3. Make sure brakes are fully released.
4. Check the engine full throttle and stall speeds are correct as specified (See Section 2002).
B. Oil temperature remains overheated.
1. Check for dirty radiator - airflow restricted.
2. Check for engine overheating problem.
3. Check for faulty oil temperature gauge and sender or switch (See Section 4002).
3. Perform all the pressure and flow tests.
4. Compare the pressure and flow test results to the specifications in this section to determine if any circuits are
not within specifications.
5. Refer to Pressure Test Results to determine possible cause of any test results not within specifications.
6002-20
ERROR CODES
In case of possible errors in the system, an amber or red warning appears on the instrument panel, combined with
a recorded error number. See section 4005 for error code retrieval procedures and definitions.
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.
6003
4 & 5 SPEED TRANSMISSION
6003-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.0 Electro-hydraulic control and oil filter (replaceable filter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.0 Inductive sensor Hall effect sensor, breather, oil filler and oil drain plug . . . . . . . . . . . . . . . . . . . . . . . . 9
3.0 Engine connection, oil pressure pump, converter back-pressure valve and temperature sensor (measuring
point “63” after the converter as described in the specifications, pressure checks and troubleshooting section
of the manual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.0 Emergency steering pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.0 Outputs and closure parts pump shaft (PTO-shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.0 Removal of input shaft, output shaft, pump shaft (PTO -shaft) and clutches . . . . . . . . . . . . . . . . . . . . 15
7.0 Clutches KV/KR/K1/K2/K3/K4 input and output shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8.0 Clutches KV/KR/K1/K2/K3/K4 input and output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
9.0 Installation of input shaft, output shaft, pump shaft (power-take off shaft) and clutches . . . . . . . . . . . 66
10.0 Outputs and closure parts pump shaft (PTO-shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
11.0 Reassembly: Engine connection, oil pressure pump, converter back-pressure valve and temperature sen-
sor (measuring point “63” after the converter as described in the specifications, pressure checks and trouble-
shooting section of the manual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
12.0 Reassembly - Emergency steering pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
13.0 Reassembly: Inductive sensor, Hall sensor, breather, oil filler and oil drain plug . . . . . . . . . . . . . . . . 81
14.0 Reassembly Electro-hydraulic control with proportional valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
6003-3
SPECIAL TOOLS
CAS2802 ALIGNMENT
380001556 CLUTCH PACK DOWEL SET
H0LDER AND SPRING
COMPRESSOR TOOLS
CAS2801 TRANSMISSION
CAS2796 NESTING MOUNTING BRACKETS
PLATE
SPECIAL TORQUES
Oil pipes
Studs ............................................................................................................................... 9 Nm (80 pound inches)
Socket head bolt................................................................................................................. 23 Nm (17 pound feet)
Screw plug.......................................................................................................................... 51 Nm (38 pound feet)
Clutch K1, K2, K3, K4 Stud ............................................................................................. 17 Nm (150 pound inches)
Plugs........................................................................................................................................ 25 Nm (18 pound feet)
Output shaft
Output shaft bolts (apply Loctite 243 to threads) ............................................................... 23 Nm (17 pound feet)
Housing cover bolts (apply Loctite 574 to threads) ............................................................ 46 Nm (34 pound feet)
Output flange bolts ............................................................................................................. 34 Nm (25 pound feet)
Oil feed housing and transmission pump
Transmission pump bolts.................................................................................................... 46 Nm (34 pound feet)
Oil feed housing bolts......................................................................................................... 25 Nm (18 pound feet)
Engine connection and converter
Input shaft bolts................................................................................................................ 115 Nm (85 pound feet)
Converter housing bolts ..................................................................................................... 68 Nm (50 pound feet)
Cover................................................................................................................................... 23 Nm (17 pound feet)
Converter cover.................................................................................................................. 46 Nm (34 pound feet)
Input flange ......................................................................................................................... 34 Nm (25 pound feet)
Duct plate
bolts.................................................................................................................................... 25 Nm (18 pound feet)
bolt plug.............................................................................................................................. 30 Nm (22 pound feet)
Hydraulic control unit ........................................................................................................ 9.5 Nm (84 pound inches)
Filter
Filter head bolts.................................................................................................................. 25 Nm (18 pound feet)
Oil distribution cover bolts .................................................................................................. 25 Nm (18 pound feet)
Speed sensor and inductive transmitter
Speed sensor bolt .............................................................................................................. 23 Nm (17 pound feet)
Inductive transmitter ........................................................................................................... 30 Nm (22 pound feet)
Cover plate ......................................................................................................................... 23 Nm (17 pound feet)
bolt plug.......................................................................................................................... 140 Nm (103 pound feet)
SPECIFICATIONS
Clutch KV and KR plate clearance ..................................................................... 2.65 to 2.95 mm (0.104 to 0.116 in)
Clutch K1plate clearance.................................................................................... 2.35 to 2.65 mm (0.092 to 0.104 in)
Clutch K2 and K3 plate clearance ...................................................................... 1.75 to 2.05 mm (0.069 to 0.081 in)
Clutch K4 plate clearance................................................................................... 1.35 to 1.65 mm (0.053 to 0.065 in)
6003-5
DISASSEMBLY
1.0 Electro-hydraulic control and oil filter STEP 2
(replaceable filter)
STEP 1
1.1 Removal of filter
1
BILD-02
STEP 3
2
1
BILD-01
1
1
4
BILD-06
STEP 5
2
S
1
1 BILD-07
2 3
1
BILD-11
2
1
BILD-12
BILD-09
STEP 13
Mark installation position of wiring harness (1)
towards the valve block (2). 1
STEP 10
2
1
3
BILD-13
BILD-10
2 S
3
BILD-14 BILD-17
Remove wiring harness (1). Remove cylindrical bolts Loosen the adjusting bolts (S) equally releasing the
(3), securing plates and pressure controllers (2). valve’s spring pressure. Remove the housing.
STEP 15 STEP 18
1 2
BILD-18
BILD-15
Remove cylindrical bolts, securing plates and Remove individual parts including pressure reducing
pressure controllers (1) on opposite side. valve (1), vibration dampers (2), follow-on slide (3).
STEP 16 STEP 19
1 S
3 2
BILD-19
BILD-16
Remove two Torx bolts (1) and temporarily attach Remove individual parts of opposite side including
housing using 380001577 adjusting bolts (S). main pressure valve (1), vibration dampers (2),
(Housing is spring-loaded.) Remove remaining Torx follow-on slide (3).
bolts.
6003-9
STEP 20 STEP 22
1.3 Version with torque converter lock-up clutch
solenoid valve
1 1
5
4 4
3
2 2
3 BILD-20
STEP 1
1 3 4
2 5
3 6
BILD-31
2
1
BILD-01
BILD-02 BILD-04
Remove cylindrical bolt (1) and remove Hall effect Separate cover from converter bell housing using a
speed sensor - n output and O-ring (2). suitable lifting device.
3.0 Engine connection, oil pressure
STEP 3
pump, converter back-pressure valve
and temperature sensor (measuring
point “63” after the converter as
described in the specifications, pressure
checks and troubleshooting section of
the manual)
STEP 1
3.1 Engine connection (remote mount)
1
2 BILD-05
STEP 4
BILD-03
BILD-06
BILD-07
1 21
BILD-08
BILD-09
Remove hex bolts (1) and flex plate (2) from input
shaft (3).
6003-12
STEP 10 STEP 12
2
1
1
BILD-12 BILD-14
Separate oil pressure pump (1) from oil feed housing Check oil gear pump for wear. In case of wear marks
(2). on the pump housing, cover, inner rotor, or outer
rotor; replace the oil pressure pump.
STEP 11 1. Cover
2. Inner rotor
3. Outer rotor
1 4. Pump housing
2
STEP 13
BILD-13
BILD-15
1
BILD-18
STEP 15
1
2
3
1 2
BILD-19
Remove individual parts of converter safety valve NOTE: The pressure relief valve is not mounted on
which are released. all versions. Versions concerned, see the
corresponding spare parts list.
1. Pressure plate
2. Compression spring
3. Piston
6003-14
4.0 Emergency steering pump STEP 2
STEP 1 1
4.1 Version without emergency steering pump
2
2
1
BILD-02
Pull off output flange (1) and remove shaft seal (2).
5.2 Output flange on output side with parking
BILD-01 brake FSG-88
Remove hex bolts (1), cover (2) and seals.
STEP 3
5.0 Outputs and closure parts pump
shaft (PTO-shaft)
5.1 Output flange on converter side (Standard 2 1
version)
STEP 1
BILD-11
BILD-01
STEP 4
Remove hex bolts (1), washer and O-ring.
BILD-12
BILD-13
STEP 6 BILD-01
STEP 2
BILD-14
STEP 7
3 BILD-02
2 Loosen bolted connection (1) of oil screen sheets.
1
BILD-15
1 2
BILD-03 BILD-06
Remove output shaft (1) and lower oil screen sheet Secure all clutches K1, K2, K3 and K4 by using
(2) from housing. 380001557 handle (1).
WARNING: Clutches KV, KR and input shaft (2) are
STEP 4 only secured by the gear chain. Care must be taken
to ensure these non-secured components do not
detach.
2
NOTE: Due to the installation conditions, the
1 removal of single clutches without using the special
tool is not possible.
STEP 7
BILD-04
STEP 5 1
3
1 4
2
BILD-07
BILD-08 BILD-10
Remove cylindrical bolts of oil tubes (1) from the front Remove bearing outer rings (arrows) from the front
housing. housing.
NOTE: If contrary to recommendation, the tapered
STEP 9 roller bearings of clutches, input and output are not
replaced, the technician must ensure the previous
pairing (bearing outer ring/bearing inner ring).
Bearing outer ring and bearing inner ring must be
marked.
2
STEP 11
BILD-09
1
2
BILD-12 BILD-14
Press ball bearing (1) off the pump shaft. Snap out Remove bearing outer rings (arrows) from the rear
rectangular ring (2). housing.
NOTE: If contrary to recommendation, the tapered
STEP 13 roller bearings of clutches, input and output are not
replaced, the technician must ensure the previous
7 pairing (bearing outer ring/bearing inner ring).
Bearing outer ring and bearing inner ring must be
6 marked.
2 STEP 15
5
3
4 1 1
2
BILD-13
STEP 1
2 6
4 5
3
1
BILD-03
1. K1 clutch STEP 4
2. K2 clutch
1
3. K3 clutch
4. K4 clutch
5. KR clutch
6. KV clutch
7. Input shaft.
STEP 2
7.1 KV clutch
BILD-04
STEP 5
BILD-02
1
Remove stud bolt (1) and snap out piston ring (2).
BILD-05
1 2
BILD- 06 BILD-09
Secure idler gear (1) using a cut-off device and pull it Turn shaft (2) 180 degrees and snap out piston ring
off the clutch shaft. (1).
STEP 7 STEP 10
BILD-07 BILD-10
Snap retaining ring (1) out of the idler gear (2) and Pull tapered roller bearing off shaft with special tool
remove ball bearing (3). CAS2798.
STEP 8 STEP 11
1
1
BILD-08 BILD-11
Remove needle cage (1) from the shaft (2). Unsnap snap ring (1).
6003-21
STEP 12 STEP 15
1
2
BILD-12 BILD-15
Remove end shim (1) and disc set (2) from the disc Using compressed air, remove the piston (1) from the
carrier (3). disc carrier.
STEP 13 STEP 16
1 2
BILD-13 BILD-16
Preload compression spring with special tool Remove both O-rings (1 and 2).
380001556 and unsnap L-ring (1).
STEP 1
STEP 14 7.2 KR clutch
1 1 2
BILD-14
BILD-01
Remove support shim (1), compression spring (2)
Remove stud bolt (1) and snap out piston ring (2).
and washer (3).
6003-22
STEP 2 STEP 5
BILD-02 BILD- 05
Pull tapered roller bearing off the shaft with special Secure idler gear (1) using a cut-off device and pull it
tool CAS2798. off the clutch shaft.
STEP 3 STEP 6
1 1
BILD-03 BILD-06
Snap out retaining ring (1). Snap retaining ring (1) out of the idler gear (2) and
remove ball bearing (3).
STEP 4
STEP 7
1
BILD-04
NOTE: For disassembly of clutch see Steps 10-15. Remove needle cage (1) from the shaft (2).
6003-23
STEP 8 STEP 11
1
1
BILD-08 BILD-11
Turn shaft (2) 180 degrees and snap out piston ring Remove end shim (1) and disc set (2) from the disc
(1). carrier (3).
STEP 9 STEP 12
BILD-09 BILD-12
Pull tapered roller bearing off shaft using special tool Preload compression spring with special tool
CAS2798. 380001556 and unsnap L-ring (1).
STEP 10 STEP 13
1
1
2
BILD-10 BILD-13
Unsnap snap ring (1). Remove support shim (1), compression spring (2)
and washer (3).
6003-24
STEP 14 STEP 2
BILD-14 BILD-02
Using compressed air, remove the piston (1) from the Pull tapered roller bearing off the shaft with special
disc carrier. tool CAS2798.
STEP 15 STEP 3
BILD-15 BILD-03
Remove both O-rings (1 and 2). Snap out retaining ring (1).
STEP 1 STEP 4
7.3 K1 clutch
1
1 2
BILD-04
Remove stud bolt (1) and snap out piston ring (2).
6003-25
STEP 5 STEP 8
BILD-05 BILD-08
Take off idler gear (1), remove needle cage (2) and Pull tapered roller bearing off the shaft with special
axial bearing assembly (3). tool CAS2798.
STEP 6 STEP 9
BILD-06 BILD-09
Pull clutch (1) off the shaft. Unsnap snap ring (1).
NOTE: For disassembly of clutch see Steps 9-14.
STEP 10
STEP 7
1
1
2
3
BILD-10
Remove end shim (1) and disc set (2) from the disc
BILD-07
carrier (3).
Turn shaft (2) 180 degrees and snap out piston ring
(1).
6003-26
STEP 11 STEP 14
1 2
BILD-11 BILD-14
Preload cup springs using special tool 380001556 Remove both O-rings (1 and 2).
and unsnap L-ring (1).
STEP 1
STEP 12 7.4 K2 clutch
1 2
1
BILD-12
BILD-01
Remove cup spring package (1).
Remove stud bolt (1) and snap out piston ring (2).
STEP 13 STEP 2
BILD-13
BILD-02
Using compressed air, remove the piston (1) from the
Pull tapered roller bearing off the shaft using special
disc carrier.
tool CAS2798.
6003-27
STEP 3 STEP 6
1
BILD-03 BILD-06
Snap out retaining ring (1). Pull clutch (1) off the shaft.
NOTE: For disassembly of clutch see Steps 9-14.
STEP 4
1 STEP 7
BILD-04
Turn shaft (2) 180 degrees and snap out piston ring
STEP 5 (1).
STEP 8
1
3
2
BILD-05
1
1
BILD-09 BILD-12
STEP 10 STEP 13
1
2
BILD-10 BILD-13
Remove end shim (1) and disc set (2) from the disc Using compressed air, remove the piston (1) from the
carrier (3). disc carrier.
STEP 11 STEP 14
2
1
BILD-11 BILD-14
Preload cup springs using special tool 380001556 Remove both O-rings (1 and 2).
and unsnap L-ring (1).
6003-29
STEP 1 STEP 4
7.5 K3 clutch
1
1
3
BILD-04
Take off idler gear (1), remove needle cage (2) and
BILD-01
axial bearing assembly (3).
Snap out piston ring (1).
STEP 5
STEP 2
BILD-05
BILD-02
Pull clutch (1) off the shaft.
Pull tapered roller bearing off the shaft using special
tool CAS2798. NOTE: For disassembly of clutch see Steps 8-13.
STEP 3 STEP 6
1 2
1
BILD-03 BILD-06
Remove axial bearing assembly (1). Remove stud bolt (1) and snap out piston ring (2).
6003-30
STEP 7 STEP 10
BILD-07 BILD-10
Pull tapered roller bearing off the shaft using special Preload cup springs using special tool 380001556
tool CAS2798. and unsnap L-ring (1).
STEP 8 STEP 11
1 1
BILD-08 BILD-11
STEP 9 STEP 12
1
2
BILD-09 BILD-12
Remove end shim (1) and disc set (2) from the disc Using compressed air, remove the piston (1) from the
carrier (3). disc carrier.
6003-31
STEP 13 STEP 3
1
1
BILD-13 BILD-03
Remove both O-rings (1 and 2). Snap out retaining ring (1).
STEP 1 STEP 4
7.6 K4 clutch
1
2
BILD-04
Remove stud bolt (1) and snap out piston ring (2). NOTE: For disassembly of clutch see Steps 9-14.
STEP 2 STEP 5
1
BILD-02 BILD-05
Pull tapered roller bearing off the shaft using special Remove axial bearing assembly (1) and idler gear
tool CAS2798. (2).
6003-32
STEP 6 STEP 9
2 1
BILD-06 BILD-09
Remove needle cage (1) and axial bearing assembly Unsnap snap ring (1).
(2).
NOTE: The gear (3) cannot be removed, it is a STEP 10
shrink fit.
1
STEP 7
1 2
2 BILD-10
Remove end shim (1) and disc set (2) out of the disc
carrier (3).
BILD-07
Turn shaft (2) by 180 degrees and snap out piston STEP 11
ring (1).
STEP 8
BILD-11
2
1
BILD-12
1 STEP 2
BILD-13
STEP 14
BILD-02
BILD-14
BILD-03
STEP 1
7.8 Output shaft
BILD-01
STEP 2
BILD-02
REASSEMBLY
8.0 Clutches KV/KR/K1/K2/K3/K4 input STEP 3
and output shaft
1
STEP 1
8.1KV Clutch
BILD-03
Mount bearing cage (1) onto the shaft and oil it.
STEP 4
BILD-01
STEP 2 2
2
1 1
BILD-04
Install ball bearing (2) into the idler gear (1) until
contact occurs and secure it using retaining ring (3).
STEP 5
BILD-02
BILD-05
1
1 S
BILD-06 BILD-09
Place both O-rings (1 and 2) into the piston grooves Mount inner installer (S) onto the disc carrier. Install
and oil them. disc (1), compression spring (2), support shim (3)
and L-ring (4).
NOTE: Check function of the drain valve (see arrow).
The ball must not jam. NOTE: For installation position of support shim and
L-ring see Step 11. (S) Inner installer, see Step 10.
STEP 7
STEP 10
1
S1
S2
BILD-07
BILD-08
6 2
3
7
4 1
BILD-11 BILD-12
Disc carrier with piston retraction: Install outer and inner discs into the disc carrier (4).
1. Washer 1. Friction disc - coated on one side (1 pcs)
2. Compression spring 2. Outer discs (10 pcs)
3. Support shim 3. Inner discs (10 pcs)
4. L-Ring NOTE: Make sure that the uncoated (blank) side of
the friction disc (1) is showing towards the piston.
5. Disc carrier
Number of friction surfaces is 20.
6. Drain valve (piston)
NOTE: Different clutch disc arrangements with
7. Piston with O-Rings relevant disc clearance can be installed depending
on the parts list version.
NOTE: The actual installed clutch and disc
arrangement must be taken from the corresponding
spare parts list. The spare parts list is binding.
STEP 13
1
2
BILD-15
BILD-16 BILD-18
Press on end plate with F (approximately 100 N = 10 Heat clutch to approximately +120° C (+248° F).
kg) and set dial indicator to “zero”.
STEP 17
STEP 15
L R
F
BILD-19
BILD-20
BILD-21 BILD-24
Heat bearing inner ring to approximately +120° C Check clutch operation using compressed air at the
(+248° F). hole (see arrow). Closing and opening of the clutch
must be clearly audible.
STEP 20
STEP 23
1 1
BILD-22
2
1
BILD-23
BILD-04
Install ball bearing (2) into the idler gear (1) until
BILD-01
contact occurs and secure it using retaining ring (3).
Heat bearing to approximately +120° C (+248° F).
STEP 5
STEP 2
2
1
BILD-05
BILD-02
Press in pre-assembled idler gear (1) onto the shaft
Mount bearing (1) until contact is made. Adjust
until contact occurs.
bearing after it cools. Fit rectangular ring (2).
WARNING: Always wear protective gloves to STEP 6
prevent burning your hands when handling heated
parts.
STEP 3
1
1
3
BILD-06
1 S1
S2
BILD-07 BILD-10
Place piston (1) into the disc carrier. Preload compression spring using special tool
assembly 380001556 (S1) and pressure piece (S2),
NOTE: Observe installation position.
until L-Ring has engaged the annular grove.
STEP 8 NOTE: Always use a new L-ring.
STEP 11
1 2 3
S
5
6
7
4
BILD-08
2 4. L-Ring
5. Disc carrier
1 6. Drain valve (piston)
BILD-09
3 2
4 1
BILD-12 BILD-16
Install outer and inner discs into the disc carrier (4). Press on end plate (F) approximately 100 N = 10 kg
and set dial indicator to “zero”.
1. Friction disc - coated on one side (1 pcs)
2. Outer discs (10 pcs) STEP 15
3. Inner discs (10 pcs)
NOTE: Make sure that the uncoated (blank) side of F
the friction disc (1) is showing towards the piston.
Number of friction surfaces is 20.
NOTE: Different clutch disc arrangements with
relevant disc clearance can be installed depending
on the parts list version.
NOTE: The actual installed clutch and disc
arrangement must be taken from the corresponding
spare parts list. The spare parts list is binding.
STEP 13 BILD-17
BILD-15
BILD-18 BILD-21
Heat clutch to approximately +120° C (+248° F). Heat bearing to approximately +120° C (+248° F).
STEP 17 STEP 20
L R 1
BILD-19 BILD-22
Install clutch until contact is made. Mount inner discs Mount bearing (1) until contact is made. Adjust
onto the inner disc carrier using shor t left/right bearing after it cools.
rotations.
WARNING: Always wear protective gloves to
WARNING: Always wear protective gloves to prevent burning your hands when handling heated
prevent burning your hands when handling heated parts.
parts.
STEP 21
STEP 18
2
2 1
BILD-23
BILD-24
BILD-02
BILD-25
Install sealing cap on orifice (1). Mount bearing (1) until contact is made. Adjust
bearing after it cools. Fit rectangular ring (2).
NOTE: Wet contact surface with Loctite (Type No.
262). WARNING: Always wear protective gloves to
prevent burning your hands when handling heated
NOTE: The sealing cap is not mounted on all parts.
versions. Versions concerned, see corresponding
spare parts list.
6003-45
STEP 3 STEP 6
2
1
1
3
2 S
BILD-03 BILD_06
Place both O-rings (1 and 2) into the piston grooves Mount inner installer (S) onto the disc carrier. Install
and oil them. cup spring package (1) and L-ring (2).
NOTE: Check function of the drain valve (3). There NOTE: For installation position of cup spring
must be no jamming of the ball. package and L-ring see Step 8. (S) Inner installer,
see Step 7.
STEP 4
STEP 7
S2 S1
BILD-04
BILD-05
1 2
1
3 2
BILD-08 BILD-11
Disc carrier with piston retraction: Mount end plate (1) and secure disc package using
snap ring (2) e.g. thickness = 2.65 mm(0.104
1. Cup spring package
in.)/recommended value.
2. L-Ring
3. Disc carrier STEP 11
4. Piston with O-rings
STEP 9 F
3 2
BILD-12
Install outer and inner discs into the disc carrier (4).
1. Friction disc - coated on one side (1 pcs)
2. Outer discs (9 pcs)
3. Inner discs (9 pcs)
NOTE: Make sure that the uncoated (blank) side of
the friction disc (1) is showing towards the piston.
Number of friction surfaces is 18.
NOTE: Different clutch disc arrangements with
relevant disc clearance can be installed depending
on the parts list version.
NOTE: The actual installed clutch and disc
arrangement must be taken from the corresponding
spare parts list. The spare parts list is binding.
6003-47
STEP 12 STEP 14
F
1
BILD-13 BILD-15
Press end plate against the snap ring (upwards) and Install clutch (1) until contact is made.
read disc clearance. Disc clearance should be 2.35
WARNING: Always wear protective gloves to
to 2.65 mm(0.092 to 0.104 in.).
prevent burning your hands when handling heated
NOTE: In cases of deviation, the disc clearance parts.
must be corrected with an appropriate snap ring.
Optional thicknesses range from 2.1 to 4.2 mm STEP 15
(0.083 to 0.165 in.).
STEP 13 2 3
BILD-16
STEP 16
BILD-17
L
R
BILD-18 BILD-21
Install (1) idler. Mount inner discs onto the inner disc Heat bearing to approximately +120° C (+248° F).
carrier (idler) by using short left/right rotations.
STEP 21
STEP 18
3 1
2
BILD-22
STEP 19 STEP 22
2 1 2
BILD-20 BILD-23
Secure idler gear (1) and single par ts by using Mount stud bolt (1) and torque to 17 Nm (150 pound
retaining ring (2). inches). Fit rectangular ring (2).
6003-49
STEP 23 STEP 2
2
1
BILD-24 BILD-02
Check clutch operation by using compressed air at Mount bearing (1) until contact is made. Adjust
the hole (see arrow). Closing and opening of the bearing after it cools. Fit rectangular ring (2).
clutch must be clearly audible.
WARNING: Always wear protective gloves to
prevent burning your hands when handling heated
STEP 1 parts.
8.4 Clutch K2
STEP 3
BILD-01
1
S2 S1
BILD-04 BILD-07
Place piston (1) into the disc carrier. Preload cup spring package using special tool
380001556 (S1) and pressure piece (S2), until
NOTE: Observe installation position.
L-Ring has engaged into the annular grove.
STEP 5 NOTE: Always use a new L-ring.
STEP 8
1 2
S
3
BILD-05
BILD_06
2
3
4 1
BILD-09 BILD-12
Install outer and inner discs into the disc carrier (4). Press on end plate with (F) approximately 100 N = 10
kg and set dial indicator to “zero”.
1. Friction disc - coated on one side (1 pcs)
2. Outer discs (7 pcs) STEP 12
3. Inner discs (7 pcs)
NOTE: Make sure that the uncoated (blank) side of F
the friction disc (1) is showing towards the piston.
Number of friction surfaces is 14.
NOTE: Different clutch disc arrangements with
relevant disc clearance can be installed depending
on the parts list version.
NOTE: The actual installed clutch and disc
arrangement must be taken from the corresponding
spare parts list. The spare parts list is binding.
STEP 10 BILD-13
BILD-11
BILD-14 BILD-17
Heat clutch to approximately +120° C (+248° F). Mount needle bearing (1) and oil it.
STEP 14 STEP 17
L R
1
BILD-15 BILD-18
Mount clutch (1) until contact is made. Install (1) idler. Mount inner discs onto the inner discs
carrier (idler) by using short left/right rotations.
WARNING: Always wear protective gloves to
prevent burning your hands when handling heated
parts. STEP 18
3
STEP 15
2
3
2 1
BILD-19
Mount running disc (1), axial cage (2) and axial NOTE: Install chamfer (see arrow) of running disc
washer (3) and oil it. (3) showing towards the axial cage.
NOTE: Install chamfer (see arrow) of running disc
(1) showing towards the axial cage.
6003-53
STEP 19 STEP 22
2 1 2
BILD-20 BILD-23
Secure idler gear (1) and single parts using retaining Mount stud bolt (1) and torque to 17 Nm (150 pound
ring (2). inches). Fit rectangular ring (2).
STEP 20 STEP 23
BILD-21 BILD-24
Heat bearing to approximately +120° C (+248° F). Check clutch operation by using compressed air at
the hole (see arrow). Closing and opening of the
STEP 21 clutch must be clearly audible.
STEP 1
1 8.5 Clutch K3
BILD-22
prevent burning your hands when handling heated Heat bearing to approximately +120° C (+248° F).
parts.
6003-54
STEP 2 STEP 4
3 2
1 1
BILD-02 BILD-04
Mount bearing (1) until contact is made. Adjust Place piston (1) into the disc carrier.
bearing after it cools. Fit rectangular ring (2). Mount
NOTE: Observe installation position.
stud bolt and torque to 17 Nm (150 pound inches).
WARNING: Always wear protective gloves to STEP 5
prevent burning your hands when handling heated
parts.
STEP 3
S
3
2 BILD-05
BILD-03 STEP 6
Place both O-rings (1 and 2) into the piston grooves
and oil them. 2
NOTE: Check function of the drain valve (3). There
must be no jamming of the ball.
1
BILD_06
2
S2 S1
3
4 1
BILD-07 BILD-09
Preload cup spring package using special tool Install outer and inner discs into the disc carrier (4).
380001556 (S1) and pressure piece (S2), until
1. Friction disc - coated on one side (1 pcs)
L-Ring has engaged into the annular grove.
2. Outer discs (7 pcs)
NOTE: Always use a new L-ring.
3. Inner discs (7 pcs)
STEP 8 NOTE: Make sure that the uncoated (blank) side of
the friction disc (1) is showing towards the piston.
1 2 Number of friction surfaces is 14.
NOTE: Different clutch disc arrangements with
3
relevant disc clearance can be installed depending
on the parts list version.
NOTE: The actual installed clutch and disc
4 arrangement must be taken from the corresponding
spare parts list. The spare parts list is binding.
STEP 10
BILD-08
BILD-11
BILD-12 BILD-14
Press on end plate with (F) approximately 100 N = 10 Heat clutch inner diameter to approximately +120° C
kg and set dial indicator to “zero”. (+248° F).
STEP 12 STEP 14
F
1
BILD-13 BILD-15
Press end plate against the snap ring (upwards) and Mount clutch (1) until contact is made.
read disc clearance. Disc clearance should be 1.75
WARNING: Always wear protective gloves to
to 2.05 mm (0.069 to 0.081 in.).
prevent burning your hands when handling heated
NOTE: In cases of deviation, the disc clearance parts.
must be corrected with an appropriate snap ring.
Optional thicknesses range from 2.1 to 4.2 mm
(0.083 to 0.165 in.).
6003-57
STEP 15 STEP 18
3 3
2 2
1 1
BILD-16 BILD-19
Mount running disc (1), axial cage (2) and axial Mount axial washer (1), axial cage (2) and running
washer (3) and oil it. disc (3) and oil it.
NOTE: Install chamfer (see arrow) of running disc NOTE: Install chamfer (see arrow) of running disc
(1) showing towards the axial cage. (3) showing towards the axial cage.
STEP 16 STEP 19
BILD-17 BILD-20
Mount needle bearing (1) and oil it. Make sure that the running disc is flush with the shaft
collar (see arrow) to ensure that all inner discs are
STEP 17 mounted on the idler gear teeth.
STEP 20
1
L R
BILD-18
Install (1) idler. Mount inner discs onto the inner disc
carrier (idler) using short left/right rotations. BILD-21
BILD-22
STEP 22 2
1
BILD-02
2 2
1
BILD-03 BILD-05
Cool shaft (1) to approximately -80° C (-112° F), heat Mount lower axial washer (1), axial needle cage (2)
gear (2) to approximately +120° C (+248° F) and and upper axial washer (1) and oil it.
mount until contact is made.
NOTE: Upper and lower axial washer are identical.
WARNING: Always wear protective gloves to
prevent burning your hands when handling heated STEP 6
parts.
STEP 4 1
1
BILD-06
BILD-04 STEP 7
Secure gear using retaining ring (1).
BILD-07
3
2
1
1
BILD-08 BILD-10
Mount axial washer (1), axial needle bearing (2) and Place piston (1) into the disc carrier.
running disc and oil it.
NOTE: Observe installation position.
NOTE: Mount running disc (3) with the chamfer (see
arrow) pointing to the needle cage. STEP 11
STEP 9
3
2
BILD-11
BILD-12
3
S2
S1 2
4 1
BILD-13 BILD-15
Preload cup spring package using special tool Install outer and inner discs into the disc carrier (4).
380001556 (S1) and pressure piece (S2), until
1. Friction disc - coated on one side - (1pcs)
L-Ring has engaged into the annular groove.
2. Inner discs (6 pcs)
NOTE: Always use a new L-ring.
3. Outer discs (6 pcs)
STEP 14 NOTE: Make sure that the uncoated (blank) side of
the friction disc (1) is showing towards the piston.
1 2 Number of friction surfaces is 12.
NOTE: Different clutch disc arrangements with
3 relevant disc clearance can be installed depending
on the parts list version.
NOTE: The actual installed clutch and disc
4 arrangement must be taken from the corresponding
spare parts list. The spare parts list is binding.
STEP 16
BILD-14
BILD-16
BILD-17 BILD-19
Press on end plate with (F) approximately 100 N = 10 Heat clutch inner diameter to approximately +120° C
kg and set dial indicator to “zero”. (+248° F).
STEP 18 STEP 20
F L
R
BILD-18 BILD 20
Press end plate against the snap ring (upwards) and Mount clutch (1) until contact is made. Mount inner
read disc clearance. Disc clearance should be 1.35 discs onto the inner disc carrier using short left/right
to 1.65 mm (0.053 to 0.065 in.) see step 15. rotations.
NOTE: In cases of deviation, the disc clearance WARNING: Always wear protective gloves to
must be corrected with an appropriate snap ring. prevent burning your hands when handling heated
Optional thickness range from 2.1 to 4.2 mm (0.083 parts.
to 0.165 in.).
STEP 21
BILD-21
BILD-22 BILD-24
Heat bearing inner ring to approximately +120° C Check clutch operation by using compressed air at
(+248° F). the hole (see arrow). Closing and opening of the
clutch must be clearly audible.
STEP 23
STEP 1
3 8.7 Input shaft
2
1
2
1
BILD-23
BILD-02 BILD-05
Secure drive gear using retaining ring (1). Heat bearing to approximately +120° C (+248° F).
STEP 3 STEP 6
BILD-03 BILD-06
Heat bearing to approximately +120° C (+248° F). Mount bearing (1) until contact is made. Adjust
bearing after it cools.
STEP 4 WARNING: Always wear protective gloves to
prevent burning your hands when handling heated
parts.
1 STEP 7
2
BILD-04
parts. Install snap ring (1) into the annular groove of the
turbine shaft (2).
6003-65
STEP 8 STEP 1
8.8 Output Shaft
BILD-08
STEP 9
3 1
BILD-02
BILD-03
STEP 1
BILD-04
STEP 2
BILD-05
BILD-02
3 3
1 2
1 2
4 4
BILD-03 BILD-05
Mount O-rings into the oil tube annular grooves (1 NOTE: The lubricating oil tubes (1 and 2) are
and 2) and oil them. Then insert tubes into the front supplied as a complete package with the rear
housing. Oil cylindrical bolts (3 and 4) and secure housing. Single parts delivery available only upon
them. Torque to 23 Nm (17 pound feet). request.
NOTE: Always use new cylindrical bolts. NOTE: Assembly is only possible with special
tool380001287 (EU), North American Dealers
STEP 4 contact special tools.
STEP 6
4
3 1
6 8
1 7
5
2
2
BILD-04
housing. Insert all bearing outer rings into the bearing holes of
both housing sections. Front housing.
1. Input
2. Output
3. Forward clutch
4. Reverse clutch
5. K1 = 1st gear clutch
6. K2 = 2nd gear clutch
7. K3 = 3rd gear clutch
8. K4 = 4th gear clutch.
NOTE: For installation position, see Step 6 and 7.
6003-68
STEP 7 STEP 9
3 1
4
1
8 6
5 7 2
BILD-07 BILD-09
Rear housing legend see Figure 6. Place bearing Slightly lift drive gear (1) and position K4 clutch (2).
outer rings into the bearing holes using assembly
grease. STEP 10
NOTE: If contrary to manufacturer recommendation,
the tapered roller bearings of clutches, input and
output are not replaced, you must ensure the
previous pairing (bearing inner ring/bearing outer
ring) - see disassembly instructions.
1
STEP 8
1
BILD-10
3
Mount K3 clutch (1).
STEP 11
BILD-08
1
Place KR clutch (1), AN input shaft (2) and KV clutch
(3) into the housing rear section at the same time.
WARNING: Risk of injury.
NOTE: Due to installation conditions, the installation
of single clutches without using the special tool is not
possible.
NOTE: Housing rear section will be removed again
later. BILD-11
1 7 5
2 2
6
1
3
4
S
BILD-12 BILD-15
Slightly lift K4 clutch (1) and position K1 clutch (2). Secure clutches K1 (1), K2 (2), K3 (3) and K4 (4) by
using a special handle tool 380001557 (S). Check all
STEP 13 rectangular rings, grease and align them centrically.
NOTE: This step shows the installation position of
the individual clutches in the rear housing.
WARNING: Clutches KV (5), KR (6) and input shaft
AN (7) are only secured by the gear chain. Care must
2 be taken to ensure these non-secured components
do not detach.
STEP 16
3
1
BILD-13
Press ball bearing (1) onto the pump shaft (2) until
contact is made. Mount rectangular ring (3). Grease
and centrically align rectangular ring.
STEP 14 3
1
2 4
BILD-16
1 3. Clutch KR
4. Pump shaft.
2
WARNING: Clutches KV, KR and input shaft (2) are
BILD-14
only secured by the gear chain. Care must be taken
Mount pump shaft (1) until contact is made. Attach to ensure these non-secured components do not
pump shaft using retaining ring (2). detach.
6003-70
STEP 17 STEP 20
4 2 3 1
BILD-17 BILD-20
Use the suitable lifting device to bring the rear Oil cylindrical bolts (1) and use them to attach screen
housing into contact position with the front housing sheet (1). Torque to 23 Nm (17 pound feet). Mount
by cautiously assembling the clutches. Then remove O-rings (2) into the annular grooves of the oil tubes
handles. and oil them. Mount all rectangular rings (4), grease
and align them centrally. Wet mounting face (3) with
STEP 18 sealing agent Loctite (type No. 574).
NOTE: Always use new cylindrical bolts.
STEP 21
BILD-18
STEP 19 BILD-21
BILD-19
1 3 1
1 2 1
BILD-22 BILD-24
Fit both cylindrical pins (1) centrically to the mounting Join front and rear housing sections using cylindrical
face bolts (1). Torque to 46 Nm (34 pound feet). Mount
securing plate (2). Mount stud bolts (3) and torque to
STEP 23 15 Nm (133 pound inches).
NOTE: Wet bolt-in thread with Loctite (type No. 243).
S
STEP 25
1 1
BILD-23
NOTE: If interference of the movable parts (e.g. on The bolt plugs (1) must be mounted with a hydraulic
the screen sheet or on the oil tubes) is found, it must pneumatic pressing tool.
be corrected. Do this step on all clutch shafts.
NOTE: In case of damage the pre-mounted rear
transmission housing must be fully replaced.
6003-72
10.0 Outputs and closure parts pump STEP 3
shaft (PTO-shaft)
STEP 1 1 3
2
10.1 Output flange output side with brake FSG-88
BILD-16
1 BILD-17
BILD-18 BLD-20
Attach parking brake (1) on transmission housing Insert setting gauge on both sides between base disc
using the hex bolt - guide pin (2). Torque to 46 Nm and brake disc and hold in its position. Clearance:
(34 pound feet). 0.5 - 1.5 mm (0.02 to 0.06 in), Nominal clearance: 1.0
mm (0.04 in.).
STEP 6 NOTE: For all installation, fitting and maintenance
instructions, functional characteristics and setting
specifications of the parking brake, see
manufacturer’s documentation.
STEP 8
10.2 Output flange on converter side (Standard
versions)
S
BILD-19
BILD-26
2 3
1 3
1
4
2
5
BILD-27 BILD-29
1. Shaft seal Insert O-ring into the space between output flange
and shaft. Secure output flange (1) using washer (2)
2. Gearbox housing - rear section
and hex bolts (3). Oil hex bolts before the assembly.
3. Roller bearing Torque to 46 Nm (34 pound feet).
4. Output shaft NOTE: Always use new hex bolts.
5. Screen sheet
STEP 10
2
BILD-28
STEP 1
11.1 Converter back-pressure valve
1 BILD-03
STEP 4
4 11.2 Oil pressure pump
BILD-01
BILD-02
1
1
BILD-05 BILD-08
Install two adjusting bolts (S) and mount stator shaft Position control disc and secure it radially using two
(1). cylindrical bolts (1). Place O-ring (2) into the annular
groove and oil it.
NOTE: Pay attention to radial installation position.
NOTE: Do not tighten the cylindrical bolts - only turn
STEP 6 them in until contact is made and then turn them
back by approximately 1/2 a turn. Pay attention to the
installation position of the control disc in figure.
STEP 9
BILD-06
BILD-07
2 1
1 2
4 2
3
BILD-10 BILD-13
Oil sliding bearing (see arrow) before assembly. Secure oil feed housing (1) equally using Torx bolts
Mount inner installer (S) onto the stator shaft. Mount (2). Torque to 23 Nm (17 pound feet). Secure plate
pre-assembled transmission pump (1). (3) using cylindrical bolts (4). Torque to 34 Nm (25
pound feet).
NOTE: Pay attention to radial installation position.
STEP 14
STEP 11
1
2
BILD-14
BILD-11
Secure converter bell housing (1) using hex bolts (2).
Mount pre-assembled pump with driver (S) until
Torque to 65 Nm (48 pound feet).
contact is made.
STEP 12
2
1
BILD-12
BILD-20
Bolt input shaft (1) to flex plate (2) using hex bolts (3).
Torque to 115 Nm (85 pound feet). STEP 18
NOTE: Wet threads of hex bolts with Loctite (Type
No. 262). S
STEP 16
1 2 1
BILD-21
BILD-22
3
1
BILD-23 BILD-25
Heat flange inner diameter to approximately +120° C Secure input flange (3) using washer (1) and hex
(+248° F). bolts (2). Oil hex bolts before assembly. Torque to 34
Nm (25 pound feet).
STEP 21 NOTE: Always use new hex bolts.
1 STEP 23
BILD-24
2
Mount input flange (1) until contact is made.
WARNING: Always wear protective gloves to BILD-26
prevent burning your hands when handling heated Position converter using a suitable lifting device until
parts. the cover (1) is in contact with the converter bell
housing (2).
6003-80
STEP 24 STEP 2
1 1
2
3
BILD-27 BILD-02
Bolt converter bell housing (1) to cover (2) using Attach cover using hex bolts (1). Torque to 23 Nm (17
cylindrical bolts and hex nuts (3). Torque to 46 Nm pound feet).
(34 pound feet).
NOTE: Pay attention to radial installation position
markings made during disassembly (see arrows).
12.0 Reassembly - Emergency steering
pump
STEP 1
12.1 Version without emergency steering pump
1
S
BILD-01
3 5
1
BILD-02
9 8
BILD-01
STEP 1
Main pressure valve 16+2 bar Pressure reducing valve 9 bar Wiring harness
A A
B
B
Cover Cover
Electro-hydraulic Control
NOTE: Different versions regarding the wiring
harness position are possible. Please observe the
vehicle manufacturer’s specifications.
The following sketches show the sectional views of
the electro-hydraulic control.
6003-83
STEP 2
Proportional valve P5
Vibration damper
Pressure controller
Follow-on slide
STEP 3
Main pressure valve 16+2 bar Valve block Wiring harness
STEP 4
14.1 Fitting of electric control
1 1
BILD-04
2
1
3 S
S
2
1
BILD-05 BILD-07
NOTE: See arrows for installation position. Fit adjusting bolts 380001577 (S). Mount seal (1) and
housing (2). Then position housing equally using the
This Step shows the following single parts:
adjusting bolts until contact is made.
1. Pressure reducing valve (1x, piston and
compression spring) STEP 8
2. Vibration damper (3x, piston and compression
spring) 1
3. Follow-on slide (3x, piston and compression
spring)
STEP 6
BILD-08
BILD-09
2 1
BILD-10 BILD-12
Mount pressure controllers with O-ring (1) and Install the single parts shown in Step 11. Preload the
secure them using securing plates (2) and Torx bolts compression springs of the follow-on slides and
(3). Torque to 5.5 Nm (49 pound inches). temporarily fasten the pistons using the 5.0 mm
diameter cylindrical pins (S).
NOTE: Install securing plate with the claw side
facing downward. Pay attention to the radial Install two adjusting bolts (S). Assemble flat gasket
installation position of pressure controllers. (1) and housing cover. Place the housing cover
equally until contact by using the adjusting bolts.
STEP 11
STEP 13
1
1
3 2
BILD-11
single parts: Preload the pistons with Torx bolts and remove the
cylindrical pins (assembly aid) again. Then secure
1. Main pressure valve (1x, Piston and
the housing cover using Torx bolts (1). Torque to 5.5
compression spring)
Nm (49 pound inches).
2. Vibration damper (3x, Piston and compression
spring)
3. Follow-on slide (3x, Piston and compression
spring).
6003-86
STEP 14 STEP 16
1 1
BILD-14 BILD-16
Mount the pressure regulators with O-ring (1) and Install flat gasket (1) and assemble the plug socket
fasten them using securing plates and cap screws. with the slot facing the lug of the cover until it makes
Torque to 5.5 Nm 49 pound inches). contact. Secure the cover using cap screws and
torque to 5.5 Nm (49 pound inches).
NOTE: Install the securing plate with the neck facing
downward. Observe radial installation position of the
pressure regulators. STEP 17
STEP 15 1
BILD-17
Assemble the wiring harness (1) and connect the NOTE: For version with torque converter lock-up
pressure regulators. clutch solenoid valve, go to Steps 29 & 30.
NOTE: See Step 1 for installation position of
pressure regulators. Pay attention to the installation STEP 18
position of the wiring harness - see markings made
during disassembly. S
BILD-18
1 1 1 2
BILD-19 BILD-21
Flush-mount screens (1) into the holes of the sealing Position duct plate (1) and secure it equally using
plate, see arrows. Torx bolts (2). Torque to 10.5 Nm (93 pound inches).
NOTE: Pay attention to the installation position, -
screens should face upwards toward the duct plate. STEP 22
STEP 20
1
2 3
BILD-22
BILD-23
2 1
1
2
3 4
BILD-24 BILD-26
Mount stud bolts (1) and torque to 15 Nm (133 pound Mount compression spring (4), piston (3) and switch
inches). (2) with new O-ring. Torque to 30 Nm (22 pound feet).
NOTE: Wet bolt-in thread with Loctite (Type No. 1. Filter differential pressure valve
243).
2. Switch with O-ring
Position seal (2) and duct plate (3) on the rear
3. Piston
housing until contact is made.
4. Compression spring
NOTE: Use assembly grease.
STEP 27
STEP 25
S
2
4
1
3
1
BILD-27
BILD-25
Fit two adjusting bolts (S). Mount sealing plate (1)
Secure duct plate (1) using Torx bolts (2) and hex
and electro-hydraulic control unit (2).
nuts (3). Torque to 23 Nm (17 pound feet). Mount
plug (4) with new O-ring and torque to 30 Nm (22 NOTE: Do not re-assemble the seal plate after
pound feet). opening the threaded joint of the shift unit/gearbox
housing. In the case of repair, a new seal plate must
be mounted.
6003-89
STEP 28 STEP 30
3 1
4
2
BILD-28 BILD-30
Secure electro-hydraulic control unit (1) evenly using Secure pressure controller (1) using cylindrical bolts
Torx bolts (2) and torque them to 9.5 Nm (84 pound (2) and torque to 10 Nm (89 pound inches). Fit bolt
inches). necks (3) with O-ring and torque to 25 Nm (18 pound
feet). Fit plug (4) with O-ring and torque to 10 Nm (89
NOTE: For version with torque converter lock-up
pound inches).
clutch solenoid valve, go to Steps 31 and 32.
NOTE: Go back to Step 18.
STEP 29
14.2 Version with torque converter lock-up clutch STEP 31
solenoid valve Pipe - System pressure to lock-up clutch valve.
3
2 1
BILD-29 BILD-31
Position seal (1) and secure connecting housing (2) Secure pipe (1) with hollow bolt (2) and bolt nut (3).
using Torx bolts (3). Tightening torque 5.5 Nm (49 Fit O-ring on to hollow bolt (2), insert it into the eye of
pound inches). the pipe and torque to 45 Nm (33 pound feet). Attach
bolt nut (3) and torque to 35 Nm (26 pound feet).
NOTE: Pay attention to installation position of
connection housing, see markings applied during
disassembly.
6003-90
STEP 32 STEP 34
Pipe - System pressure from lock-up clutch valve
to lock-up clutch.
3 BILD-34
STEP 33
14.3 Fitting of filter (pressure filter)
BILD-33
6004
MULTITRAC MT-L 3085 II / 3095 II AXLES
6004-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GEAR TOOTH CONTACT PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
WEAR MEASUREMENT ON MULTI-DISC BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OUTPUT AND BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
AXLE HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Disassembly Multi-disk Differential Lock DHL-2400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Disassembly Differential D-2400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Disassembly Multi-disc Differential DL-2400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Reassembly Multi-disk Differential Lock DHL-2400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Reassembly Differential D-2400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Reassembly Multi-disc Differential DL-2400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Reassembly Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
AXLE HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
OUTPUT AND BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6004-3
SPECIAL TOOLS
Planetary bearing puller collet set ............................................................................................................... CAS2881
Brake housing seal installer......................................................................................................................... CAS2880
Differential bearing cone puller collet set..................................................................................................... CAS2871
Differential bearing preload wrench ............................................................................................................. CAS2851
Brake housing inner bearing cup installer ................................................................................................... CAS2877
Brake housing outer bearing cup installer ................................................................................................... CAS2878
Brake housing inner bearing cup installer ................................................................................................... CAS2879
Wear ring installer adapter .......................................................................................................................... CAS2874
Wear ring installer adapter ......................................................................................................................... CAS2875
Pinion depth gauge set................................................................................................................................ CAS2872
Pinion depth gauge block ............................................................................................................................ CAS2873
Puller body and screw ................................................................................................................................. CAS2882
Support bracket ........................................................................................................................................... CAS2883
Slide hammer puller adapter ..................................................................................................................... CAS10846
Slide hammer ..............................................................................................................................................OEM4252
Replacer ...................................................................................................................................................... CAS2297
Magnetic base with indicator ................................................................................................................... CAS10066A
Heat gun .................................................................................................................................................... CAS10810
Lifting sling...................................................................................................................................................OEM4106
Engine stand................................................................................................................................................OEM4135
Snap ring pliers............................................................................................................................................OEM6484
Snap ring pliers............................................................................................................................................OEM6177
Snap ring pliers............................................................................................................................................OEM6492
Step plate set (includes 8061, 8067, and 8073) ..........................................................................................OEM4288
Step plate ............................................................................................................................................................8061
Step plate ............................................................................................................................................................8067
Step plate ............................................................................................................................................................8073
Hexagonal Wrench 105 mm ..............................................................................................................SPX 380003004
6004-4
BS01D011 BS01D009
COAST SIDE (CONCAVE)
BS01D013
COAST SIDE (CONCAVE)
BS01D012
DRIVE SIDE (CONVEX)
BS01D014
DRIVE SIDE (CONVEX)
6004-5
Pinion Distance Must Be Decreased
BS01D016
BS01D015
COAST SIDE (CONCAVE)
6004-6
LUBRICATION
821F Limited Slip Front Axle
5 4
3
2 1
RH11C095.PNG RH11C096.PNG
1. OIL DRAIN HOLE (AXLE CASING) 3. OIL FILLER HOLE 5. BLEEDER
2. OIL DRAIN HOLE (OUTPUTS) 4. BRAKE BLEEDER
5 4
2
3
2 1
RH11C099.PNG RH11C100.PNG
1. OIL DRAIN HOLE (AXLE CASING) 3. OIL FILLER HOLE 5. BLEEDER
2. OIL DRAIN HOLE (OUTPUTS) 4. BRAKE BLEEDER
5 4
2
3
2 1
RH11C097.PNG RH11C098.PNG
1. OIL DRAIN HOLE (AXLE CASING) 3. OIL FILLER HOLE 5. BLEEDER
2. OIL DRAIN HOLE (OUTPUTS) 4. BRAKE BLEEDER
6004-7
821F/921F Open Differential Rear Axle
5 4
2
3
2 1
RH11C101.PNG RH11C102.PNG
1. OIL DRAIN HOLE (AXLE CASING) 3. OIL FILLER HOLE 5. BLEEDER
2. OIL DRAIN HOLE (OUTPUTS) 4. BRAKE BLEEDER
6004-8
BD00M234 BS00M071
NOTE: A wear measurement on the multi-disc brake has to be made at least once a year, especially in case of a
changed braking behavior.
A wear measurement has to be made on both wheel ends.
Remove plug, actuate brake and determine dimension “X” using a feeler gauge.
If dimension “X” is less than or equal to 4.0 mm (0.16 in) the lined discs on both output sides have to be replaced.
Replace O-ring when installing the level plug. Tighten plug to 70 Nm (52 pound-feet).
6004-9
Disassembly STEP 3
NOTE: Tools and axle shown in the following images
may appear slightly different than the tools and axle
you may have. The use of the tools and
disassembly/assembly of axle is the same regardless
of appearance.
STEP 1
1-03.PNG
STEP 4
1-01.PNG
STEP 2
1-04.PNG
1-02.PNG
1-05.PNG 1-08.PNG
Attach load carrying device 380002303 to output Use a lever to remove output shaft cover.
assembly. Remove hex bolts and separate output
from axle housing. STEP 9
WARNING: Attach load carrying device with a wheel
nut.
STEP 6
1-09.PNG
STEP 10
1-06.PNG
STEP 7
1-10.PNG
1-07.PNG
1-11.PNG 1-14.PNG
Use a suitable lifting device and lift planetary carrier Pull off planetary gears.
out of brake housing.
STEP 15
STEP 12
1-15.PNG
1-16.PNG
1-17.PNG
STEP 18
1-20.JPG
1. Brake housing
2. Guide ring
3. Back-up ring
4. Piston seal
5. Piston seal
1-18.PNG
6. Back-up ring
Mount bleeder valve. Use compressed air to remove
piston from brake housing. 7. Slide ring seal (Metal face seal - HD option only
or combi seal standard version)
STEP 19 8. Output shaft
STEP 21
1-19.PNG
1-22.PNG
STEP 23
1-23.PNG
STEP 24
1-24.PNG
AXLE HOUSING
Disassembly STEP 3
STEP 1
2-03.PNG
STEP 2
2-04.PNG
2-02.PNG
INPUT
Disassembly STEP 3
STEP 1
3-03.PNG
STEP 2
3-04.PNG
3-02.PNG
3-05.PNG 3-07.PNG
Heat slotted nut with a hot air blower. Remove input flange from pinion. Use a lever to
remove shaft sea.
NOTE: Slotted nut is secured with Loctite (Type no.
262).
STEP 8
WARNING: Always wear protective gloves to
prevent burning your hands when handling heated
parts.
STEP 6
3-08.PNG
STEP 9
3-06.PNG
3-09.PNG
STEP 10
6004-17
3-10.PNG
DIFFERENTIAL
4-04.PNG
1 4
4-05.PNG
4-03.PNG
4-06.PNG 4-09.PNG
Preload differential using a press. Remove locking Remove both shor t differential axles. Remove
bolts and housing cover. releasing spider gears and thrust washers from
differential housing.
STEP 7
STEP 10
4-07.PNG
4-08.PNG
STEP 12
6004-20
STEP 15
4-12.PNG
STEP 16
STEP 13
4-16.PNG
4-13.PNG
Remove axle bevel gear with thrust washers from
Pull both tapered roller bearings from differential.
differential housing.
STEP 14 STEP 17
4-14.PNG
4-17.PNG
Preload differential using a press. Remove hex bolts
Force out both slotted pins.
and releasing housing cover.
6004-21
STEP 18 STEP 21
4-18.PNG 4-21.PNG
Force out both shor t differential axles. Remove Press crown wheel from differential carrier.
releasing spider gears with thrust washers from
differential housing. Disassembly Multi-disc Differential
STEP 19
DL-2400
STEP 22
4-19.PNG
4-20.PNG
4-23.PNG
Remove axle bevel gear and shim.
Preload differential with a press. Remove locking
screws and housing cover.
6004-22
STEP 24 STEP 27
4-24.PNG 4-27.PNG
Remove axle bevel gear with pressure ring, disc Remove pressure ring, disc package and thrust
package and thr ust washers from differential washers from the differential housing.
housing.
STEP 28
STEP 25
4-28.PNG
STEP 26
4-26.PNG
DIFFERENTIAL
5-03.PNG
STEP 4
5-01.PNG
STEP 2
5-04.PNG
I ns e r t s p i d e r g e a r s w i t h t h r u s t wa s he r s i n t o
differential housing. Secure them with long spider
shaft.
NOTE: Thrust washers must be positioned with tabs
(arrow) located in recesses of differential housing.
5-02.PNG
1 2
5-05.PNG 5-07.PNG
STEP 6
5-08.PNG
STEP 9
5-06.PNG
5-09.PNG
5-10.PNG 5-12.JPG
5-13.PNG 5-15.PNG
Preload disk package with an axial force of F = 50 +30 Position housing cover onto pressure piece (arrow).
KN. Then check setting dimension “A” = 1.05 +/-0.1 Insert two hex bolts into housing cover to radially
mm (0.041 +/-0.004 in) from collar of differential attach disc package.
cover to plane face of outer disc (also see sketch in
step 14). STEP 16
NOTE: Any deviation from specified setting
dimension must be corrected with a corresponding
outer disk.
NOTE: Special tools pressure piece and load cell
are to be determined. Contact special tools.
STEP 14
5-16.PNG
STEP 17
5-14.JPG
5-17.PNG
5-18.PNG
5-19.PNG
STEP 22
5-22.PNG
5-23.PNG 5-25.PNG
In s e r t spi der gear s wi t h th r us t wa s h e r s i nto Secure short spider shafts with slotted pins.
differential housing. Secure them with long spider
NOTE: Flush mount slotted pins.
shaft.
NOTE: Thrust washers must be positioned with tabs STEP 26
(arrow) located in recesses of differential housing.
STEP 24
1 2
5-26.PNG
5-24.PNG STEP 27
In s e r t spi der gear s wi t h th r us t wa s h e r s i nto
differential housing. Secure them with two short
spider shafts.
NOTE: Thrust washers must be positioned with tabs
(1) located in recesses of differential housing. Pay
attention to radial installation position of spider shafts
securing holes (2).
5-27.PNG
5-28.PNG 5-30.PNG
Mount two adjusting bolts and insert housing cover Heat both tapered roller bearings and insert until
until contact with differential housing is obtained. contact is made. Adjust tapered roller bearing after
Preload differential using a press. Secure with new cooling down.
locking bolts. Torque to 400 Nm (295 pound feet).
WARNING: Always wear protective gloves to
prevent burning your hands when handling heated
STEP 29 parts.
5-29.PNG
5-31.PNG
5-32.PNG 5-34.PNG
STEP 33 STEP 35
5-33.PNG 5-35.PNG
Mount outer and inner discs in alternating order Install axle bevel gear until contact is made. Then
starting with an outer disk. install inner discs with teeth.
NOTE: The installation clearance of internal parts is
corrected by mounting outer discs of different STEP 36
thicknesses.
NOTE: The difference in thickness between the left
and right disc package must be less than 0.1 mm
(0.004 in.).
5-36.PNG
5-37.PNG 5-39.PNG
Install second axle bevel gear. Mount outer and inner discs in alternating order
starting with an inner disc.
STEP 38 NOTE: The installation clearance of internal parts is
corrected by mounting outer discs of different
thicknesses.
NOTE: The difference in thickness between the left
and right disc package must be less than 0.1 mm
(0.004 in.).
STEP 40
5-38.PNG
5-40.PNG
5-41.PNG 5-43.PNG
Measure Dimension II, from the contact face of the Mount two M16 x 1.5 adjusting bolts and inser t
outer disc to the mounting face on the housing cover. housing cover until contact with differential housing is
Dimension II e.g. 43.95 mm (1.730 in.) made. Preload differential with a press. Secure with
new locking bolts and torque to 400 Nm (295 lb ft.)
Calculation Example:
Dimension I - 44.30 mm (1.744 in.) STEP 44
Dimension II - 43.95 mm (1.730 in.)
Difference + disc clearance - 0.35 mm (0.013 in.)
NOTE: Any deviation from the required installation
clearance must be corrected with corresponding
outer discs: s = 2.7 mm (0.106 in.), s = 2.9 mm
(0.114 in.), s = 3.0 mm (0.118 in.), s = 3.1 mm (0.122
in.), s = 3.2 mm (0.126 in.), s = 3.3 mm (0.130 in.), s
= 3.5 mm (0.138).
NOTE: Make sure the difference in thickness
between the left and right disc package is less than
0.1 mm (0.004 in.).
5-44.PNG
5-42.PNG
INPUT
STEP 1
Determination of shim thickness to
obtain a correct contact pattern
6-03.PNG
221.10
Determine dimension III (bearing width). Dimension
III e.g. 39.10 mm (1.54 in).
Calculation Example “A”:
6-01.PNG Dimension I: 221.10 mm (8.70 in)
R e a d d i m e n s i o n I f r o m a x l e d r i ve h o u s i n g . Dimension II: -181.00 (7.13 in)
Dimension I e.g. 221.10 mm (8.70 in)
Dimension III: -39.10 (1.54 in)
NOTE: If crown wheel or input pinion are damaged,
both parts must be replaced together. When Difference = shim s = 1.00 mm (0.04 in)
installing a complete new bevel gear set, look for
identical mating number of input pinion and crown STEP 4
wheel. Reassembly of input pinion
NOTE: Measuring procedures must be done
accurately. Inaccurate measurements lead to
incorrect contact pattern requiring additional
disassembly and reassembly of input pinion and
differential.
STEP 2
181.0 +/- 0
6-04.PNG
6-05.PNG 6-07.PNG
Insert shim into housing hole size e.g. s = 1.00 mm Heat tapered roller bearing and insert it into input
(0.04 in). pinion until contact is made.
WARNING: Always wear protective gloves to
STEP 6 prevent burning your hands when handling heated or
cooled parts.
STEP 8
Setting of rolling torque of input pinion
bearing without shaft seal 1.5 to 3.0 Nm
(13.3 to 26.6 pound inches)
6-06.PNG
6-09.PNG 6-11.PNG
Insert preassembled input pinion into axle drive Insert input flange and secure it with disk and slotted
housing. Insert heated tapered roller bearing until nut. Torque to 1200 Nm (885 pound feet). Use
contact is made. CAS2842 slotted nut wrench and 380001546
clamping device.
WARNING: Always wear protective gloves to
prevent burning your hands when handling heated or NOTE: Temporarily mount slotted nut without
cooled parts. Loctite. While tightening, rotate input pinion several
times in both directions.
STEP 10
STEP 12
6-10.PNG
6-13.PNG
6-16.JPG
1 = Axle housing
2 = Shim (crown wheel side)
3 = Shim (differential carrier side)
4 = Axle housing
6004-37
Shim
Diff. cage side 0.7 0.8 0.9 1.0
Shim thickness
Shim
DHL 2400 84395193 84354725 84354726 84354727
Order no.
Shim
D/DL 2400 84476078 84330538 84330539 84330540
Order no.
Shim
Crown wheel side 1.3 1.2 1.1 1.0
Shim thickness
Shim
D/DL/DHL 2400 84476080 84330542 84330541 84330540
Order no.
STEP 17 STEP 18
6-17.PNG 6-18.PNG
Insert selected shim e.g. s = 0.9 mm (0.04 in) into Cover some drive and coast flanks of crown wheel
hole of axle housing and adjust bearing outer ring with marking ink. Insert premounted differential into
(arrow) until contact is obtained. axle drive housing.
STEP 19
6004-38
STEP 21
6-19.PNG
hole of axle housing and adjust bearing outer ring Leak test differential lock. Pressurize lock p = 1 bar
until contact is made. (15 psi), close shut-off valve and remove air line. No
noticeable pressure loss should occur within 10
STEP 20 seconds.
NOTE: This operation is only necessary for version
S with DHL.
STEP 22
6-20.PNG
6-23.PNG 6-25.PNG
After contact pattern check, insert differential into Using CAS2841 driver tool, mount shaft seal with
axle drive housing again. seal lip facing oil chamber.
NOTE: Exact installation position of seal is obtained
STEP 24 using specified driver tool.
Reassembly of shaft seal (Step 24 to 26)
NOTE: Wet outer diameter of shaft seal with mineral
spirits just before installation. Fill space between seal
and dust lip with grease.
STEP 26
6-24.PNG
AXLE HOUSING
Reassembly STEP 3
STEP 1
7-03.PNG
STEP 2
7-04.PNG
7-05.PNG
7-06.PNG
Reassembly STEP 3
STEP 1
8-03.PNG
STEP 2
8-04.PNG
8-05.PNG 8-07.PNG
Insert both bearing outer rings (arrows) into brake Heat slide bushing and position it at collar of output
housing until contact is made. shaft. Then position slide bushing with CAS2860
pressure ring.
STEP 6 NOTE: Exact installation position is obtained when
using specified pressure ring.
WARNING: Always wear protective gloves to
prevent burning your hands when handling heated or
cooled parts.
STEP 8
8-06.JPG
Screening plate. Insert shaft seal into brake housing using CAS2880
driver tool.
NOTE: Exact installation position is obtained when
using specified driver tool. Make note of installation
position (Step 6). Wet outer diameter of shaft seal
with mineral spirits before assembly.
6004-44
STEP 9 STEP 11
8-09.PNG 8-11.PNG
Use suitable lifting device and insert premounted Clean annular groove of brake housing with mineral
brake housing over output shaft until contact is made. spirits. Insert guide ring into annular grove (go to step
12). Secure it with Loctite (type no. 415) at its ends
NOTE: Before clamping seal rings (slide ring seal) to
(arrows).
installation dimension, clean sliding surfaces and
apply an oil film. A leather cloth soaked in oil is NOTE: Full circumference of guide ring must be in
recommended for this step. an exact contact position.
WARNING: Upon installation, orifice of guide ring
STEP 10 must show upwards - 12 o’clock position.
8-10.PNG
8-14.PNG
STEP 15
8-12.JPG
1. Brake housing
2. Guide ring
3. Back-up ring
4. Grooved ring
5. Grooved ring
6. Back-up ring
7. Slide ring seal
8. Output shaft
8-15.PNG
STEP 13 Insert disk and cup spring with convex side facing
upwards into piston.
STEP 16
8-13.PNG
8-16.PNG
1
4
8-17.PNG 8-20.PNG
Insert outer and inner disks. Insert cylindrical roller bearing into planetary gear. To
do this, press cylindrical roller bearing (1) through
NOTE: For number of disks and disk arrangement,
packaging sleeve (2) until snap ring (3) engages into
refer to related spare parts list.
annular groove of planetary gear (4).
STEP 18 NOTE: Use packaging sleeve to facilitate assembly.
STEP 21
8-18.PNG
8-19.JPG
8-22.PNG 8-24.PNG
Heat tapered roller bearing and install it on planetary Align disk package centrally and radially. Insert
carrier until contact is made. planetary carrier into teeth of output shaft using a
suitable lifting device.
WARNING: Always wear protective gloves to
prevent burning your hands when handling heated
parts. STEP 25
STEP 23
1 2
8-25.PNG
8-26.PNG 8-29.PNG
Pivot output 90 degrees. Insert disk and secure Set axial play of sun gear shaft to 0.5 to 2.0 mm (0.02
planetary carrier with new locking bolts. to 0.08 in). Determine dimension I, distance from
mounting face of brake housing to front face of stop
NOTE: Tighten locking bolts successively with a
bolt.
tightening torque of 200 Nm (148 pound feet). Then,
retighten with a torque of 500 Nm (369 pound feet). Dimension I e.g. 19.75 mm (0.78 in).
STEP 27 STEP 30
8-27.PNG 8-30.PNG
Install O-ring on cover. Insert stub shaft into teeth of axle bevel gear until
contact is made.
STEP 28 NOTE: Be aware of installation position. Mount stub
shaft side with long teeth towards differential.
8-28.PNG
8-31.PNG 8-33.PNG
Insert sun gear shaft until contact is made. Insert sun gear shaft into planetary carrier.
STEP 32 STEP 34
8-32.PNG 8-34.PNG
Measure dimension II, from front face of sun gear Insert shim(s) e.g. s = 1.60 mm (0.06 in) with grease
shaft to mounting surface of axle housing. into sun gear shaft.
Dimension II e.g. 17.15 mm (0.68 in)
STEP 35
CALCULATION EXAMPLE:
Dimension I: 19.75 mm (0.78 in)
Dimension II: 17.15 mm (0.68 in)
Difference: 2.60 mm (0.10 in)
Required axial play e.g.: 1.00 mm (0.04 in)
Difference = shim e.g. s = 1.60 mm (0.06 in)
8-35.PNG
8-36.PNG 8-39.PNG
Grease O-ring and install it in axle housing. Check brake hydraulics for leakage. Before starting
test bleed brake hydraulics. Pressurize brake
STEP 37 temporarily 5 times with a max pressure of p = 100
bar (1450 psi).
High-pressure test:
Build up test pressure p = 100-10 bar maximum and
close connection to pump via shut-off valve. A
maximum pressure drop of 2% or 2 bar (29 psi) is
permissible during a 5 minute test period.
Low-pressure test:
Reduce test pressure p = 5 bar (73 psi) and close
shut-off valve. No pressure drop is allowed during a 5
minute test period.
Test media:
8-37.PNG
Mount adjusting bolts and use 380002303 lifting Engine oils SAE 10-W corresponds to MIL-L 2104 C,
device to bring output into contact position with axle MIL-L 46152, API-CC, CD, SC, SD, SE, ATF-oils type
housing. Secure output using hex bolts. Torque to A, Suffic A Dexron of II D.
390 Nm (288 pound feet).
NOTE: Attach lifting device with wheel stud.
STEP 38
8-40.PNG
6004
MULTITRAC MT-L 3105 II AXLE
6004-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GEAR TOOTH CONTACT PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
WEAR MEASUREMENT ON MULTI-DISC BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OUTPUT AND BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
AXLE HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Disassembly Multi-disk Differential Lock DHL-2400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Disassembly Differential D-2400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Reassembly Multi-disk Differential Lock DHL-2400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Reassembly Differential D-2400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
AXLE HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
OUTPUT AND BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6004-3
SPECIAL TOOLS
Planetary bearing puller collet set ............................................................................................................... CAS2881
Brake housing seal installer......................................................................................................................... CAS2880
Differential bearing cone puller collet set..................................................................................................... CAS2871
Differential bearing preload wrench ............................................................................................................. CAS2851
Brake housing inner bearing cup installer ................................................................................................... CAS2877
Brake housing outer bearing cup installer ................................................................................................... CAS2878
Brake housing inner bearing cup installer ................................................................................................... CAS2879
Wear ring installer adapter .......................................................................................................................... CAS2874
Wear ring installer adapter ......................................................................................................................... CAS2875
Pinion depth gauge set................................................................................................................................ CAS2872
Pinion depth gauge block ............................................................................................................................ CAS2873
Puller body and screw ................................................................................................................................. CAS2882
Support bracket ........................................................................................................................................... CAS2883
Slide hammer puller adapter ..................................................................................................................... CAS10846
Slide hammer ..............................................................................................................................................OEM4252
Replacer ...................................................................................................................................................... CAS2297
Magnetic base with indicator ................................................................................................................... CAS10066A
Heat gun .................................................................................................................................................... CAS10810
Lifting sling...................................................................................................................................................OEM4106
Engine stand................................................................................................................................................OEM4135
Snap ring pliers............................................................................................................................................OEM6484
Snap ring pliers............................................................................................................................................OEM6177
Snap ring pliers............................................................................................................................................OEM6492
Step plate set (includes 8061, 8067, and 8073) ..........................................................................................OEM4288
Step plate ............................................................................................................................................................8061
Step plate ............................................................................................................................................................8067
Step plate ............................................................................................................................................................8073
Hexagonal Wrench 105 mm ..............................................................................................................SPX 380003004
6004-4
BS01D011 BS01D009
COAST SIDE (CONCAVE)
BS01D013
COAST SIDE (CONCAVE)
BS01D012
DRIVE SIDE (CONVEX)
BS01D014
DRIVE SIDE (CONVEX)
6004-5
Pinion Distance Must Be Decreased
BS01D016
BS01D015
COAST SIDE (CONCAVE)
6004-6
LUBRICATION
921F Open Differential Front Axle
5 4
3
2 1
RH11C105.PNG RH11C106.PNG
1. OIL DRAIN HOLE (AXLE CASING) 3. OIL FILLER HOLE 5. BLEEDER
2. OIL DRAIN HOLE (OUTPUTS) 4. BRAKE BLEEDER
5 4
4
2
3
2 1
RH11C103.PNG RH11C104.PNGBS00M070
1. OIL DRAIN HOLE (AXLE CASING) 3. OIL FILLER HOLE 5. BLEEDER
2. OIL DRAIN HOLE (OUTPUTS) 4. BRAKE BLEEDER
6004-7
BD00M234 BS00M071
NOTE: A wear measurement on the multi-disc brake has to be made at least once a year, especially in case of a
changed braking behavior.
A wear measurement has to be made on both wheel ends.
Remove plug, actuate brake and determine dimension “X” using a feeler gauge.
If dimension “X” is less than or equal to 4.0 mm (0.16 in) the lined discs on both output sides have to be replaced.
Replace O-ring when installing the level plug. Tighten plug to 70 Nm (52 pound-feet).
6004-8
Disassembly STEP 3
NOTE: Tools and axle shown in the following images
may appear slightly different than the tools and axle
you may have. The use of the tools and
disassembly/assembly of the axle is the same
regardless of appearance.
STEP 1
1-03.PNG
STEP 4
1-01.PNG
STEP 2
1-04.PNG
1-02.PNG
1-05.PNG 1-08.PNG
Attach lifting device 380002303 to output assembly. Use a lever to remove output shaft cover.
Loosen hex bolts and separate output assembly from
axle housing. STEP 9
WARNING: Attach load carrying device with wheel
nut.
STEP 6
1-09.PNG
STEP 10
1-06.PNG
STEP 7
1-10.PNG
1-07.PNG
1-11.PNG 1-14.PNG
Use a suitable lifting device. Lift planetary carrier out Pull off planetary gears.
of brake housing.
STEP 15
STEP 12
1-15.PNG
1-16.PNG
1-13.PNG Lift disk package out of brake housing.
Remove retaining rings.
6004-11
STEP 17 STEP 20
1-17.PNG
STEP 18
1-20.JPG
1. Brake housing
2. Guide ring
3. Back-up ring
4. Piston seal
5. Piston seal
1-18.PNG
6. Back-up ring
Mount breather valve. Use compressed air to remove
piston from brake housing. 7. Metal Face Seal (Heavy Duty Option) Combi
Seal (Standard)
STEP 19 8. Output shaft
STEP 21
1-19.PNG
1-22.PNG
STEP 23
1-23.PNG
STEP 24
1-24.PNG
AXLE HOUSING
Disassembly STEP 3
STEP 1
2-03.PNG
STEP 2
2-04.PNG
2-02.PNG
INPUT
Disassembly STEP 3
STEP 1
3-03.PNG
STEP 2
3-04.PNG
3-02.PNG
3-05.PNG 3-07.PNG
Heat slotted nut. Pull input flange from pinion. Use a lever to remove
shaft seal.
NOTE: Slotted nut is secured with Loctite (Type no.
262).
STEP 8
WARNING: Always wear protective gloves to
prevent burning your hands when handling heated
parts.
STEP 6
3-08.PNG
STEP 9
3-06.PNG
3-09.PNG
3-10.PNG
DIFFERENTIAL
4-04.PNG
1 4
4-05.PNG
4-03.PNG
4-06.PNG 4-09.PNG
Preload differential using a press. Remove locking Remove both shor t differential axles. Remove
bolts and housing cover. releasing spider gears and thrust washers from
differential housing.
STEP 7
STEP 10
4-07.PNG
differential housing. Remove long differential axle, spider gears and thrust
washers from differential housing.
STEP 8
STEP 11
4-08.PNG
4-12.PNG 4-15.PNG
Press crown wheel from differential carrier. Preload differential using a press. Remove locking
bolts and housing cover.
Disassembly Differential D-2400
STEP 16
STEP 13
4-16.PNG
4-13JPG
Remove axle bevel gear with thrust washers from
Pull both tapered roller bearings from differential. differential housing.
STEP 14 STEP 17
4-17.PNG
4-14.PNG
Preload differential using a press. Remove hex bolts Force out both slotted pins.
and releasing housing cover.
6004-20
STEP 18 STEP 21
4-18.PNG 4-21.PNG
Force out both shor t differential axles. Remove Press crown wheel from differential carrier.
releasing spider gears with thrust washers from
differential housing.
STEP 19
4-19.PNG
STEP 20
4-20.PNG
DIFFERENTIAL
5-03.PNG
STEP 4
5-01.PNG
STEP 2
5-04.PNG
I ns e r t s p i d e r g e a r s w i t h t h r u s t wa s he r s i n t o
differential housing. Secure them with long spider
shaft.
NOTE: Thrust washers must be positioned with tabs
(arrow) located in recesses of differential housing.
5-02.PNG
1
2
5-05.PNG 5-07.PNG
STEP 6
5-08.PNG
STEP 9
5-06.PNG
5-09.PNG
5-10.PNG
5-13.PNG 5-15.PNG
Preload disk package with an axial force of F = 50 Position housing cover onto dealer fabricated
+30 KN. Then check setting dimension “A” = 1.05 pressure piece (arrow). Insert two hex bolts into
+/-0.1 mm (0.04 +/- 0.003 in) from collar of differential housing cover to radially attach disc package.
cover to plane face of outer disc (also see illustration
in step 14). STEP 16
NOTE: Any deviation from specified setting
dimension must be corrected with a corresponding
outer disk.
NOTE: Special tooling to be determined. Contact
Special Tools for assistance.
STEP 14
5-16.PNG
STEP 17
5-14.JPG
5-17.PNG
5-18.PNG
5-19.PNG
STEP 22
5-22.PNG
5-23.PNG 5-25.PNG
In s e r t spi der gear s wi t h th r us t wa s h e r s i nto Secure short spider shafts with slotted pins.
differential housing. Secure them with long spider
NOTE: Flush mount slotted pins.
shaft.
NOTE: Thrust washers must be positioned with tabs STEP 26
(arrow) located in recesses of differential housing.
STEP 24
1 2
5-26.PNG
5-24.PNG STEP 27
In s e r t spi der gear s wi t h th r us t wa s h e r s i nto
differential housing. Secure them with two short
spider shafts.
NOTE: Thrust washers must be positioned with tabs
(1) located in recesses of differential housing. Pay
attention to radial installation position of spider shafts
securing holes (2).
5-27.PNG
5-28.PNG 5-30.PNG
Mount two adjusting bolts and insert housing cover Heat both tapered roller bearings and insert until
until contact with differential housing is obtained. contact is made. Adjust tapered roller bearing after
Preload differential using a press. Secure with new cooling down.
locking bolts. Torque to 400 Nm (295 pound feet).
WARNING: Always wear protective gloves to
prevent burning your hands when handling heated
STEP 29 parts.
5-29.PNG
INPUT
Reassembly STEP 3
STEP 1
Determination of shim thickness to
obtain a correct contact pattern
6-03.PNG
STEP 2
6-04.PNG
6-05.PNG 6-07.PNG
Insert determined shim size e.g. s = 1.00 mm (0.04 Heat tapered roller bearing. Insert it onto input pinion
in) into housing hole. until contact is made.
WARNING: Always wear protective gloves to
STEP 6 prevent burning your hands when handling heated or
cooled parts.
STEP 8
Setting rolling torque of input pinion
bearing without shaft seal 1.5 to 3.0 Nm
(13.3 to 26.6 pound inches)
6-06.PNG
6-09.PNG 6-11.PNG
Insert preassembled input pinion into axle drive Insert input flange and secure it with disk and slotted
housing. Insert heated tapered roller bearing until nut. Torque to 1200 Nm (885 pound feet). Uses
contact is made. slotted nut wrench CAS2842 and clamping device
380001564.
WARNING: Always wear protective gloves to
prevent burning your hands when handling heated or NOTE: Temporarily mount slotted nut without
cooled parts. Loctite. While tightening, rotate input pinion several
times in both directions.
STEP 10
STEP 12
6-10.PNG
6-13.PNG
6-16.JPG
1 = Axle housing
2 = Shim (crown wheel side)
3 = Shim (differential carrier side)
4 = Axle housing
6004-32
6-17.PNG 6-20.PNG
Insert selected shim e.g. s = 1.0 mm (0.04 in) into Mount two locating pins and bring axle housing into
hole of axle housing and adjust bearing outer ring contact position with axle drive housing using a
(arrow) until contact is obtained. suitable lifting device. Temporarily attach axle
housing with hex bolts. Torque to 560 Nm (413 pound
STEP 18 feet).
NOTE: Test mount axle housing without O-ring.
STEP 21
6-18.PNG
6-19.PNG
6-22.PNG
STEP 23
6-25.PNG
6-26.PNG
AXLE HOUSING
Reassembly STEP 3
STEP 1
7-03.PNG
STEP 2
7-04.PNG
7-05.PNG
7-06.PNG
Reassembly STEP 3
STEP 1
8-03.PNG
STEP 2
8-04.PNG
WARNING: Always wear protective gloves to WARNING: Risk of injury - metal rings have
prevent burning your hands when handling heated or extremely sharp edges. Wear protective gloves.
cooled parts.
6004-39
STEP 5 STEP 7
8-05.PNG 8-07.PNG
Insert both bearing outer rings (arrows) into brake Insert back-up rings and grooved rings into annular
housing until contact is made. grooves of brake housing (arrows).
NOTE: For installation position, go to Step 9.
STEP 6
STEP 8
8-06.PNG
8-11.PNG
STEP 12
8-09.JPG
1. Brake housing
2. Guide ring
3. Back-up ring
4. Piston seal
5. Piston seal
6. Back-up ring
7. Metal Face Seal (Heavy Duty Option) Combi
Seal (Standard)
8-12.PNG
8. Output shaft Insert disk and cup spring with convex side showing
upwards into piston.
STEP 10
STEP 13
8-10.PNG
1 3
4
8-14.PNG 8-17.PNG
Insert outer and inner disks. Insert cylindrical roller bearing into planetary gear. To
do this, press cylindrical roller bearing (1) through
NOTE: For number of disks and disk arrangement,
packaging sleeve (2) until snap ring (3) engages into
refer to related spare parts list.
annular groove of planetary gear (4).
STEP 15 NOTE: Use packaging sleeve to facilitate assembly.
STEP 18
8-15.PNG
8-16.JPG
8-19.PNG 8-21.PNG
Heat tapered roller bearing. Install it on planetary Align disk package centrally and radially. Heat output
carrier until contact is made. shaft. Use a suitable lifting device to insert planetary
carrier into teeth of output shaft.
WARNING: Always wear protective gloves to
prevent burning your hands when handling heated WARNING: Always wear protective gloves to
parts. prevent burning your hands when handling heated or
cooled parts.
STEP 20
STEP 22
2
1
8-20.PNG
Wet contact face of bearing inner ring (1) and profile 8-22.PNG
teeth (2) in output shaft with anti-corrosive agent. Bring planetary carrier into contact position with
c ove r a n d o l d l o ck i n g b o l t s r e m ove d d u r i n g
disassembly. Remove old locking bolts.
6004-43
STEP 23 STEP 25
8-23.PNG 8-25.PNG
Pivot output 90 degrees. Insert disk and secure Insert cover into output shaft until contact is made.
planetary carrier with new locking bolts.
NOTE: Tighten locking bolts successively with a STEP 26
tightening torque of 200 Nm (148 pound feet). Then,
retighten locking bolts successively with a torque of
500 Nm (369 pound feet).
STEP 24
8-26.PNG
8-27.PNG 8-29.PNG
Insert stub shaft into teeth of axle bevel gear until Using a straight edge measure dimension II, from
contact is made. front face of sun gear shaft to mounting surface of
axle housing.
NOTE: Be aware of installation position. Mount stub
shaft with long teeth towards differential. Dimension II e.g. 38.20 mm (1.50 in)
CALCULATION EXAMPLE:
STEP 28
Dimension I: 40.80 mm (1.61 in)
Dimension II: 38.20 mm (1.50 in)
Difference: 2.60 mm (0.10 in)
Required axial play e.g.: 1.00 mm (0.04 in)
Difference = shim e.g.: s = 1.60 mm (0.06 in)
STEP 30
8-28.PNG
8-30.PNG
8-314.PNG 8-34.PNG
STEP 35
8-32.PNG
8-33.PNG
8-36.PNG
8-37.PNG
6005
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CENTER DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REAR DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ENGINE DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
UNIVERSAL JOINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6005-3
SPECIAL TORQUES
Coupler to Flywheel Bolts...................................................................................... 53 to 62 Nm (39 to 46 pound feet)
Engine Drive Shaft to Coupler Bolts ...................................................................... 53 to 62 Nm (39 to 46 pound feet)
Engine Drive Shaft to Coupler Bolts (821F/921F 5-Speed Transmission)........... 86 to 126 Nm (63 to 93 pound feet)
Engine Drive Shaft to Transmission Bolts.............................................................. 75 to 81 Nm (55 to 60 pound feet)
Center, Rear and Front Drive Shaft Bolts .............................................................. 75 to 81 Nm (55 to 60 pound feet)
Carrier Bearing Bolts ........................................................................................... 99 to 128 Nm (73 to 94 pound feet)
Lock Nut for Yoke on Front Drive Shaft.......................................................... 339 to 375 Nm (250 to 275 pound feet)
6005-4
Removal STEP 5
Loosen the set screws that secure the center bearing
NOTE: The 921F Series machines use mechanical
to the front drive shaft.
style yokes (no bearing straps) and may appear
different from the machine pictured.
STEP 6
STEP 1 Remove any paint or rust from the rear of the front
drive shaft and apply WD40 or similar oil to loosen
any rust between the inner race and the front drive
shaft.
STEP 7
BD03A166
Loosen and remove the bolts and straps that fasten
the center drive shaft to the yoke of the front drive
shaft.
STEP 2 BD03A167
STEP 8
Use a prybar to disengage the front drive shaft from
the front axle and remove the front drive shaft from
the machine.
NOTE: If necessary, use a brass hammer to drive
the front drive shaft out of the center bearing.
BD03A183
Remove the lock nut that fastens the yoke to the front
drive shaft.
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.
STEP 4
Use an acceptable puller and remove the yoke from
the end of the front drive shaft.
6005-5
Installation STEP 14
NOTE: The 921F Series machines use mechanical
style yokes (no bearing straps) and may appear
different from the machine pictured.
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.
BD03A183
STEP 11
Install the lock nut and washer which fastens the
yoke to the front drive shaft. Tighten the lock nut to a
torque of 339 to 375 Nm (250 to 275 pound feet).
STEP 15
Tighten the set screws that secure the center bearing
to the front drive shaft alternately until they stop
turning and the hex head socket wrench starts to
spring.
STEP 16
BD03A167
Install the bolts and straps that fasten the front drive
shaft to the front axle. Tighten the bolts to a torque of
75 to 81 Nm (55 to 60 pound feet).
STEP 12
Apply antiseize compound to the splines on the front
drive shaft.
STEP 13
Install the yoke to the front drive shaft, making sure BD03A166
the alignment marks made during removal are Install the bolts and straps that fasten the front drive
aligned. shaft to the center drive shaft. Tighten the bolts to a
NOTE: If a new front drive shaft has been installed, torque of 75 to 81 Nm (55 to 60 pound feet).
make sure the yoke being installed is 90° to the yoke
on the other end of the front drive shaft.
6005-6
CENTER BEARING
Removal STEP 19
NOTE: The 921F Series machines use mechanical
style yokes (no bearing straps) and may appear
different from the machine pictured.
STEP 17
BD03A183
Loosen and remove the lock nut that fastens the yoke
to the front drive shaft.
STEP 20
Make an alignment mark on the yoke and the front
BD03A166
drive shaft to be sure that the yoke is installed
Loosen and remove the bolts and straps that fasten
correctly.
the center drive shaft to the front drive shaft.
STEP 21
STEP 18
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.
STEP 23
Loosen the set screws that secure the center bearing
to the front drive shaft.
BD03A183
Loosen and remove the lubrication hose from the
center bearing.
6005-7
STEP 24
BD03A183
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.
6005-8
CENTER BEARING
Installation STEP 29
NOTE: The 921F Series machines use mechanical
style yokes (no bearing straps) and may appear
different from the machine pictured.
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
BC05M214
front drive shaft.
Turn the set screw down to the shaft and then back it
off 1/4th turn and lock it with the jam nut. Repeat the
STEP 27 procedure with the other set screw.
Install the bearing housing so that the lubrication
fitting is at the top.
STEP 30
Apply antiseize compound to the splines on the front
STEP 28 drive shaft. Install the yoke to the front drive shaft,
making sure the alignment marks made during
removal are aligned.
STEP 31
BD03A183
Apply Loctite 242 to bolt threads. Install the bolts,
washers and nuts that fasten the bearing housing to
the front frame. Tighten the bolts to a torque of 99 to
128 Nm (73 to 94 pound feet).
BD03A183
Install the washer and lock nut that fasten the yoke to
the front drive shaft. Tighten the lock nut to a torque
of 339 to 375 Nm (250 to 275 pound feet).
6005-9
STEP 32
BD03A166
Install the straps and bolts that fasten the center
drive shaft to the yoke on the front drive shaft.
Tighten the bolts to a torque of 75 to 81 Nm (55 to 60
pound feet).
STEP 33
Install the lubrication hose into the fitting on the
bearing housing.
STEP 34
Lubr icate the center bear ing with the grease
specified in Section 1002.
6005-10
Removal Installation
NOTE: The 921F Series machines use mechanical NOTE: The 921F Series machines use mechanical
style yokes (no bearing straps) and may appear style yokes (no bearing straps) and may appear
different from the machine pictured. different from the machine pictured.
STEP 35 STEP 39
BD03A166 BD03A165
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 75
to 81 Nm (55 to 60 pound feet).
STEP 36
Use a prybar to disengage the center drive shaft from STEP 40
the yoke of the front drive shaft.
STEP 37
BD03A166
STEP 38
Hold the center drive shaft and remove from the
machine.
6005-11
Removal Installation
NOTE: The 921F Series machines use mechanical NOTE: The 921F Series machines use mechanical
style yokes (no bearing straps) and may appear style yokes (no bearing straps) and may appear
different from the machine pictured. different from the machine pictured.
STEP 41 STEP 45
BD01D323 BD01F304
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 75 to 81 Nm
STEP 42 (55 to 60 pound feet).
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
BD01F304
shaft to the transmission. Tighten the bolts to a
Loosen and remove the bolts and straps that fasten torque of 75 to 81 Nm (55 to 60 pound feet).
the rear drive shaft to the rear axle.
STEP 44
Hold the rear drive shaft and remove from the
machine.
6005-12
Removal Installation
NOTE: The 921F Series machines use mechanical NOTE: The 921F Series machines use mechanical
style yokes (no bearing straps) and may appear style yokes (no bearing straps) and may appear
different from the machine pictured. different from the machine pictured.
STEP 47 STEP 50
BD01D342 BD01D342
Remove and discard the bolts and straps that fasten Place the engine drive shaft into position on the
the engine drive shaft to the transmission. transmission and install new straps and bolts.
Tighten the bolts to a torque of 61 to 81 Nm
IMPORTANT: The bolts and straps that fasten the
(45 to 60 pound feet).
engine drive shaft to the transmission must be
replaced when removed.
STEP 51
STEP 48
BD03A172
UNIVERSAL JOINTS
Removal Installation
NOTE: The 921F Series machines use mechanical NOTE: The 921F Series machines use mechanical
style yokes (no bearing straps) and may appear style yokes (no bearing straps) and may appear
different from the machine pictured. different from the machine pictured.
NOTE: The bearing race and journal that make up
STEP 52 the universal joint are not serviced separately. If the
Remove the drive shaft from the machine. bearing race or journal is worn or damaged, a new
universal joint must be used.
STEP 53
STEP 55
Clean the slots in the yoke of the drive shaft.
2
1
STEP 56
Install the universal joint and install the bearings (2)
and the rings (1). Refer to the photo in Step 53.
STEP 57
Install the drive shaft.
BD01F304
1. RING 2. BEARING
Remove the ring (1) and the bearing (2) from the
drive shaft.
NOTE: The above photo shows the drive shaft on
the machine and is for reference of the ring and
bearing only.
STEP 54
Remove the universal joint from the drive shaft.
6005-14
Section
6006
6006
6006-2
TABLE OF CONTENTS
WHEELS AND BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Torque Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FRONT TIRE PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REAR TIRE PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHANGING TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTALLING A WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
6006-3
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
When inflating a tire off the machine, put death.
the wheel in a tire inflation cage. The 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.
6006-4
INSTALLING A WHEEL
1. Make sure the mounting surfaces of the rim and
axle flange are clean and free of dirt and grease.
2. Install the wheel, hardened washers and wheel
bolts or nuts depending on axle configuration.
THe 721F/821F Heavy Duty Axles and all 921F
axles have wheel studs on the axles and use
wheel nuts.
3. Use a hand wrench (not an impact) to tighten the
wheel b olts to pu ll the wheel against the
planetar y housing. DO NOT use an impact
wrench to tighten the wheel bolts.
4. Tighten the wheel bolts to 278 Nm (205 lb ft.) in
the sequence shown in Figure 1, Figure 2 or
Figure 3. Then tighten to final torque of 640 - 720
Nm (475 - 530 lb ft.).
1 84324413_205.TIF
10 8 FIGURE 2. 821F SERIES WHEEL NUT/BOLT TORQUE
SEQUENCE
6 12
3
4
11 5
7 9
2
B0987A88.TIF
FIGURE 1. 721F SERIES WHEEL NUT/BOLT TORQUE
SEQUENCE
OROR201007RCIL10WHL288BAL1.TIF
FIGURE 3. 921F SERIES WHEEL NUT/BOLT TORQUE
SEQUENCE
TABLE OF CONTENTS
BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE BRAKE AND PARKING BRAKE ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
BRAKE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7001-3
9
5
1 6
10
8
2
BC05M136
BRAKE VALVE
Removal Installation
1. Park the machine on a level surface and lower 1. Install the brake valve (1) in the cab or canopy.
the loader bucket to the floor. Stop the engine. Refer to the illustration on page 5.
2. Put blocks on both sides of each tire to prevent 2. Remove the plugs from the hydraulic lines and
machine movement. connect the hydraulic lines to the brake valve (1).
3. Make sure the brake accumulators are 3. Stop the vacuum pump and remove.
completely discharged. Push down and release 4. Connect all of the electrical connections.
the brake pedals at least 30 times.
5. Turn the master disconnect switch to the ON
4. Turn the master disconnect switch to the OFF position.
position.
6. Bleed the brake system. See Section 7002.
5. Remove the cab skirts located under the cab or
canopy. 7. Install the cab skirts.
6. To release the pressure on the parking brake 8. Check the hydraulic reservoir oil level and add oil
accumulator, the line at the accumulator must be as required. See Section 1002 for the correct oil.
SLOWLY cracked open. A pan will be needed to
catch the hydraulic oil.
7. Connect a drain hose to the quick disconnect
couplings in each brake circuit to release any
pressure in the brake circuit.
8. Clean the brake valve (1) and lines, refer to the
illustration on page 5.
9. Put identification tags on all electrical and
hydraulic lines that are connected to the brake
valve (1).
10. Connect a vacuum pump to the hydraulic
reservoir. Start the vacuum pump
11. Disconnect the lines from the brake valve (1) and
put plugs in each line.
12. Remove the brake valve (1).
7001-5
1
6
2 7
9
4 10
8
5
BC05M137
1. Park the machine on a level surface and lower 20. Install plugs in hoses.
the loader bucket to the floor. Stop the engine.
Installation
2. Put blocks on both sides of each tire to prevent
machine movement. NOTE: 821F and 921F machines are now equipped
with brake Damping Accumulators located on the
3. Make sure the service brake accumulators (1),
front axle (9) and frame (10). See illustration on page
the parking brake accumulator (2), and brake
3.
damping accumulators (9) and (10) are
completely discharged. Push down and release 1. Mount the accumulators (1) in the accumulators
the brake pedal at least 30. clamps (7), do not tighten clamps at this time.
Refer to illustration on page 7.
4. Turn the master disconnect switch to the OFF
position. 2. Connect the tubes to both brake accumulators
(1) and tighten.
5. Remove the left cab skirt located under the cab
or canopy to gain access to accumulators. 3. Tighten accumulator clamp studs (7) to 17Nm
(13 pound feet).
6. To release the pressure on the parking brake
accumulator, the line at the accumulator must be 4. Install the parking brake accumulator (2) into the
SLOWLY cracked open. A pan will be needed to bracket.
catch the hydraulic oil.
5. Install the nut (3) and tighten.
7. Connect a drain hose to the quick disconnect
6. Connect the line to the parking brake
couplings in each brake circuit to release any
accumulator (2).
pressure in the brake circuit.
7. Install the brake damping accumulators (9) and
8. Clean the brake accumulators (1), parking brake
(10).
accumulator (2), brake damping accumulators
(9) and (10) and lines. Refer to illustrations on 8. Connect the lines to the brake damping
pages 3 and 7. accumulators (9) and (10).
9. Put identification tags on the line that is 9. Stop the vacuum pump and remove.
connected to the parking brake accumulator (2).
10. Install the left cab skirt.
10. Connect a vacuum pump to the hydraulic
11. Turn the master disconnect switch to the ON
reservoir. Start the vacuum pump.
position.
11. Disconnect the tubes from both brake
12. Bleed the brake system. See Section 7002.
accumulators (1).
13. Refer to Section 7008 and perform the Parking
12. Loosen the clamp stud (8) on the accumulator
Brake Test Procedure.
clamp (7).
14. Check the hydraulic reservoir oil level and add oil
13. Remove the accumulators (1) from the
as required. See Section 1002 for the correct oil.
accumulator clamps (7).
14. Install plugs in the tubes.
15. Disconnect the hose from parking brake
accumulator (2).
16. Remove the nut (3), remove the parking brake
accumulator (2).
17. Install a plug in the hose.
7001-7
2 3
6
4
7
8
7
1
1
BC05M138
BRAKE PUMP
Removal Installation
1. Park the machine on a level surface and lower 1. Install gear (6) onto the pump shaft, install
the loader bucket to the floor. Stop the engine. washer (7) and slotted nut (8), torque nut to 70 to
79 Nm (52 to 58 pound feet). Refer to the
2. Put blocks on both sides of each tire to prevent
illustration on page 9.
machine movement.
2. Install the cotter pin (9).
3. Turn the master disconnect switch to the OFF
position. 3. Install the brake pump (1), mounting bolts (2) and
washers (3).
4. Clean the brake pump (1) and lines, refer to the
illustration on page 9. 4. Torque mounting bolts (2) to 57 to 65 Nm (42 to
48 pound feet).
5. Put identification tags the lines that are
connected to the brake pump (1). 5. Remove the plugs or caps and connect the lines
to the brake pump (1).
6. Connect a vacuum pump to the hydraulic
reservoir. Start the vacuum pump. 6. Stop the vacuum pump and remove.
7. Disconnect the lines from the brake pump (1) 7. Turn the master disconnect switch to the ON
and put plugs in each line. position.
8. Remove the mounting bolts (2) and washers (3) 8. Bleed the brake system. See Section 7002.
from the brake pump (1) and remove the brake
9. Check the hydraulic reservoir oil level and add oil
pump (1).
as required. See Section 1002 for the correct oil.
7001-9
9 8
7
6
3
2
BC05M139
ABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TROUBLESHOOTING THE HYDRAULIC BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CHARGING THE ACCUMULATOR WITH DRY NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
BLEEDING THE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
BRAKE MODULATION PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Testing the Brake Modulation Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Adjusting the Brake Modulation Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SERVICE BRAKE SYSTEM PERFORMANCE (STORED ENERGY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
BRAKE PUMP OUTPUT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
7002-3
SPECIFICATIONS
Brake pump output ..............................................................................................................42 to 45 L/min at 172 bar
(11 to 12 gpm at 2500 psi at 2000 rpm)
SPECIAL TOOLS
G
94L95
CAS-10899 NITROGEN CHARGING KIT USED TO CHECK AND
CHARGE THE ACCUMULATOR WITH NITROGEN.
BC04A001
380001168 ACCUMULATOR CHARGING ADAPTER
7002-4
2 3
BD06F145
2. Stop the engine. Pump the brake pedal until 9. Make a note of the pressure on the gauges for
there is no pressure in the brake system. the front and rear brakes.
3. Remove the cab skirts to gain access to the 10. The front brake pressure should read 80 to 87
brake test ports. bar (1160 to 1260 psi). This is the modulation
pressure for the front axle.
4. Connect two 207 bar (3000 psi) pressure gauges
to the front brake test port (1) and the rear brake 11. The rear brake pressure should read 78 to 85 bar
test port (2). (1130 to 1230 psi). This is the modulation
pressure for the rear axle
5. Connect two 207 bar (3000 psi) pressure gauges
to the front brake accumulator test port (4) and 12. If the pressures are not within the specified
the rear brake accumulator test port (3). ra n g e, i t w i l l b e n e c e s s a r y t o a d j u s t t h e
modulation pressures.
7002-8
Adjusting the Brake Modulation 1. Remove the tamper evident cover (1).
Pressure NOTE: This is a tamper evident cover and it will be
necessary to install a new cover after the modulation
NOTE: The adjusting bolt to adjust the modulation pressure is adjusted.
pressure is located under the cab, under the brake
pedal. 2. Turn the adjusting bolt to adjust the modulation
pressure.
NOTE: The rear brake modulation pressure cannot
be adjusted separately from the front brake
modulation pressure.
3. Repeat steps 5 through 11 in the Testing the
Brake Modulation Pressure procedure.
4. Repeat these steps until the brake modulation
pressure is within the specified range.
BD00N121
7002-9
2 3
4
BD06F145
NOTE: Prior to doing this procedure make sure that 6. Start the engine and let idle until both the front
the accumulator pressures are correct. and rear accumulators 3 and 4 are fully charged.
1. Check the level of the hydraulic fluid in the The accumulators are fully charged at 190 to 196
reservoir, add as needed. bar (2755 to 2842 psi).
7. Stop the engine.
8. Push the brake pedal down slowly, allowing for
full piston actuation.
NOTE: Depress the brake pedal at the rate of three
strokes per minute.
9. Continue pressing the brake pedal down. The
low brake pressure light should activate when the
pressure reaches 106 to 115 bar (1530 to 1670
psi). After the low brake pressure light activates,
press the brake pedal eight more times.
1 10. Record the readings on the pressure gauges.
The pressure gauges should read at or above
BD00M030 48 to 59 bar (700 to 850 psi).
1. ARTICULATION LOCK
11. If the pressures are at or above 48 to 59 bar (700
2. Install the articulation lock (1) before doing this to 850 psi), the test is complete.
test. 12. If the pressures are not within the required
3. Remove the left side cab skirt to gain access to specifications, then the brake system must be
the brake accumulator test ports. bled.
4. Pump the brake pedal until there is no hydraulic 13. After bleeding the brake system, perform the
pressure in the brake system (approximately 20 brake system check again.
pumps).
5. Connect two 207 bar (3000 psi) pressure gauges
to the test ports 3 and 4.
7002-10
NOTE
4
3
BS03B021
7003
BRAKE PUMP
7003-2
TABLE OF CONTENTS
BRAKE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
7003-3
14
17 15
16
10
18
10
19 13
7
8
9
11
12
11
9 10
8
7
5
4 6
3
2
1
BC06F594
BRAKE PUMP
Disassembly Assembly
1. Secure the pump by the port end cover (13) in a 1. Install a new lip seal (3) into the seal retainer (2)
soft jawed vise. so the lip of the seal will be facing away from the
2. Draw a line the length of the pump to assist gears when the seal retainer (2) is installed into
during assemble. the shaft end cover housing (6).
3. Loosen and remove bolts (15). 2. Install a new lip seal (4) into the shaft end cover
housing (6) with the lip of the seal facing towards
4. Tap the shaft end cover housing (6) with soft the gears.
hammer to loosen it, remove the shaft end cover
housing (6). 3. Install a new O-ring (3) onto the seal retainer (2),
lubricate the O-ring with hydraulic oil.
5. Remove the backup seal (8), channel seal (9),
and thrust plate (11). 4. Press the seal retainer (2) into the shaft end
cover housing (6) and install the retaining ring
6. Remove the drive gear (17) from the gear (1).
housing (12).
5. Place the shaft end housing (6), facing down,
7. Remove the driven gear (16) from the gear into a soft jawed vise.
housing (12).
6. Install new backup seals (8) and channel seals
8. Tap the gear housing (12) with a soft hammer to (9) into the thrust plates (11).
loosen it, remove the gear housing (12).
7. Place a thrust plate (11) onto the shaft end cover
9. Remove the backup seal (8), channel seal (9), housing (6).
and thrust plate (11).
IMPORTANT: Be sure to place the thrust plate (11)
10. Remove the retaining ring (1) form the shaft end
onto the shaft end cover housing (6) in the position
cover housing (6).
shown in the illustration on page 3.
11. Remove the seal retainer (2), O-ring (3), and
8. Lubricate the driven gear (16) with hydraulic oil,
outer lip seal (4) from the shaft end cover
slide the driven gear (16) through the thrust plate
housing (6).
(11) into the shaft end cover housing (6).
12. Remove the inner lip seal (5) from the shaft end
9. Lubricate the drive gear (17) with hydraulic oil,
cover housing (6).
slide the drive gear (17) through the thrust plate
(11) into the shaft end cover housing (6).
Inspection
10. Install a new quad ring (7) into the gear housing
(12). Check that dowel pins (10) are in place
1. Discard all seals and quad rings. Clean all parts either in the gear housing (12) or the shaft end
in cleaning solvent. Check all machined surfaces cover housing (6).
for damage or wear.
11. Align the marks made during disassembly,
2. Hold a straightedge across each gear housing carefully place the gear housing (12) onto the
and use a feeler gauge to measure the amount gears.
of wear caused by the gear teeth in the gear
12. Slide the thrust plate (11) onto the shafts of the
pocket. If the wear in any gear pocket is more
gears.
than 0.18 MM. (0.007 inch), use a new gear
housing. IMPORTANT: Be sure to place the thrust plate (11)
3. Inspect the thrust plates for scoring, pitting, or onto the gears in the position shown in the illustration
other damage. on page 3.
4. Inspect the gears for wear and damage. There 13. Install a new quad ring (7) into the gear housing
must be no scoring on the gear hubs or on the (12). Check that dowel pins (10) are in place
outside edges of the gear teeth. There must be either in the gear housing (12) or the port end
no more than 0.05 MM. (0.002 inch) wear in the cover housing (13).
seal area of the drive shaft. If any gear must be 14. Align the marks made during disassembly, place
discarded, you must use a new hydraulic pump. the port housing (12) onto the gear housing (12).
15. Install bolts (15) with clean and dry threads,
washers (14). Torque bolts to 192 ± 5.5 Nm
(141.5 ± 4 pound feet).
Section
7004
7004
BRAKE ACCUMULATORS
7004-2
TABLE OF CONTENTS
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHARGING THE ACCUMULATOR WITH DRY NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Temperature/Charge Pressure Brake Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
7004-3
SPECIAL TOOL
C E
G
D B A
94L95 BC04A001
PARKING BRAKE
7008
7008-2
TABLE OF CONTENTS
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PARKING BRAKE TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
7008-3
PARKING BRAKE
Disassembly STEP 7
STEP 1
Park the machine on a hard level surface and lower
the loader bucket to the ground.
STEP 2
Place wheel chocks on each wheel to prevent
machine movement.
STEP 3
BD03A185
STEP 8
BD01F143
STEP 4
Place the master disconnect switch in the OFF
position.
STEP 5 BD03A186
Remove the retainer pin and brake pin.
Pump the brake pedal at least 30 times to discharge
the accumulators.
STEP 9
STEP 6
BD03A187
Remove the two brake pads from the parking brake
BD03A184 assembly.
Loosen and remove the cover from the parking
brake.
7008-4
Inspection STEP 14
Disengage the parking brake.
STEP 10 NOTE: Hydraulic pressure will not be applied to the
Clean and inspect all parts for wear and damage. parking brake until the parking brake rocker switch is
Inspect the brake disc for wear and damage. turned off, the service brakes applied and the
transmission is put into gear.
Replace all parts that are worn or damaged.
A. Place the parking brake rocker switch in the
OFF position.
Assembly
B. Apply the service brake and put the machine
STEP 11 into gear.
C. The parking brake light on the cluster will turn
off at this time.
Place the transmission back into neutral before
proceeding.
STEP 15
BD03A187
STEP 12
BD0CA185
STEP 16
Install the cover on the parking brake.
STEP 17
Perfor m the Parking Brake Test Procedure as
BD03A186
described in this section.
Install the brake pins and retainer pins.
STEP 18
STEP 13
Return the articulation lock to the operating position.
Place the master disconnect switch to the on
position. Start the machine and run the engine at low
idle with the bucket resting on the ground.
IMPORTANT: It will be necessary to have an
assistant help for this procedure. An operator must
be present in the cab at all times to apply the service
brakes and shut down the machine in the event of
mechanical failure.
7008-5
STEP 20
Start the machine and run the engine at low idle in
third gear neutral.
RCPH10WH381BAH
STEP 22
Place the Parking Brake switch to the ON position.
STEP 23
BD06F143
STEP 26
Shift the gear selector into third gear forward and
slowly increase the engine speed to wide open
throttle.
STEP 27
Verify that the machine does not move.
STEP 28
Reduce the engine speed to low idle and return the
transmission neutral.
7008-6
STEP 29
Shift the gear selector to third gear reverse and
slowly increase the engine speed to wide open
throttle.
STEP 30
Verify that the machine does not move.
STEP 31
Reduce the engine speed to low idle and return the
transmission to neutral.
STEP 32
BD06F141
STEP 33
If any machine movement was detected, the parking
brake must be adjusted, see procedures this section.
8001
Section
8001
TABLE OF CONTENTS
LOADER CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic Valve Pilot Line Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Loader Control Valve Line Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REMOTE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Joystick and 2 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Joystick and 1 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Joystick Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
LIFT CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
BUCKET CYLINDER - Z-BAR LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
RIDE CONTROL ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
RIDE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
FAN REVERSING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
THERMAL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8001-3
Removal STEP 5
STEP 1
Park the machine on a level surface.
IMPORTANT: If machine is equipped with
quick-attached components, disconnect them from
machine prior to proceeding.
STEP 2
BD06H198
STEP 6
Loosen the filler cap on the reservoir to release the
air pressure in the reservoir.
BD03A092
STEP 7
Raise the lift arms and install the safety link on the lift
arm cylinder. Drain the hydraulic reservoir.
STEP 3 STEP 8
Stop the engine and apply the parking brake.
IMPORTANT: With the engine NOT running, pump
the brake repeatedly to be sure the brake
accumulators have no hydraulic pressure, put the
ignition switch in the ON position then move the
loader control valve back and forth several times to
release any hydraulic pressure in the pilot control
circuit, turn ignition switch OFF.
STEP 4
Place the master disconnect switch in the OFF
position.
BD03A093
REAR OF MACHINE
6
7
5
3
1
2 4
BC05M094
1 2
3
4
6 7
BC05M093
STEP 10
Loosen and remove tilt cylinder lines (1 and 2). Install
a plug in each line and a cap on each fitting.
STEP 11
Loosen and remove lines (3 and 4). Install a plug in
each line and a cap on each fitting.
STEP 12 BC05M096
Loosen and remove lines (6 and 7). Install a plug in Install and align the loader control valve with the
each line and a cap on each fitting. valve mounting plate.
STEP 13 STEP 17
Loosen and remove supply and return lines. Install a Install the bolts and washers that fasten the loader
plug in each line and a cap on each fitting. control valve to the valve mounting plate. Tighten the
bolts.
STEP 14
Attach proper lifting equipment to lift loader control STEP 18
valve. Tighten the left lift cylinder lines (6 and 7).
STEP 15 STEP 19
Install and tighten the supply and return lines.
STEP 20
Install and tighten right lift cylinder lines (3 and 4).
STEP 21
Install and tighten tilt cylinder lines (1 and 2).
STEP 22
Connect the hoses (3, 4, 7, 8 if equipped 1, 2, 5, and
6) to the remote control valve(s) at the loader control
BC05M096
valve. Refer to the illustration on page 4 for color
Loosen and remove the three bolts and washers that
coding.
hold the loader control valve to the valve mounting
plate. Remove the loader control valve.
8001-7
STEP 23 STEP 27
Fill the hydraulic reservoir with oil. Refer to Section Run engine at half throttle.
1002 for the correct oil.
STEP 28
STEP 24 Slowly and completely extend and retract all
Tighten the accumulator manual bleeder valve cylinders at least 10 times to remove any air from the
located on the top of the ride control valve to a torque circuits.
of 3.5 Nm (31 lb-in). Install the plug and torque to
7 Nm (62 lb-in). STEP 29
Stop the engine and check for leaks.
STEP 25
Place the master disconnect switch in the ON STEP 30
position. Install the access cover on the front of the machine.
STEP 26 STEP 31
Check the level of the hydraulic oil and add hydraulic
oil as required.
BD03A092
Removal STEP 37
STEP 32
Park the machine on a level surface and lower the
bucket to the floor. Stop the engine and apply the
parking brake.
IMPORTANT: With the engine NOT running, pump
the brake repeatedly to be sure the brake
accumulators have no hydraulic pressure, put the
ignition switch in the ON position then move the
loader control valve back and forth several times to
release any hydraulic pressure in the pilot control
circuit, turn ignition switch OFF. BD06F208
STEP 34
Unlatch and open the right hand side access door.
STEP 35
Lift the access door up and remove the access door
from the pins.
STEP 36
BD06F209
STEP 39
BD06F207
BD06F210
STEP 40
Loosen the filler cap on the reservoir to release any
air in the reservoir. Connect a vacuum pump to the
hydraulic reservoir, turn on the pump.
8001-9
STEP 41 Installation
Put identification tags on each hose and disconnect
one at a time from the remote control valve. Install STEP 45
plugs in the hoses and caps on the fittings. Install new O-rings on the adapters for the remote
control valve.
STEP 42
Loosen and remove the screws and washers holding STEP 46
the hydraulic control tower cover. Remove the cover. Install the remote control valve and screws in the
hydraulic control tower and tighten the screws.
STEP 43
Loosen and remove the screws that fasten the STEP 47
remote control valve to the hydraulic control tower. Install the cover over the remote control valve and
install the screws and washers.
STEP 44
Remove the remote control valve from the hydraulic STEP 48
control tower. Remove the plugs from the hoses and the caps from
the fittings and connect the hydraulic hoses to the
fittings according to the identification tags. (Refer to
illustrations on pages 11, 12, and 13 as necessary.
STEP 49
Turn off the vacuum pump and disconnect from the
hydraulic reservoir.
STEP 50
BD06F210
STEP 51
Place the master disconnect switch in the ON
position.
STEP 52
Start the engine and run the engine at low idle.
STEP 53
Check to see that the remote control valve works
correctly.
8001-10
STEP 54 STEP 57
Check for hydraulic oil leakage at the remote control
valve.
STEP 55
Check the level of hydraulic oil in the reservoir and
add as required.
STEP 56
BD06F208
STEP 58
BD06F209
BD06F207
3
8
6
7
1
5
7 8
7 5
1 2
8 3
6 4
BC05M092
5 5
7 1 4 7
3
4
6 3
2 1
6
2
7 7
7 7
1 1
2 2
6 6
3 3
4 5 4 5
BC05M091
1
5
4 5 4 6
6 3 2
3 1
2
2 1 2 1
6 6
3 3
4 5 4 5
BC05M090
HYDRAULIC PUMP
10
7 15
4
6
4
16
5
8 15
6
2 13
3
14
11
9
12
BC05M095
1. PUMP MAIN HYDRAULIC 5. SPLIT FLANGE 9. STEERING HIGH PRESSURE 13. LOADER HIGH PRESSURE
2. MOUNT BOLTS 6. TUBE 10. CLAMPS 14. STEERING PRIORITY MANIFOLD
3. DRAIN HOSE 7. HOSE SUCTION 11. STEERING LOAD SENSE HOSE 15. CLAMPS
4. BOLT 8. HOSE CASE DRAIN 12. LOADER LOAD SENSE HOSE 16. FITTINGS
8001-15
Removal STEP 69
Connect lifting equipment to hydraulic pump (1). Take
NOTE: When disconnecting hydraulic fittings, plug
up all slack in lifting equipment. Remove four
hoses and cap fittings to prevent entry of foreign
mounting bolts (2) and washers securing pump to
matter into hydraulic system.
transmission. Pull hydraulic pump from transmission
and remove from loader. Remove and discard O-ring
STEP 59 from pump.
Park the machine on a level surface and lower the
bucket to the floor. Stop the engine and apply the Installation
parking brake.
NOTE: Install new O-rings where required.
STEP 60
Place the master disconnect switch in the OFF STEP 70
position. Install new O-ring on hydraulic pump flange. Move
pump into position and install in transmission. Install
STEP 61 four washers and bolts (2) to secure pump (1) to
Loosen the filler cap on the reservoir to release any transmission, tighten the bolts. Disconnect lifting
air in the reservoir. Connect a vacuum pump to the equipment from pump.
hydraulic reservoir, turn on the pump.
STEP 71
STEP 62 Connect pump pressure hoses (9 and 13) to steering
Refer to Section 9007 and remove the ROPS cab or priority manifold (14).
ROPS canopy.
STEP 72
STEP 63 Connect drain hose (3).
Remove eight bolts (4) and washers. Remove four
split flanges (5). Disconnect tubes (6) with suction STEP 73
hoses (7) from hydraulic pump. Remove and discard Connect load sense hoses (11 and 12).
O-ring face seals from flange heads of tubes.
STEP 74
STEP 64 Install and connect case drain hoses (8).
Loosen clamps (10). Tag and disconnect suction
hoses (7) from hydraulic reservoir and remove from STEP 75
machine. Install suction hoses (7), tighten clamps (10) to 10 to
11 Nm (90 to 100 pound inches).
STEP 65
Tag and disconnect case drain hoses (8) from fittings STEP 76
(16); remove hoses (8). Remove and discard O-ring Install four split flanges (5). Install eight bolts (4) and
face seals from fittings. washers, tighten bolts (4) to 73 to 90 Nm (53.8 to
66.3 pound feet).
STEP 66
Tag and disconnect load sense hoses (11 and 12). STEP 77
Remove and discard O-ring face seals from fittings. Refer to Section 9007 and install the ROPS cab or
ROPS canopy.
STEP 67
Tag and disconnect drain hose (3). Remove and STEP 78
discard O-ring face seals from fittings. Turn off the vacuum pump and disconnect from the
hydraulic reservoir.
STEP 68
Tag and disconnect pump pressure hoses (9 and 13) STEP 79
from steering priority manifold (14). Remove and Place the master disconnect switch in the ON
discard O-ring face seals from flange heads of position.
hoses.
8001-16
STEP 80 STEP 81
Start the engine and run the engine at low idle for two Stop the engine and check for hydraulic oil leakage at
minutes. the hydraulic pump.
NOTE: If any unusual vibration is heard coming from
the pump, stop the machine immediately and check STEP 82
for obstructions in the pump suction line. Check the level of the hydraulic oil in the reservoir
and add hydraulic oil as required.
8001-17
LIFT CYLINDERS
Removal STEP 87
STEP 83
Park the machine on a level surface and lower the
bucket to the floor. Stop the engine and apply the
parking brake.
IMPORTANT: With the engine NOT running, pump
the brake repeatedly to be sure the brake
accumulators have no hydraulic pressure, put the
ignition switch in the ON position then move the
loader control valve back and forth several times to
release any hydraulic pressure in the pilot control
circuit, turn ignition switch OFF.
BD01D709
STEP 84 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 88
STEP 85
Loosen the filler cap on the hydraulic reservoir to
release any pressure.
STEP 86
BD01D711
STEP 89
BD01D708
BD01D712
Remove the pivot pin from the yoke end of the lift
cylinder.
8001-18
STEP 90 Installation
STEP 93
Apply antiseize compound to the bores in the front
frame and the yoke on the piston rod.
STEP 94
BD01D710
STEP 91
BD01D714
STEP 95
BD01D713
Remove the pivot pin from the closed end of the lift
cylinder.
STEP 92
Remove the lift cylinder from the machine
BD01D713
Align the closed end of the lift cylinder with the front
frame and install the pivot pin.
8001-19
STEP 96 STEP 99
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 100
STEP 97
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 101
STEP 98 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 102
SLOWLY move the yoke into alignment with the Lubricate the pivot pins with molydisulfide grease.
loader frame.
STEP 103
Check the level of hydraulic oil in the reservoir and
add as required. Tighten the filler cap on the
hydraulic reservoir.
8001-20
STEP 104
Park the machine on a level surface and lower the
bucket to the floor. Stop the engine and apply the
parking brake.
STEP 105
With the engine stopped, move the bucket control
lever to release pressure in the bucket circuit.
STEP 106
BD01D695
STEP 109
BD01D694
STEP 107
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 114
STEP 111
BD01D704
BD01D700 Remove the pivot pin from the head end of the bucket
Use acceptable equipment to hold the 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 112 replaced.
STEP 115
BD01D698
STEP 116
Apply antisieze compound to the bores in the front
frame and the bores in the loader arm for the bucket
cylinder.
STEP 117
BD01D699
STEP 121
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 123
BD01D704
STEP 119 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.
8001-23
STEP 124 STEP 127
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 129
Start and run the engine at low idle.
STEP 130
SLOWLY extend and retract the piston rod three
times to remove any air from the bucket cylinder.
STEP 131
Lubricate the pivot pins with molydisulfide grease.
BD01D695
Install the two bolts for the mounting bracket for the STEP 132
target bar.
Check the level of the hydraulic oil in the reservoir
and add as required. Tighten the filler cap on the
STEP 126 hydraulic reservoir.
BD01D696
Install the two bolts that fasten the target bar to the
mounting bracket.
8001-24
OIL COOLER
STEP 133
Park the machine on a level surface and lower the
bucket to the ground. Stop the engine and apply the
parking brake.
STEP 134
Place the master disconnect switch in the OFF
position.
STEP 135
Raise the engine hood and remove the shield on the
right side of the machine between the tire and the oil BD03A154
cooler. Disconnect the top hose and install a plug in the hose
and a cap on the fitting.
STEP 136
STEP 139
BD03A120
BD06H195
Disconnect the hose from the bottom of the oil cooler.
Install a plug in the hose and a cap on the fitting.
Remove the two mounting nuts, remove the oil cooler
from the machine.
8001-25
STEP 141
BD03A120
STEP 147
Start the engine and run the engine at low idle for two
minutes. Stop the engine and check for hydraulic oil
leakage at the ports on the oil cooler.
STEP 148
Install the shield between the right rear tire and the
oil cooler and tighten the two bolts holding the shield.
BD03A179
Install the bolt and washer that fasten the oil cooler to STEP 149
the cooling frame Check the level of the hydraulic oil in the reservoir
and add hydraulic oil as required.
STEP 143
BD03A154
STEP 150
Park the machine on a level surface and lower the
bucket to the floor. Stop the engine and apply the
parking brake.
IMPORTANT: With the engine NOT running, pump
the brake repeatedly to be sure the brake
accumulators have no hydraulic pressure, put the
ignition switch in the ON position then move the
loader control valve back and forth several times to
release any hydraulic pressure in the pilot control
circuit, turn ignition switch OFF. BD06H196
Disconnect the hose from the elbow at the bottom of
STEP 151 the ride control accumulator. Install a plug in the hose
and a cap on the fitting.
STEP 154
BD06H198
valve two turns counter-clockwise. Loosen and remove the nuts and washers from the
U-bolt. Remove the U-bolt.
STEP 152
Loosen the filler cap on the hydraulic reservoir to
STEP 155
Loosen and remove the two bolts that fasten the
release the air pressure in the reservoir. Connect a
accumulator bracket to the front frame. Remove the
vacuum pump to the hydraulic reservoir, turn on the
ride control accumulator from the machine.
pump.
8001-27
STEP 156
Place the ride control accumulator in position on the
front frame.
STEP 157
Install the two bolts that fasten the accumulator
bracket to the front frame. Tighten the bolts.
STEP 158
BD06H196
STEP 160
Turn off and disconnect the vacuum pump from the
hydraulic reservoir.
STEP 161
BD06H197
Tighten the accumulator manual bleeder valve
Install the U-bolt, washers and nuts. Tighten the nuts. located on the top of the ride control valve to a torque
of 3.5 Nm (31 lb-in). Install the plug and torque to
7 Nm (62 lb-in).
STEP 162
Refer to Section 8002 Testing the Ride Control for
the proper charging of the accumulator to check for
leaks.
STEP 163
Check the level of the hydraulic oil in the reservoir
and add as required. Tighten the filler cap on the
hydraulic reservoir.
8001-28
STEP 170
Loosen and remove the two bolts and washers that
fasten the ride control valve to the frame.
STEP 171
Remove the ride control valve from the machine.
STEP 172
BD06H198 Remove and discard all O-rings.
Relieve the pressure in the ride control accumulator
with the manual bleeder valve located on the top of
the ride control valve. Remove the plug and turn the
valve two turns counter-clockwise.
8001-29
STEP 181
Start and run the engine at low idle for two minutes.
STEP 182
Stop the engine and check for hydraulic oil leakage at
the ride control valve.
STEP 183
Check the level of the hydraulic oil in the reservoir
and add as required. Tighten the filler cap on the
BD06H198 hydraulic reservoir.
Tighten the accumulator manual bleeder valve
located on the top of the ride control valve to a torque STEP 184
of 3.5 Nm (31 lb-in). Install the plug and torque to Refer to Section 8002 and perform the Ride Control
7 Nm (62 lb-in). Test Procedure.
STEP 176
Lubricate and install new O-rings.
STEP 177
Connect the hoses to the ride control valve.
8001-30
STEP 185
Park the machine on a level surface and lower the
bucket to the ground. Stop the engine and apply the
parking brake.
IMPORTANT: With the engine NOT running, pump
the brake repeatedly to be sure the brake 2
accumulators have no hydraulic pressure, put the
ignition switch in the ON position then move the
loader control valve back and forth several times to
1
release any hydraulic pressure in the pilot control
circuit, turn ignition switch OFF.
BD03A174
STEP 186 Tag and disconnect the fan forward hose (1) from the
Loosen the filler cap on the hydraulic reservoir to fan reversing valve. Install a plug in the hose and a
release the air pressure in the reservoir. Connect a cap on the fitting. Tag and disconnect the fan reverse
vacuum pump to the hydraulic reservoir, turn on the hose (2) from the fan reversing valve. Install a plug in
pump. the hose and a cap on the fitting.
3
4
BD03A173
BD03A174
Tag and disconnect the fan valve return hose (3) from
Disconnect the electrical connector for the fan the fan reversing valve. Install a plug in the hose and
reversing valve. a cap on the fitting. Tag and disconnect the fan valve
supply hose (4) from the fan reversing valve. Install a
plug in the hose and a cap on the fitting.
STEP 190
Loosen and remove the nuts, washers and bolts.
STEP 191
Remove the fan reversing valve from the machine.
STEP 192
Remove and discard all O-rings from the fittings.
8001-31
STEP 193
Place the fan reversing valve into position on the
machine.
STEP 194
Lubricate and install new O-rings in the fittings.
STEP 195
Install the bolts, washers and nuts. Tighten the nuts.
STEP 196
BD03A174
STEP 199
Turn off the vacuum pump and disconnect from the
hydraulic reservoir.
STEP 200
3 Check the level of the hydraulic oil in the reservoir.
4
STEP 201
BD03A173
Connect the fan valve supply hose (4) to the fitting on Start the engine and run the engine at low idle for two
the fan reversing valve. Connect the fan valve return minutes.
hose (3) to the elbow on the fan reversing valve.
STEP 202
STEP 197 Stop the engine and check for hydraulic oil leakage at
the fan reversing valve.
STEP 203
Check the level of the hydraulic oil in the reservoir
and add as required. Tighten the filler cap on the
reservoir.
BD03A174
THERMAL VALVE
Removal Installation
STEP 204 STEP 208
Park the machine on a level surface and lower the Place the thermal valve into position on the machine.
bucket to the ground. Stop the engine and apply the
parking brake. STEP 209
IMPORTANT: With the engine NOT running, pump Lubricate and install new O-rings in the fittings.
the brake repeatedly to be sure the brake
accumulators have no hydraulic pressure, put the STEP 210
ignition switch in the ON position then move the Install the bolts, washers and nuts. Tighten the nuts.
loader control valve back and forth several times to
release any hydraulic pressure in the pilot control STEP 211
circuit, turn ignition switch OFF.
Connect the hoses to the thermal valve, remove and
discard tags.
STEP 205
Loosen the filler cap on the hydraulic reservoir to STEP 212
release the air pressure in the reservoir. Connect a
Turn off the vacuum pump and disconnect from the
vacuum pump to the hydraulic reservoir, turn on the
hydraulic reservoir.
pump.
STEP 213
STEP 206
Check the level of the hydraulic oil in the reservoir.
STEP 214
Start the engine and run the engine at low idle for two
minutes.
STEP 215
Stop the engine and check for hydraulic oil leakage at
the thermal valve.
STEP 216
BD06F211
Check the level of the hydraulic oil in the reservoir
Tag and disconnect the hoses from the thermal valve. and add as required. Tighten the filler cap on the
Install a plug in the hose and a cap on the fitting. reservoir.
STEP 207
Remove the mounting bolts from the thermal valve,
remove the valve from the machine.
8002
Section
8002
TABLE OF CONTENTS
821F - SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
921F - SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Problems in All Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Problem in All Loader Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Problem in the Braking Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Problem in a Single Loader Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Problem in the Steering Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Problem in the Ride Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TESTING AND ADJUSTING THE HIGH PRESSURE
PUMP DIFFERENTIAL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Adjusting the High Pressure Pump Differential Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
TESTING AND ADJUSTING THE LOW PRESSURE
PUMP DIFFERENTIAL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Adjusting the Low Pressure Pump Differential Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
TESTING AND ADJUSTING THE LOADER LIMIT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Adjusting the Loader Limit Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
TESTING AND ADJUSTING THE STEERING LIMIT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Adjusting the Steering Limit Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
TESTING AND ADJUSTING THE LOADER PUMP CUTOFF PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Adjusting the Loader Pump Cutoff Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
TESTING THE HYDAULIC CONTROLLER PILOT SUPPLY PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
HIGH PRESSURE PUMP FLOW TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
TESTING AND ADJUSTING THE CIRCUIT RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
TESTING THE RIDE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
HYDRAULIC COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8002-3
821F - SPECIFICATIONS
Manufacturer........................................................................................................................................ Bosch-Rexroth
High pressure pump (closest to transmission) .................................................... 120 L/min at 172 bar, at 2000 r/min
(31.6 gpm at 3600 psi at 2000rpm)
Low pressure pump (furthest from transmission) ................................................ 120 L/min at 172 bar, at 2000 r/min
(31.6 gpm at 2000 psi at 2000rpm)
Main relief valve pressure settings .........................................................................248 to 255 bar (3600 to 3700 psi)
Circuit relief valve pressure setting
Auxiliary A and B port.................................................................................................................290 bar (4200 psi)
Bucket A port..............................................................................................................................290 bar (4200 psi)
Bucket B port..............................................................................................................................290 bar (4200 psi)
Pilot accumulator pressure .............................................................................................13 to 15 bar (188 to 218 psi)
Steering relief valve pressure setting ............................................................................................. See Section 5002
Brake accumulator pressure .......................................................................................................... See Section 7002
NOTE: Both pump sections provide flow for both the steering and loader functions.
8002-4
921F - SPECIFICATIONS
Manufacturer ....................................................................................................................................... Bosch-Rexroth
High pressure pump (closest to transmission) ............................................... 170 L/min at 24822 kPa, at 2000 r/min
(44.9 gpm at 3600 psi at 2000rpm)
Low pressure pump (furthest from transmission) ........................................... 120 L/min at 24822 kPa, at 2000 r/min
(31.6 gpm at 2000 psi at 2000rpm)
Main relief valve pressure settings .........................................................................248 to 255 bar (3600 to 3700 psi)
Circuit relief valve pressure setting
Auxiliary A and B port ................................................................................................................290 bar (4200 psi)
Bucket A port..............................................................................................................................290 bar (4200 psi)
Bucket B port..............................................................................................................................290 bar (4200 psi)
Pilot accumulator pressure .............................................................................................13 to 15 bar (188 to 218 psi)
Steering relief valve pressure setting ............................................................................................ See Section 5002
Brake accumulator pressure .......................................................................................................... See Section 7002
NOTE: Both pump sections provide flow for both the steering and loader functions.
8002-5
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
8002-6
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
See Section 8003 and check for contaminated See Page 19. Do the flow meter test 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 21. Check and adjust the circuit See Section 8005. Disassemble the loader
relief valves. Then check the operation of c o n t r o l va l ve a n d c h e ck fo r wo r n o r
No
the circuit again. Does the circuit work damaged parts.
correctly?
Yes
Yes
Yes
STEP 1
BD06G180
BD00M041
1. ARTICULATION LOCK 2
STEP 2
Make sure that the temperature of the hydraulic oil is
at least 54°C to 57°C (129°F to 135°F). The following
is the procedure for heating the hydraulic oil.
BD06F148
● To measure the oil temperature with the instrument 1. TEST PORT (LOAD SENSE)
cluster: 2. TEST PORT (PUMP PRESSURE)
A. Start the engine and run at full throttle. IMPORTANT: Do not steer or operate loader controls
while the gauges are connected, gauges could be
B. Hold the bucket control lever in the damaged.
RO L L B AC K p o s i t i o n w h i l e ra i s i n g a n d
lowering the lift arms from ground level to full STEP 4
height.
Start the engine and run at low idle.
C. Continue this procedure until the temperature
of the hydraulic oil is 54° to 57°C (129° to STEP 5
135°F).
Make sure all of the controls are in the neutral
After heating oil to operating temperature, lower position and record the readings on the test gauges
bucket to the ground, turn off the engine, and relieve (1) and (2).
all pressure in the hydraulic system.
STEP 6
Subtract the reading of the test port (1) from the
reading of the test port (2).
8002-9
STEP 7 Adjusting the High Pressure Pump
The difference between the two readings should be Differential Pressure
24 to 27 bar (350 to 390 psi).
STEP 9
STEP 8
The load-sense adjusting screw is directly below the
If this reading is more or less than specified, it will be load-sense pressure tap. Turn the screw clockwise to
necessary to adjust the pump load-sense pressure. increase the load-sense pressure. Turning the screw
counterclockwise will decrease the load-sense
pressure.
NOTE: One turn of the adjustment screw will change
the pressure approximately 16 bar (230 psi).
8002-10
STEP 1
BD06G180
1
2
BD00M041
1. ARTICULATION LOCK
STEP 2
Make sure that the temperature of the hydraulic oil is
at least 54°C to 57°C (129°F to 135°F). The following
is the procedure for heating the hydraulic oil.
BD06F148
● To measure the oil temperature with the instrument 1. TEST PORT (LOAD SENSE)
cluster: 2. TEST PORT (PUMP PRESSURE)
A. Start the engine and run at full throttle. IMPORTANT: Do not steer of operate loader controls
while the gauges are connected, gauges could be
B. Hold the bucket control lever in the damaged.
RO L L B AC K p o s i t i o n w h i l e ra i s i n g a n d
lowering the lift arms from ground level to full STEP 4
height.
Start the engine and run at low idle.
C. Continue this procedure until the temperature
of the hydraulic oil is 54° to 57°C (129° to STEP 5
135°F).
Make sure all of the controls are in the neutral
After heating oil to operating temperature, lower position and record the readings on the test gauges
bucket to the ground, turn off the engine, and relieve (1) and (2).
all pressure in the hydraulic system.
STEP 6
Subtract the reading of the test port (1) from the
reading of the test port (2).
8002-11
STEP 7 Adjusting the Low Pressure Pump
The difference between the two readings should be Differential Pressure
25 to 28 bar (360 to 400 psi).
STEP 9
STEP 8
The differential adjusting screw is directly below the
If this reading is more or less than specified, it will be load-sense pressure tap. Turn the screw clockwise to
necessary to adjust the pump differential pressure. increase the load-sense pressure. Turning the screw
counterclockwise will decrease the differential
pressure.
NOTE: One turn of the adjustment screw will change
the pressure approximately 16 bar (230 psi).
8002-12
STEP 4
1 Run the engine at full throttle.
STEP 5
Roll the loader bucket back against the stops.
STEP 6
Record the reading on the test gauge.
BD06F148
BD06H193
8002-14
STEP 4
1 Start the engine and run at full throttle.
STEP 5
Steer hard in either direction over relief pressure.
STEP 6
Record the reading on the test gauge.
BD06F148
BD06F147
STEP 4
Start the engine and run at full throttle.
STEP 5
Roll the loader bucket back against the stops.
STEP 6
Record the reading on the test gauge.
BD06F148
BD06G179
STEP 5
Start machine and lower the bucket to the ground
and turn off the engine. Turn the ignition switch to the
“RUN” position, operate the pilots controls a
minimum of 30 strokes to relieve any pressure in the
system.
8002-19
STEP 2 STEP 8
Disconnect the load sense hose (7) and install a cap Open the needle valve (8) and operate the engine at
(12) the fitting at the loader valve (15). 2000 rpm. At 0 bar (0 psi) the flow should be 250 to
NOTE: This is the line that returns to the pump 255 L/min (66 to 67.4 gpm).
compensator valve.
STEP 9
STEP 3 Close the flow meter valve slowly and read the flow
Connect a “T” fitting (10) into the loader control valve at 34.5 bar (500 psi) the flow should be 249 to 255
inlet hose (6) and to the flow meter inlet hose (11). L/min (65.8 to 66.8 gpm).
STEP 4 STEP 10
Use a union (9) and connect an in line needle valve Close the flow meter valve slowly and read the flow
(8) to the open port in the “T” fitting (10), connect the at 2000 psi @ 2000 rpm. The flow should read 244.5
load sense hose (7) to the needle valve (8). to 247.5 L/min (64.6 to 65.4 gpm).
STEP 5 STEP 11
Make sure that the flow meter valve and the installed Continue to close the flow meter valve slowly, at
needle valve are in the open position. Start and run approximately 2900 psi the flow should drop
the engine at high idle, slowly close the flow meter significantly, this will be the low pressure pump
valve until a pressure reading of 103 bar (1500 psi) is destroking.
obtained.
STEP 12
Continue slowly closing the flow meter valve until
3500 psi is reached. The flow should read between
120 to 122 L/min (31.6 and 32.1 gpm).
STEP 13
If any of the pump flow readings are not within
specifications, the pump may be out of calibration
and Technical Support Services should be contacted.
8002-20
2 4
3
5
6
11
12
13
7
10
9
12
8
14
15
BS06G117
1. HYDRAULIC RETURN MANIFOLD 6. HOSE M42 ORB 11. FLOW METER INLET HOSE
2. FLOW METER RETURN HOSE 7. LOAD SENSE HOSE M14 ORB 12. CAP
3. FLOW METER 8. NEEDLE VALVE 13. VALVE TUBE SUPPLY
4. PUMPS 9. UNION 14. ELBOW M14 ORB
5. PRIORITY VALVE 10. T FITTING 15. LOADER VALVE
NOTE: IF UNIT IS EQUIPPED WITH AUXILIARY STEERING A TEE FITTING WILL HAVE TO BE USED IN THIS LOCATION
8002-21
4 STEP 5
3 5
1 Connect the hand pump to the disconnected line that
1 goes to the loader control valve.
2
STEP 6
Make sure that the hand pump is full of hydraulic oil
and that the temperature of the oil is approximately
21°C (70°F).
STEP 7
Operate the handle of the hand pump and read the
highest pressure. Repeat this step several times to
6 be sure of the reading.
STEP 8
Compare the reading to the specifications on Page 3.
STEP 9
1 If the pressure is not correct, adjust the circuit relief
1
valve.
3 5
4 Adjustment
BS03B022
STEP 10
If test was completed in the allotted time and the lift
arms still do not rise, test the nitrogen charge in the
accumulator, see section 8013.
8002-23
5
6 8
7
9
4 10
2 8
3
11
15 12
14 13
16
19
18
17
1
BC00N140
1. REAR BRAKE CYLINDERS 11. FRONT BRAKE CYLINDERS
2. BRAKE ACCUMULATOR PRESSURE DIAGNOSTIC 12. RIDE CONTROL ACCUMULATOR BLEEDER VALVE AND
COUPLER RIDE CONTROL VALVE (OPTIONAL)
3. BRAKE ACCUMULATORS 13. PARKING BRAKE CYLINDER
4. FRONT AND REAR AXLE BRAKE PRESSURE 14. STEERING PRESSURE DIAGNOSTIC COUPLER
DIAGNOSTIC COUPLERS 15. STEERING PRIORITY VALVE
5. BRAKE LIGHT PRESSURE SWITCH 16. STEERING CYLINDERS
6. BRAKE WARNING PRESSURE SWITCH 17. AUXILIARY STEERING PUMP AND MOTOR
7. BRAKE AND ACCUMULATOR CHARGING VALVE
18. AUXILIARY STEERING PRIORITY VALVE
8. LIFT CYLINDERS
19. AUXILIARY STEERING PRESSURE SWITCH
9. BUCKET CYLINDER (TILT CYLINDER)
10. RIDE CONTROL ACCUMULATOR
NOTE: The hydraulic schematic is located in the rear pocket. All numbers are coordinated with the hydraulic
schematic for reference.
8002-24
23
24
21 25
26
22
20
30
29 27
28
31
32
33
34
BC00N140
8003
CLEANING THE HYDRAULIC SYSTEM
8003-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TYPES OF CONTAMINATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CLEANING THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FLUSHING WATER FROM THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
8003-3
SPECIAL TOOLS
806128
806127
TR98H032
GENERAL INFORMATION
Contamination in the hydraulic system is a major 1. Cylinder rod seals leak.
cause of the malfunction of hydraulic components.
2. Control valve spools do not return to neutral.
Contamination is any foreign material in the hydraulic
oil. Contamination can enter the hydraulic system in 3. Movement of control valve spools is difficult.
several ways.
4. Hydraulic oil becomes too hot.
1. When you drain the oil or disconnect any line.
5. Pump gears, housing, and other parts wear
2. When you disassemble a component. 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 power.
All hydraulic systems operate with some
contamination. The design of the components in this If your machine has any of these problems, check the
hydraulic system permits efficient operation with a hydraulic oil for contamination. See types of
small amount of contamination. An increase in this contamination below. If you find contamination, use
amount of contamination can cause problems in the the Portable Filter to clean the hydraulic system.
hydraulic system. The following list includes some of
these problems.
TYPES OF CONTAMINATION
There are two types of contamination, microscopic 3. Visible contamination is foreign material that can
and visible. be found by sight, touch, or odor. Visible
contamination can cause a sudden failure of
1. Microscopic contamination occurs when very fine
components. Examples of 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. B. Air in the oil
Microscopic contamination can be found by
C. The oil is dark and thick.
identification of the following problems or by
t e s t i n g i n a l a b o r a t o r y. E x a m p l e s o f t h e D. The oil has an odor of burned oil.
problems:
E. Water in the oil. See page 7.
A. Cylinder rod seal leak.
B. Control valve spools do not return to
NEUTRAL.
C. The hydraulic system has a high operating
temperature.
8003-5
39-4
17. Start the engine and run the engine at low idle.
NOTE: Any attachment or part of an attachment that 18. Slowly and completely extend all cylinders. As
is raised must be supported with acceptable the piston rod comes in/out of the cylinder, oil will
equipment to prevent the attachment from falling. be pushed out of the OPEN end of the cylinders.
3. Move each control lever in both directions to NOTE: Any attachment or part of an attachment that
release pressure in the hydraulic circuits. is raised must be supported with acceptable
4. Loosen and remove the filler cap from the equipment to prevent the attachment from falling.
reservoir. 19. Support any attachments that will be in the
5. Drain the hydraulic oil from the reservoir. RAISED position.
A. See Section 1002 for capacity specifications. 20. Stop the engine.
B. Have available acceptable equipment to drain 21. Disconnect the drain lines and connect the
the hydraulic oil. system lines to the cylinders.
C. Remove the drain plug from the bottom of the 22. Check the oil level in the hydraulic reservoir. Add
reservoir. o i l a s r e q u i r e d . S e e S e c t i o n 1 0 0 2 fo r
specifications.
6. Remove the hydraulic filter elements from the
machine. 23. Install the filler cap on the reservoir.
7. Install new hydraulic filter elements on the 24. Remove the hydraulic filter elements from the
machine. machine.
8. Install the drain plug in the bottom of the 25. Install new hydraulic filter elements on the
reservoir. machine.
9. Fill the hydraulic reservoir with hydraulic fluid. 26. Start and run the engine at 1500 rpm (r/min),
See Section 1002 for specifications. operate each hydraulic circuit to completely
extend and retract the cylinders.
10. Disconnect the line from the OPEN end and
CLOSED end of each cylinder. 27. Stop the engine and check for leaks. Check the
oil level in the hydraulic reservoir. Add oil as
11. Be sure all control levers are in the NEUTRAL required. See Section 1002 for specifications.
position.
12. Start and run the engine at low idle.
IMPORTANT: Check the oil level in the hydraulic
reservoir frequently while doing step 13. Have
another person hold a container under the hydraulic
lines while you do step 13.
8003-8
NOTES
Section
8004
8004
HYDRAULIC PUMP
8004-2
TABLE OF CONTENTS
821F - PUMP SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
921F - PUMP SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PREPARING THE EQUIPMENT PUMP FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
EQUIPMENT PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
8004-3
EQUIPMENT PUMP
7 8 9
6 5
5 4
4
3
10
2 11
1
12 24
13 23
22
21
20
19
18
17
15
14 16
30
29
15 28
27
26
25
BC06F550
Disassembly STEP 3
STEP 1
Remove all dirt, oil, and grease from the exterior of
the equipment pump.
STEP 2
BC06F552
STEP 4
BC06F551
BC06F553
BC06F555
BC06F554
Remove the end cover. Use a suitable bearing race puller and pull the
bearing race from the end cover.
NOTE: Watch for the flow plate, it can be stuck to
either the end cover or pump body. NOTE: Do not damage the sealing surfaces.
8004-7
STEP 7 STEP 9
BC06F558
STEP 10
BC06F556
STEP 8
BC06F559
BC06F557
BC06F560
STEP 12
BC06F563
STEP 15
BC06F561
STEP 13
BC06F564
BC06F562
Inspection STEP 19
STEP 16
Clean all parts in cleaning solvent. Be careful not to
remove the alignment mar ks made dur ing
disassembly.
STEP 17
BC06F567
STEP 20
BC06F565
STEP 18
BC06F568
STEP 21
BC06F566
BC06F569
BC06F572
BC06F570
Check the cylinder bores and splines for damage. Check cylinder surface for grooves, wear, embedded
particles. Check flow plate for scratches or wear.
STEP 23
STEP 25
BC06F571
BC06F573
Check ball for grooves and wear.
Check mounting surface for the flow plate for
damage.
8004-11
Assembly STEP 27
STEP 26
BC06F574 BC06F575
Install the plug in the housing and tighten to 127 Nm Put the shaft and bearing in the housing.
(93.5 pound-feet). Install shim and press in the
bearing race. STEP 28
BC06F576
BC06F579
STEP 32
BC06F577
STEP 30
BC06F578
BC06F580
BC06F582
STEP 35
BC06F581
BC06F583
BC06F584
STEP 37
BC06F585 BC06F587
Place the ball onto the pressure pins, install the Hold the pistons in the rotating housing using an
pistons into the retaining plate. O-ring, install the rotating group into the housing,
remove the O-ring.
STEP 38
BC06F586
BC06F588
Use the shim that was required for the bearing pre
load in step 30. Install the shim and bearing onto the
shaft.
BC06F589
BC06F591
BC06F590
8005
8005-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Spool Valve Housing Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Spool Valve Spool Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Spool Mounting Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 Spool Mounting Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 and 4 Spool Valve Spool Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DISSASEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Circuit Relief Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Circuit Relief Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
8005-3
SPECIFICATIONS
Manufacturer................................................................................................................................................... Rexroth
Special Torques
End plate mounting bolts.................................................................................................. 70 Nm (51.5 pound feet)
Pressure relief, flow limit, and pilot pressure reducing valves .................. 20 to 25 Nm (177 to 221 pound inches)
Allen head plugs.............................................................................................................. 240 Nm (177 pound feet)
Allen head locking screw................................................................................................ 100 Nm (73.7 pound feet)
Allen head cover screws (short) .................................................................................. 10.4 Nm (92 pound inches)
Allen head cover screws (long) ........................................................................................ 6 Nm (53 pound inches)
Anticavitation valves ....................................................................................................... 100 Nm (73.7 pound feet)
Combination anticavitation and circuit relief ................................................................. 200 Nm (147.5 pound feet)
Main relief valve pressure settings (XT and Z-Bar) ............................................... 248 to 252 bar (3596 to 3654 psi)
Circuit relief valve pressure setting
Auxiliary A and B port (XT and Z-Bar) .......................................................................................290 bar (4206 psi)
Bucket A port (XT and Z-Bar) ....................................................................................................152 bar (2205 psi)
Bucket B port (XT and Z-Bar) ....................................................................................................290 bar (4206 psi)
8005-4
4
3
5
22
6
6 7
21
6
20
19 8
18
17
6 9
16
10
11
15 14
8
12 12
13
BS03C033
1. BOLT 7. LOAD SENSE SHUTTLE CHECK 13. FLOAT SOLENOID 18. LOAD CHECK
8. ANTICAVITATION AND CIRCUIT
2. WASHER 14. PLUG 19. FLOW LIMIT VALVE
RELIEF
15. REGENERATION CHECK
3. LOCKING SCREWS 9. LOAD SENSE BLEED DOWN ORIFICE 20. PRESSURE RELIEF VALVE
VALVE
4. PLATE 10. FLOW COMPENSATOR SPOOL 16. LOCKING SCREW 21. CONE
5. REGENERATION
11. HOUSING 17. SPRING 22. LOCKING SCREW
RELIEF VALVE
6. O-RINGS 12. PLUG
2 SPOOL VALVE HOUSING CONFIGURATION
8005-5
27
26
25
24
23
6 28
31 29
30
6
6
33 33 32
34
31
6
23 24
24 23
34 6
35
32
30
29
BC06F593
37
36
37
BS03C036
38
39
BS03C035
31 29
30
33
34
6 6
23
24
23 32
35
33 23
31 24
6
6
34
29
30 32
BS03C037
3 AND 4 SPOOL VALVE SPOOL CONFIGURATION
DISSASEMBLY
STEP 1 STEP 7
Remove valve from machine, see section 8001. Remove pressure relief valve (20).
STEP 2 STEP 8
Remove bolts (27), cover (26), springs (24 and 25), Remove flow limit valve (19).
and spring retainer (23).
STEP 9
STEP 3 Remove locking screw (16), spring (17), and cone
Remove bolts (32), covers (33), spring (24), and (18).
spring retainer (23).
STEP 10
STEP 4 Remove regeneration check valve (15).
Use wooden dowel or brass drift and push spools
(35) from housing (11). STEP 11
IMPORTANT: Do not force spools from housing, if Remove locking screw (14).
spool binds work back and forth until spool comes
out freely. STEP 12
NOTE: Repeat steps 3 and 4 for a 3 and 4 spool Remove load sense shuttle check valve (7).
valve configuration.
STEP 13
STEP 5 Remove locking screws (12).
Remove anticavitation valves (5, 8, 10, and 13).
STEP 14
NOTE: Repeat step for a 3 and 4 spool anticavitation
Remove pilot pressure reducing valve (9).
valves (37).
STEP 15
STEP 6
Remove bolts (1) and washers (2), remove plate (4)
Remove locking screw (22) and cone (21).
from housing (11).
NOTE: For 4 spool configuration remove nut (38)
from stud (39), remove housings (36) from housing
(11).
8005-10
STEP 16 STEP 18
2
1
2
1
1
1
BS03C025 BS03C027
STEP 17
2 STEP 19
1
2
1
1
3
1 1
BS03C026 2
1. O-RINGS 2. THRUST RINGS BS03C028
Remove and discard O-rings and thrust rings from 1. O-RINGS 2. THRUST RING 3. SPOOL SEAL
flow limit valve (19).
Remove and discard O-rings, thrust ring, and spool
seal from anticavitation valve (5).
8005-11
STEP 20
1
1
2
BS03C029
STEP 21
1
2
1
2
BS03C030
BS03C031
1. O-RINGS 2. COIL
Remove and discard O-rings and thrust rings from anticavitation valve (13).
8005-13
STEP 23
3
4
2 1
1
1
BS03C032
INSPECTION
1. Discard all O-rings, thrust rings, and spool seals. 4. Check the parts of the pressure relief valve,
anticavitation valves, and the anticavitation and
2. Clean all parts in cleaning solvent.
circuit relief valves. Use new parts as necessary.
3. Check the spools and the spool bores for
Inspect the other parts of the control valve. If any of
damage and wear.
the parts are damaged, install new parts.
ASSEMBLY
STEP 1
3
4
A
2 1
1 See Note
1
BS03C032
A
1
BS03C031
1. O-RINGS 2. COIL
Install new O-rings and thrust rings on anticavitation valve (13). Hand tighten coil nut (A).
STEP 3
1
2
1
2
1 A
BS03C030
1
1
2
BS03C029
1
1
3
1 1
2
BS03C025 BS03C028
STEP 6 STEP 9
Install and torque regeneration check valve (15) to
2
100 Nm (73.7 pound feet).
STEP 10
Install and torque locking screw (14) to 100 Nm
2 (73.7 pound feet).
1
1 STEP 11
Install and tighten load sense shuttle check valve (7).
STEP 12
BS03C026 Install and torque locking screws (12) to 240 Nm
1. O-RINGS 2. THRUST RINGS (177 pound feet).
Install new O-rings and thrust rings on flow limit valve
(19). STEP 13
Install and torque pilot pressure reducing valve (9) to
STEP 7 60 Nm (44 pound feet).
STEP 14
1 Install new O-rings on housing (11). Install plate (4),
bolts (1) and washers (2), onto housing (11). Torque
2 bolts to 70 Nm (51.5 pound feet).
STEP 15
BS03C027 Install anticavitation valves (5, 10, and 13) and torque
1. O-RINGS 2. THRUST RING to 100 Nm (73.7 pound feet).
Install new O-rings and thrust ring on locking screw NOTE: Repeat step for a 3 and 4 spool anticavitation
(14). valves (37).
8005-18
STEP 16 Circuit Relief Pressure Test
Install anticavitation valves (8) and torque to 200 Nm
(147.5 pound feet). STEP 1
Connect the hand pump to the port for anticavitation
STEP 17 and circuit relief valves (21).
Install and torque flow limit valve (19) to 20 to 25 Nm
NOTE: Repeat steps for machines that are
(177 to 221 pound inches).
configured with a 3 or 4 spool valve.
STEP 18 STEP 2
Install cone (18), spring (17), locking screw (16).
Make sure that the hand pump is full of hydraulic oil
Torque locking screw to 100 Nm (73.7 pound feet).
and that the temperature of the oil is approximately
21°C (70°F).
STEP 19
Install cone (21) and locking screw (22). Torque STEP 3
locking screw to 40 Nm (30 pound feet).
Operate the handle of the hand pump and read the
highest pressure. Repeat this step several times to
STEP 20 be sure of the reading.
Lubricate spools with hydraulic oil and push spools
(35) into housing (11). STEP 4
IMPORTANT: Do not force spools into housing. Compare the reading to the specifications on Page 3.
STEP 21 STEP 5
Install spring retainers (23), springs (24), covers (33), If the pressure is not correct, adjust the circuit relief
and bolts (32). Torque bolts to 10.4 Nm (92 pound valve.
inches).
NOTE: Repeat steps 18 and 19 for a 3 and 4 spool Circuit Relief Adjustment
valve configuration.
STEP 1
STEP 22 Loosen the lock nut. Turn the adjustment screw
Install spring retainers (23), spring (24 and 25), cover clockwise to increase the pressure or
(26), and bolts (27). Torque bolts to 6 Nm (53 pound counterclockwise to decrease the pressure.
inches). NOTE: One turn of the adjusting screw will change
NOTE: Prior to installation in the machine, circuit the pressure approximately 138 bar (2000 psi).
reliefs can be tested.
STEP 2
STEP 23 Check the pressure again. Repeat the adjustment as
Install valve in machine, see section 8001. necessary.
STEP 24
Check loader limit pressure, see section 8002.
Section
8006
CYLINDERS
8006
8006-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
BUCKET CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
REPLACING THE BUSHINGS FOR THE LIFT CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
REPLACING BUSHINGS FOR THE BUCKET CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
8006-3
SPECIFICATIONS
Approximate weight
Lift Cylinder...........................................................................................................................142.2 kg (313.5 pounds)
Bucket Cylinder........................................................................................................................199.2 kg (439 pounds)
SPECIAL TORQUES
Gland Bolts Bucket Cylinder .......................................................................420 to 500 Nm (310 to 368.8 pound-feet)
Screw in Gland for Lift Cylinders ...................................................................135 to 542 Nm (100 to 400 pound-feet)
Piston Bolt for Lift Cylinders................................................................2830 to 3220 Nm (2087 to 2374.9 pound-feet)
Lock Screw for Lift Cylinders ............................................................................................. 2.3 Nm (20 pound-inches)
SPECIAL TOOLS
Torque Multiplier ......................................................................................................................................... CAS-1039
8006-4
LIFT CYLINDER
Disassembly Inspection
1. Clean exterior of cylinder. If hoses were removed 1. Clean all parts in cleaning solvent. Use only lint
with cylinder, remove hoses from cylinder. free cloths for cleaning and drying.
2. Fasten tube (1) in an acceptable repair stand or 2. Check to be sure that piston rod (13) is straight. If
other holding equipment. Do not damage tube piston rod is not straight, replace it with a new
(1). piston rod.
3. Loosen and remove self-tapping screw (12). 3. Shine a light inside tube (1) and check for deep
grooves and other damage. If there is any
4. Use a spanner wrench to loosen and remove
damage to tube, replace with a new tube.
gland (4) from tube (1).
4. Remove any small scratches on piston rod (13)
5. Pull piston rod (13) straight out of tube (1) to
or inside tube (1) with emery cloth of medium
prevent damage to tube.
grit. Use emery cloth with a rotary motion.
6. Fasten piston rod eye or yoke in a vise and put a
5. Inspect bushings (2) in tube eye. Replace as
support under piston rod (13) near piston (15).
required.
Put a shop cloth between support and piston rod
to prevent damage to piston rod. 6. Inspect gland (4) for rust. Clean and remove rust
as necessary.
7. Use a torque multiplier, CAS-1039, to loosen and
remove bolt (14) that fastens piston (15) to piston 7. Inspect gland end of tube (1) for sharp edges
rod (13). that may cut gland O-ring (11) and remove as
necessary.
8. Remove piston (15) from piston rod (13).
8. Inspect piston (15) for damage and wear. If
9. Remove gland (4) from piston rod (13).
piston is damaged or worn, replace with a new
10. Remove and discard seal (16), ring (17), and piston.
wear ring (18) from piston (15).
11. Remove and discard O-ring (10), backup ring (9),
O-ring (11), wiper (5), rod seal (6), buffer seal (7),
and bushing (8) from gland (4).
8006-5
13
5
6
7
4
8
11
9
10
15
12
17
16
18
14
1
3
2
2
3
BC05J002
Assembly 17. Install a new ring (17) in the other groove on the
outside of the piston (15).
NOTE: If a new gland is being used, put part number
of cylinder on new gland. 18. Install a new seal (16) on top of ring (17).
1. Install bushing (8) in gland (4). 19. Fasten tube (1) in an acceptable repair stand or
other holding equipment. Be careful to prevent
2. Install rod seal (6) in gland (4). Rod seal is to be damage to tube.
installed so that lips of seal are toward bushing
(8). Rod seal (6) can be difficult to install. 20. Lubricate inside of the tube (1) and piston (15)
with clean oil.
3. Install buffer seal (7) in gland (4). The side of
buffer seal with groove must be toward bushing 21. Push piston (15) straight into tube (1).
(8). 22. When the piston (15) is in smooth part of tube
4. Install a new wiper (5) in gland (4). Lips of wiper (1), start gland (4) into tube.
must be toward outside end of gland (4). 23. Lubricate O-rings (10 and 11) on gland (4) with
5. Install a new O-ring (11) in groove on OD of clean oil.
gland (4). 24. Turn gland (4) into tube (1). Tighten gland to a
6. Install a new backup ring (9) in groove on OD of torque of 135 to 542 Nm (100 to 400 pound-feet).
gland (4). If both sides of backup ring are not flat, 25. If the original parts are being assembled:
side that is not flat must be toward small end of
gland (4). A. Tighten gland to a torque of 135 to 542 Nm
(100 to 400 pound-feet).
7. Install a new O-ring (10) next to backup ring (9)
in groove on outside of gland (4). O-ring must be B. Install and tighten self-tapping screw (12) to a
toward small end of gland. torque of 2.3 Nm (20 inch-pounds).
8. Fasten piston rod (13) eye or yoke in vise. C. If, after tightening gland, the self-tapping
screw (12) holes are not aligned, a new hole
9. Remove any marks and sharp edges on chamfer for self-tapping screw must be drilled. See
at end of piston rod (13). Make sure that piston Step 26.
rod is clean.
26. If a new gland (4) or a new tube (1) are being
10. Lubricate bore of gland (4) and piston rod (13) assembled:
with clean oil.
A. Tighten gland (4) to 135 to 542 Nm (100 to
11. Push gland (4) onto piston rod (13). If necessary, 400 pound-feet).
use a soft hammer to drive gland onto piston rod.
B. Use a No. 27 drill bit and drill a hole half in
12. Put a support below and near end of piston rod gland (4) and half in tube (1). Drill to a depth of
(13). Use a shop cloth between support and the 11 mm (7/16 inch). Do not drill within 13 mm
piston rod to prevent damage to piston rod. (1/2 inch) of a hole for gland wrench.
13. Start piston (15) onto piston rod (13). C. Install and tighten self-tapping screw (12) to a
14. Clean the threads on the end of the piston rod torque of 2.3 Nm (20 inch-pounds).
(13) and the threads of the bolt (14) using Loctite 27. If hoses were removed with cylinder, install new
cleaning solvent. Allow to dry. Apply Loctite 242 O-rings, if equipped, on hose fittings. Lubricate
to piston rod threads 6.3 mm (1/4 inch) from O-rings with clean oil. Install hoses.
open end of piston rod so that there is 13 mm
(1/2 inch) of Loctite 242 on piston rod threads.
DO NOT apply Loctite to first 6.3 mm (1/4 inch)
of piston rod threads.
15. Install bolt (14) into piston rod (13). Tighten bolt
to a torque of 2830 to 3220 Nm (2087 to 2374.9
pound-feet). A torque multiplier can be used to
help torque the bolt.
16. Install a new wear ring (18) in wide groove on
outside of piston (15).
8006-7
BUCKET CYLINDERS
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. Do not damage the 3. Check to be sure that the piston rod is straight. If
tube (1). the piston rod is not straight, replace it with a new
3. Loosen and remove the cap screws (2) and piston rod.
hardened washers (18) from the gland (3) and 4. Illuminate the inside of the tube for deep grooves
the tube (1). and other damage. If there is any damage to the
4. Pull the piston rod (4) straight out of the tube (1) tube, replace it with a new tube.
to prevent damage to the tube (1). 5. Remove any small scratches on the piston rod or
5. Fasten the piston rod eye or yoke in a vise and inside the tube with emery cloth of medium grit.
put a support under the piston rod (4) near the Use the emery cloth with a rotary motion.
piston (7). Put a shop cloth between the support 6. Inspect the bushings in the piston rod eye or
and the piston rod (4) to prevent damage to the yoke and the tube. Replace as required.
piston rod (4).
7. Inspect the gland for rust and clean and remove
6. Remove the retaining ring (10) that fastens the rust as necessary.
pin (11) in the piston (7) and piston rod (4).
8. Inspect the gland end of the tube for sharp edges
7. Remove the pin (11) from the piston (7) and the that will cut the gland O-ring and remove as
piston rod (4). necessary.
8. Turn the piston (7) off the piston rod (4) and 9. Inspect the piston for damage and wear. If the
remove the piston (7). piston is damaged or worn, replace it with a new
9. Remove the gland (3) from the piston rod (4). piston.
10. Remove the seal (6) from the OD of the piston
(7).
11. Remove the wear ring (5) from the OD of the
piston (7).
12. Remove the backup rings (8) and the O-ring (9)
from the ID of the piston (7).
13. Remove the O-ring (16), backup ring (15), wiper
(12), wide seal (13), narrow seal (14), and
bushing (17) from the gland (3).
8006-8
19
20
19
4
2
18
3
17
15
12
16 13
11 8 14
8 9
7
6
5 1
10
19
20
19
BC05M026
Assembly 11. Install a new backup ring (8) in the groove in the
ID of the piston (7). If both sides of the backup
NOTE: If a new gland is being used, put the part ring (8) are not flat, the side that is not flat must
number of the cylinder on the new gland. be toward the O-ring (9).
1. Install the bushing (17) in the gland (3), refer to 12. Install a new O-ring (9) in the groove in the ID of
illustration on page 8. the piston (7) next to the backup ring (8).
2. Install the wide seal (13) in the gland (3). The 13. Install the other new backup ring (8) in the
wide seal (13) is to be installed so that the lips of groove in the ID of the piston (7) next to the
the wide seal (13) are toward the bushing (17). O-ring (9). If both sides of the backup ring (8) are
The wide seal (13) can be difficult to install. not flat, the side that is not flat must be toward
3. Install a new wiper (12) in the gland (3). The lips the O-ring (9).
of the wiper (12) must be toward the outside end 14. Lubricate the ID of the piston (7) with clean oil.
of the gland (3).
15. Start the piston (7) onto the piston rod (4). Turn
4. Install the narrow seal (14) in the gland (3). The the piston (7) onto the piston rod (4) until the
side of the narrow seal (14) with the groove must piston (7) is seated against the shoulder of the
be toward the bushing (17). piston rod (4).
5. Install a new backup ring (15) in the groove on 16. If none of the holes in the piston (7) align with the
the outside of the gland (3). If both sides of the holes in the piston rod (4), turn the piston (7)
backup ring (15) are not flat, the side that is not counterclockwise until one of the holes in the
flat must be toward the small end of the gland piston (7) aligns with one of holes in the piston
(3). rod (4). Do not turn the piston (7) more than 90
6. Install the O-ring (16) next to the backup ring (15) degrees.
in the groove on the outside of the gland (3). The
O-ring (16) must be toward the small end of the 7
gland (3).
11
7. Remove any marks and sharp edges on the
chamfer at the end of the piston rod (4). Make 10
sure that the piston rod (4) is clean.
8. Lubricate the bore of the gland (3) and the piston
rod (4) with clean oil.
9. Push the gland (3) onto the piston rod (4). If
necessary, use a soft hammer to drive the gland
(3) onto the piston rod (4). 4
10. Put a support below and near the end of the
GS98J804
piston rod (4). Use a shop cloth between the
support and the piston rod (4) to prevent damage PISTON AND PISTON ROD HOLE ALIGNMENT
to the piston rod (4). 17. Install the pin (11) in the piston (7) and the piston
rod (4).
18. Install the retaining ring (10) in the pin (11).
8006-10
19. Install a new wear ring (5) in the wide groove on 27. Tighten the cap screws (2) in the sequence
the OD of the piston (7). shown. Torque to 420 to 500 Nm (310 to 368.8
20. Install a new seal (6) in the groove on the OD of pound-feet).
the piston (7).
21. Fasten the tube (1) in an acceptable repair stand
or other holding equipment. Be careful to prevent
damage to the tube (1).
22. Lubricate the inside of the tube (1) and the
outside of the piston (7) with clean oil.
23. Push the piston (7) straight into the tube (1).
24. Lubricate the O-ring (16) on the gland (3) with
clean oil.
25. Push the gland into the tube (1) and align the
holes in the tube (1).
26. Install the cap screws (2) and hardened washers
(18).
BC05M027
TUBE AND GLAND HOLE ALIGNMENT
8006-11
Removal
1. Put piston tube (4) in a press.
2. Use an acceptable driver to press wipers (1) and
bushings (2) out of piston tube (4) eye.
3
3. Clean bore for bushings (2) in tube (4) eye.
1
Installation
4
1. Use an acceptable driver to press new bushings
(2) into tube (4) eye. Bushings shall be recessed
8 mm (0.315 inch) in tube eye.
2
2. Use an acceptable driver to install wipers (1) until
flush with tube (4) eye. The lips of wipers must be 1
toward outside of bore. 2
BS01C003
Removal
3
1. Put piston rod eye (3) in a press.
2. Use an acceptable driver to press wipers (1) and
bushing (2) out of piston rod eye (3). 2
3. Put tube (4) in a press. 1 1
4. Use an acceptable driver to press bushings (2) 2
out of tube (4) eye.
5. Clean bore for bushings (2) in piston rod eye (3)
and tube (4) eye.
4
1
Installation 2
1. Use an acceptable driver to press new bushings
(2) into piston rod eye (3) until recessed 8 mm
(0.315 inch).
2. Use an acceptable driver to install wipers (1) until
flush with piston rod eye (3). The lips of the 2
wipers (1) must be towards outside of bore.
3. Use an acceptable driver to press new bushings
(2) into tube (4) eye until recessed 8 mm (0.315
inch).
1
4. Use an acceptable driver to install wipers (1) until BS03B201
flush with tube (4) eye. The lips of wipers (1)
1. WIPER 3. PISTON ROD EYE
must be towards outside of bore. 2. BUSHING 4. TUBE
BUSHING AND WIPER REMOVAL AND REPLACEMENT
BUCKET CYLINDERS
Section
8007
8007
8007-2
TABLE OF CONTENTS
coupler solenoid locking valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
8007-3
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).
8007-4
NOTES
Section
8013
8013
RIDE CONTROL ACCUMULATOR
8013-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ACCUMULATOR SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CHARGING THE ACCUMULATOR WITH NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
8013-3
SPECIFICATIONS
Ride Control Accumulator Dry Nitrogen Pressure ...................................................................... See chart on page 8
Ride Control Accumulator Fluid Capacity ............................................................................. 3.79 liters (231 cu. inch)
Ride Control Accumulator Maximum Operating Pressure ...........................................................248.4 bar (3600 psi)
SPECIAL TOOLS
94L95 B786441M
CAS10899 NITROGEN ACCUMULATOR CHARGING KIT CAS1456 GLAND WRENCH
8013-4
C E
D B A
94L95
CAS10899 NITROGEN CHARGING KIT
1. Use the CAS-10899 Nitrogen Charging Kit to 7. Turn the T-handle inward on valve F to engage
d i s c h a r g e t h e a c c u m u l a t o r, r e fe r t o t h e the pin in the valve stem.
illustration above. The tool must be disconnected
8. Open valve D and check the charge pressure on
from the nitrogen tank.
gauge E.
2. Close valves B, C and D.
9. To discharge the accumulator, partially open
3. Adjust the regulator A to the minimum pressure valve B. The accumulator charge will bleed down
setting by turning the knob counterclockwise. through the regulator.
4. Turn the T-handle on valve F fully out. 10. Once the accumulator is fully discharged,
disconnect valve F from the valve stem.
5. Remove the guard and valve assembly cap from
the accumulator. 11. The accumulator can now be disassembled.
6. Connect valve F to the valve stem on the
accumulator.
8013-5
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 6.
1. Clean body (1), gland (3), cap (8) and piston (4) 11. Install the guard (11), screws (9) in the body (1).
in cleaning solvent, refer to the illustration on 12. Charge the accumulator with dry nitrogen
page 6. according to instructions on page 7.
2. Inspect the piston (4) for cracks, burrs or other
damage. WA R N I N G : U s e o n l y n i t r o g e n w h e n
charging the accumulator. DO NOT use air
3. Inspect the bore of the body (1) for scratches or or oxygen that will cause an explosion.
scoring using a light. SM115A
1 2 5 6 7 9
8
3 4
10 11
12
9
BS01B224
6 5
4 3
GS98N801
1. VALVE C 4. VALVE B
2. TO NITROGEN TANK 5. VALVE D
3. VALVE A 6. TO ACCUMULATOR
NITROGEN CHARGING KIT CAS10899
WARNING: Use only nitrogen when charging the accumulator. Do not use air or oxygen that will cause an
explosion.
M253A
WARNING: Do not drop the accumulator. A charged accumulator contains nitrogen compressed to 31 bar
(450 psi). If the charging valve breaks away from the accumulator, the escaping nitrogen will propel the
accumulator at a dangerous rate of speed.
M406
WARNING: Do not expose the accumulator to temperatures above 49° C (120° F). A charged accumulator
contains nitrogen compressed to 31 bar (450 psi). High heat will cause the safety plug to blow out of the
accumulator and the escaping nitrogen will propel the accumulator at a dangerous rate of speed.
M407
IMPORTANT: The four valves must be in the positions noted in the procedure before connecting the Nitrogen
Accumulator Charging Kit to the machine or nitrogen, refer to the above illustration.
IMPORTANT: To help prevent equipment damage, the low pressure gauge valve C MUST BE SHUT OFF during
high pressure (10 bar/150 psi and above) applications.
8013-8
1. Close the shutoff valve A by turning it all the way 12. Open the shutoff valve A on the nitrogen supply
to the left (counterclockwise), refer to the tank. While observing the pressure on the gauge,
illustration on page 7. slightly open the needle valve on the
accumulator charge hose. By regulating the
2. Open valve B by turning it out all the way to the
needle valve, fill the accumulator to pressure
left (counterclockwise).
according to temperature chart below. Close the
3. Close valve C by turning it all the way to the right needle valve. Close the shutoff valve A on the
(clockwise). nitrogen supply tank.
4. Close the gauge valve D by turning it all the way TEMPERATURE CHARGE PRESSURE
to the right (clockwise). 10° C 50° F 1606 KPA 233 PSI
13° C 55° F 1634 KPA 237 PSI
5. Connect the charging hose to the nitrogen supply
16° C 60° F 1669 KPA 242 PSI
tank.
18° C 65° F 1696 KPA 246 PSI
6. SLOWLY turn valve A clockwise while watching 21° C 70° F 1724 KPA 250 PSI
the high pressure gauge. Stop turning valve A 24° C 75° F 1751 KPA 254 PSI
when the needle on the gauge reaches 31 bar 27° C 80° F 1779 KPA 258 PSI
(450 psi). 29° C 85° F 1813 KPA 263 PSI
32° C 90° F 1841 KPA 267 PSI
NOTE: If the needle goes over the needed pressure,
35° C 95° F 1868 KPA 271 PSI
quickly open and close valve D and check the
38° C 100° F 1896 KPA 275 PSI
pressure setting again.
The charging kit is now ready to be installed on the TEMPERATURE/CHARGE PRESSURE RIDE CONTROL
accumulator. ACCUMULATOR
13. Close valve B by turning to the right (clockwise).
7. Remove the two cap screws (9) and the
After a few minutes, check the accumulator for
protection bracket (11) from the body (1) on the
leakage.
accumulator, refer to the illustration on pages 6.
14. Back off the needle valve on the accumulator end
8. Remove the valve cap from the pressure valve
of the charging hose by tur ning it
(12) on the accumulator.
counterclockwise the maximum amount. This will
9. Back off the needle valve on the accumulator end p r eve n t n it r o g e n f r o m e s c a p i n g f r o m t h e
of the charging hose by tur ning it accumulator as the hose is removed. Remove
counterclockwise to the maximum amount. This the charging hose from the accumulator pressure
prevents nitrogen from escaping from the valve (12).
accumulator when the charging hose is attached
15. Install the valve cap onto the pressure valve (12)
to the accumulator gas charging valve.
on the accumulator.
10. Install the charging hose fitting onto the
16. Install the protection bracket (11) over the
accumulator pressure valve (12).
pressure valve (12) and secure it with cap screws
11. Tighten the needle valve by turning it clockwise. (9).
Slowly open the gauge valve D and observe the
17. Remove the charging hose from the nitrogen
reading on the gauge. This reading is the
supply tank.
nitrogen pressure level inside the accumulator.
Section
8014
8014
RIDE CONTROL VALVE
8014-2
TABLE OF CONTENTS
RIDE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Dissasembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
8014-3
9 11
10
8
7 13 12
14
15
6
5
4
3 16
2
1 17
BC05B015.
Dissasembly STEP 8
Remove the pressure relief valve (17).
STEP 1
Remove ride control valve, refer to section 8001. Inspection
1. Discard all O-rings.
STEP 2
Remove plugs (1), (8), (9), and (11). 2. Clean all parts in cleaning solvent.
3. Check the spools and the spool bores for
STEP 3 damage and wear.
Remove the solenoid (12). 4. Check the parts of the pressure relief valve.
STEP 5
Remove cap screw (2), bushing (3), spring carrier
(4), springs (5 & 6) from spool (7).
STEP 6
Remove orifice (13), poppet (14), and orifice (15).
STEP 7
Remove accumulator drain screw (10).
8014-4
Assembly STEP 6
Install springs (5 &6), spring carrier (4), bushing (3),
STEP 1 cap screw (2) onto spool (7) and torque cap screw
Install new O-rings. (2) to 5.5 Nm (48.5 lb-in).
STEP 2 STEP 7
Install and torque pressure relief valve (17) to 50 Nm Install spool (7) into valve block (16).
(37 lb-ft).
STEP 8
STEP 3 Install and torque plug (1) to 270 Nm (199 lb-ft).
Install and torque accumulator drain screw (10) to
3.5 Nm (31 lb-in). Install the plug for accumulator STEP 9
drain screw and torque to 7 Nm (62 lb-in). Install plug (8) and torque to 140 Nm (103 lb-ft), plug
(9) and torque to 30 Nm (22 lb-ft), and plug (11) and
STEP 4 torque to 90 Nm (66 lb-ft).
Install and torque orifice (15) to 15 Nm (11 lb-ft),
install poppet (14), install and torque orifice (13) to STEP 10
15 Nm (11 lb-ft). Install the ride control valve in the machine, see
section 8001.
STEP 5
Install and torque solenoid valve to 12 Nm (106 lb-in). STEP 11
Test the ride control system, see section 8002.
9002
Section
9002
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
Expansion Valve Malfunctioning - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Refrigerant Contamination: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
HFC-134a Stable Saturation Pressure/ Temperature Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
9002-3
SAFETY PROCEDURES
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 (CFC’s) which are
refrigerant and when you test the system.
harmful to the earth’s 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.
mixtures of HFC-134a and air can for m a
Liquid refrigerant getting into the eyes can cause
combustible gas.
ser ious injur y. Do the following if you get
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.
9002-4
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
9002-5
OPERATION
The refrigerant circuit of the air conditioning system The refrigerant, still in a high pressure liquid form,
contains five major components: compressor, 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. evap orator mete rs refr ig erant flow based on
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 flowing
pressure gas. The compressor then compresses the through the evaporator fins. The combination of
refrigerant and sends it in the form of a high pressure increased heat and decreased pressure causes the
gas to the condenser. The air flow through the air flow through the evaporator fins to become very
c o n d e n s e r t h e n r e m o ve s t h e h e a t f r o m t h e 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 operator’s 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
Check Page 8
Compressor Runs No
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 fins that have bends or
damage must be made straight.
3. Inspect the evaporator/heater core for
r e s t r i c t i o n s. I f t h e c o r e i s d r y, u s e
compressed air or a brush and vacuum
cleaner. If the core is wet or filled with
Evaporator/Heater Core mud, flush the core with water using a
hose without pressure. Make sure the
water drains freely from the
evaporator/heater core. DO NOT USE
STEAM.
WARNING: Do not steam clean any air
conditioning systems parts while the system is
charged. The heat will cause the refrigerant to
rise to a pressure that could cause the system
to explode.
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 refrigerant charge quantity, system Pressure Test Connection
diagnosis, and operating efficiency. The manifold
C o n n e c t t h e m a n ifo l d g a u g e s e t i n t o t h e a i r
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
eva cuat io n effe ctiven ess. A vac uum rea ding
indicates a system malfunction. For this reason, it is
necessar y to use a compound gauge that will
indicate both pressure and vacuum.
9002-14
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 taken 5. Measurements taken 15 minutes after startup.
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
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)
9002-19
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
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
9003-3
SPECIFICATIONS
Air conditioning system refrigerant capacity ...................................................................................... 1.7 kg (3.75 lbs)
SPECIAL TOOLS
A22094 109L7
REFRIGERANT RECOVERY, RECYCLING AND RECHARGING SAFETY GOGGLES CAS-10073-3
STATION OEM-1415
9003-4
SAFETY PROCEDURES
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
conditioning systems. Refrigerant HFC-134a does
the air conditioner system before reclaiming
not contain chlorofluorocarbons (CFC’s) which are
refrigerant and when you test the system.
harmful to the Earth’s 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.
mixtures of HFC-134a and air can for m a
Liquid refrigerant getting into the eyes can cause
combustible gas.
ser ious injur y. Do the following if you get
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.
9003-5
STEP 1
A22114
STEP 4
BD03A213
STEP 2
A22107
BD03B001
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
BD03A213
STEP 10
A22113
STEP 12
BD03B001
A22113 A22123
Program 3.5 lbs and press the enter key. The display Press the Vacuum key. “Automatic” will appear on the
will flash once indicating the programmed data has display. Vacuum will appear on the display and after
been accepted. a slight delay, the vacuum pump will star t. The
display will show the amount of time programmed
STEP 14 and begin a countdown to zero.
When the programmed time has elapsed, an
automatic hold occurs. Check the low pressure
gauge to see that the A/C system maintains a 28 to
29-1/2 inches of mercury (Hg). The low pressure
gauge must not increase faster than one inch of
mercury (Hg) in 10 minutes. A previously charged,
l e a k - f r e e s y s t e m w i l l l e a c h r e f r i g e ra n t f r o m
compressor oil and raise system pressure under
vacuum. If the system will not hold vacuum, a leak
exists that must be corrected before recharging can
begin. See Section 9002 in the manual for a leak
test.
A22114
A22113
A22114 BD03B001
Completely close the high and low pressure manifold Stop the engine, close any open valves and carefully
valves. remove the manifold gauge hoses.
ATTENTION: Check the OEM equipment manual
before performing Step 19 to avoid damaging the STEP 22
recovery unit. The pressure reading should be
obtainable with valves closed. Damage may occur if
the machine is started with the valves accidently
open or if either or both valves are opened while the
A/C system is operating.
STEP 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 BD03B213
indicator lamp will illuminate when the relay is Install the caps on the service ports on the suction
actuated by a low or high pressure and the and discharge hoses.
compressor clutch will disengage. To restart the
compressor, the air conditioner control or blower
switch must be turned to the OFF position and then
to the ON position.
STEP 20
A22117
9004
REMOVAL AND INSTALLATION OF AIR CONDITIONING
AND HEATER COMPONENTS
9004-2
TABLE OF CONTENTS
SAFETY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
EXPANSION VALVE, EVAPORATOR/HEATER CORE,
HEATER VALVE, BLOWERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CONDENSER AND RECIEVER DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
9004-3
SAFETY PROCEDURES
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 (CFC’s) which are
refrigerant and when you test the system.
harmful to the earth’s 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.
mixtures of HFC-134a and air can for m a
Liquid refrigerant getting into the eyes can cause
combustible gas.
ser ious injur y. Do the following if you get
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.
9004-4
SPECIAL TOOLS
A22094 BS03H012
REFRIGERANT RECOVERY, RECYCLING AND CHARGING SAFETY GOGGLES CAS-10073-3
STATION OEM-1415
9004-5
COMPRESSOR
Removal STEP 4
STEP 1
Place the master disconnect switch in the OFF
position.
STEP 2
Discharge the air conditioning system according to
the instructions in Section 9003.
STEP 3
BD06F116
STEP 5
BD06F113
BD06F117
BD06F114
STEP 10
BD06F117
STEP 7
BD06F117
STEP 11
BD06F117
STEP 8 BD06F117
Remove the compressor from the machine. Connect the compressor clutch wire to the engine
harness assembly.
9004-7
STEP 12 STEP 13
Carefully remove the protective cap, install a new
O-ring, and connect the low pressure line to the
suction port on the compressor.
STEP 14
Install the belt.
STEP 15
Install the protective shield.
STEP 16
Charge the air conditioning system according to the
BD06F117 instructions in Section 9003.
Slowly remove the protective cap, install a new
O-ring, and connect the high pressure line to the
discharge port on the compressor.
IMPORTANT: Use caution when removing cap as
new compressors have internal pressure when
shipped.
9004-8
3 6
5
7
8
9
18 10
17
12 11
14
13
16
15
BS06G118
Removal STEP 23
STEP 17
Park the machine on a level surface and lower the
bucket to the floor.
STEP 18
If changing any air conditioning components,
discharge the air conditioning system according to
the instructions in Section 9003.
STEP 19
BD06G212
STEP 24
BD02N160
STEP 22
BD06G214
STEP 26
Fold the rubber mat over to gain access to the upper
BD06G202
box mounting bolts.
Remove the four bolts that fasten the operator’s seat
to the upper box, remove the seat from the machine.
9004-10
STEP 27 STEP 30
BD06G215 BD06G217
STEP 31
BD06G216
BD06G240
BD06G219
STEP 35
BD06G236
BD06G220
STEP 38
BD06G206
STEP 41
BD06G204
STEP 39
2 3
1 BD06G237
STEP 42
BD06G205
1. TRANSMISSION FILTER
2. AIR CONDITIONING HOSES
3. HEATER HOSES
BD06G236
STEP 44
Remove the expansion valve from the evaporator
core.
STEP 45
Remove and discard the O-rings from the openings
in the expansion valve.
STEP 46
Remove the screws from the heater core and remove BD06G208
BD06G209
1. FAN SPEED AND A/C SWITCH
BD06G207 2. INSIDE/OUTSIDE AIR SELECTOR SWITCH
1. RESISTORS
3. THERMOSTAT
2. RESISTOR CONNECTOR
3. BLOWER MOTOR CONNECTOR R e m ove t h e sw i t c h p a n e l f r o m t h e c o n s o l e.
Disconnect the electrical connectors and remove
Remove the fans from the lower PPE, disconnect the
switches as required.
electrical connectors. Remove the two mounting
screws for the resistor, remove the resistor.
9004-14
Installation STEP 53
STEP 51
1
1 2
3
BD06G207
1. RESISTORS
2. RESISTOR CONNECTOR
BD06G209 3. BLOWER MOTOR CONNECTOR
1. FAN SPEED SWITCH
2. INSIDE/OUTSIDE AIR SELECTOR SWITCH Install the resistor, install the two mounting screws
3. THERMOSTAT and tighten. Install the fans in the lower PPE, connect
Re place switches and connect the electr ical the electrical connectors.
connectors as required. Install the switch panel in the
console. STEP 54
Install new O-rings on the heater control valve.
STEP 52
STEP 55
Install the control valve, install and tighten the screws
to the heater core.
STEP 56
Install new O-rings on the openings of the expansion
valve.
STEP 57
Install the heater core and evaporator core into the
lower box PPE.
BD06G208 STEP 58
Install the motor and install the mounting screws and
tighten. Connect the electrical connector for the
recirculating vain motor, connect the linkage to the
vain.
BD06G236
2 3
BD06G237
STEP 62
BD06G206
BD06G204
STEP 63
BD06G238
BD06G210.
STEP 68
BD06G239
BD06G216
BD06G242 BD06G214
Install the insolation panel in the center of the upper Install and tighten the three screws securing the
box. cooler to the cab.
STEP 71 STEP 75
BD06G215 BD06G213
Install and tighten the six bolts securing the upper Install the vent cover, install and tighten the four
box. screws securing the air vent.
STEP 72 STEP 76
BD06G243
Install the right rear floor mat into the cab, if machine BD06G202
is equipped with air ride seat make sure to pull the Install and torque the four bolts to 73 to 87 Nm (55 to
wiring up above the mat for the seat. 65 pound-feet).
STEP 73
Install the remainder of the floor mat.
9004-18
STEP 77 STEP 79
Connect the wiring connector to the operator’s seat Charge the air conditioning system according to the
(if equipped with air seat option). instructions in Section 9003.
STEP 78
Fill engine coolant system with a solution of 50%
Ethylene Glycol and 50% water. Install the radiator
cap. Fill the coolant reservoir up to the FULL mark on
the reservoir.
9004-19
Removal STEP 85
STEP 80
Park the machine on a level surface and lower the
bucket to the ground.
STEP 81
Place the master disconnect switch in the OFF
position.
STEP 82
Discharge the air conditioning system according to
the instructions in Section 9003.
BS03A107
STEP 83 Fa s t e n i d e n t i f i c a t i o n t a g s o n t h e h o s e s a n d
disconnect the hoses from the condenser.
1 STEP 86
Install plugs in the hoses and caps on the fittings.
2 STEP 87
BD01D142
1. COVER 2. CONDENSER
Open the cover (1) to gain access to the condenser
(2).
STEP 84
BS03A109
BD03A109
STEP 92
BD06G211
Fa s t e n i d e n t i f i c a t i o n t a g s o n t h e h o s e s a n d
disconnect the hoses from the receiver drier.
STEP 89
Install plugs in the hoses and caps on the fittings. BS03A109
BS03A107
STEP 94
Remove the plugs from the hoses and the caps from
the fittings. Install new O-rings and connect the
hoses to the fittings. Remove and discard
identification tags that were used during
disassemble.
STEP 95
Pivot the condenser down and close the cover.
STEP 96
Mount the receiver drier and bracket, install and
tighten the mounting bolt.
9004-21
STEP 97 STEP 98
Charge the air conditioning system according to the
instructions in Section 9003.
STEP 99
Place the master disconnect switch in the ON
position.
BD06G211
LOADER
9006
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REMOVING THE LOADER FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLING THE LOADER FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
9006-3
SPECIFICATIONS
Special Torques
Bolts for the Bucket Teeth ........................................................................1315 to 1480 Nm (970 to 1090 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 lift NOT start the engine.
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 3.2 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 the
target bar (3), until an air gap of 3.2 to 5.0 mm 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.
9006-5
5
6
3
2
1
BS01C081
1. Park the machine on a level surface. 6. Adjust the proximity switch (3) out towards the
return to travel target (5) until an air gap of 3.2 to
2. Start the engine and apply the parking brake.
5.0 mm (1/8 to 3/16 inch) is obtained.
3. Lower the lift arms and place the bucket flat on
7. Lock the proximity switch (3) in this position with
the ground.
the jam nut. Torque the jam nut to 6 to 7.5 Nm
4. Stop the engine. (4.5 to 5.5 pound-feet).
NOTE: To avoid damage to the proximity switch (3),
it must be adjusted back to clear everything on the lift
arm as it passes. Refer to the illustration on this
page.
2
A
B
1
BS01C082
APPROXIMATE APPROXIMATE
RESULTING RETURN TO RESULTING HEIGHT
MACHINE A B
TRAVEL HINGE PIN CONTROL HINGE PIN
HEIGHT HEIGHT
821F Z-Bar 56 mm (2.2 inches) 414 mm (16.3 inches) 42 mm (1.6 inches) 3302 mm (130 inches)
821F XR 70 mm (2.76 inches) 587 mm (23.11inches) 61 mm (2.4 inches) 4000 mm (157.48 inches)
921F Z-Bar 56 mm (2.2 inches) 414 mm (16.3 inches) 42 mm (1.6 inches) 3302 mm (130 inches)
921F XR 70 mm (2.76 inches) 587 mm (23.11inches) 61 mm (2.4 inches) 4000 mm (157.48 inches)
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 position
positioned in its slot in the target mounting plate (3), and verify that the electromagnet holds it in that
the lower the lift arms will stop as they are raised. position until the height control target (2) passes
in front of the proximity switch (3). Refer to the
9. Tighten the height control target (1).
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.
9006-7
15. If the machine is equipped with front lamps, 22. Raise the loader frame (2) out of the front frame.
loosen and remove the cap screws and lock Carefully move the machine out of the loader
washers that fasten the lamp brackets to the front frame (2).
frame. Put the lamp brackets on the fenders.
16. Connect the chain hoist to the loader frame (2).
9006-8
10
18 8
20 18 22
16
17 15
19 9 6 7
2
1 11
21
5
5 4
14
12 5
3
13
23
BS01G022
9007
9007-2
TABLE OF CONTENTS
ROLLOVER PROTECTIVE STRUCTURE (ROPS)
CAB STRUCTURAL FRAME (CSF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MAINTENANCE AND INSPECTION OF THE (CSF) CAB OR (ROPS) CANOPY . . . . . . . . . . . . . . . . . . . . . . . . 3
CSF CAB AND ROPS CANOPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
9007-3
Removal STEP 5
NOTE: Procedures and photos in following steps
cover in detail removal and installation of CSF
structure. Removal and installation of ROPS is
similar to removal and installation of CSF structure.
STEP 1
Park machine on a level surface and lower bucket to
floor. Stop engine. Actuate brake pedal several times
to discharge brake accumulators. Put key switch in
ON position and move loader control lever back and
forth at least 30 times to release any pressure from
hydraulic circuit. Put key switch in OFF position. BD06G191
BD01F143
STEP 4
BD06G189
BD06G194 BD06G192
If machine is equipped with windshield washers, Identify, tag, and disconnect hoses from steering
identify, tag, and disconnect front and rear windshield control valve. Plug hoses and cap steering control
washer nozzle hoses from supply hoses. valve fittings to prevent entry of foreign matter into
hydraulic system.
STEP 9
STEP 12
2 3
BD06G205
1. TRANSMISSION FILTER
2. AIR CONDITIONING HOSES BD06F207
3. HEATER HOSES
Unlatch and open the window on the right hand side.
If machine is equipped with a heater disconnect
heater hoses (3), if machine is equipped with air STEP 13
conditioning discharge the air conditioning system,
see section 9003, and disconnect the air conditioning
hoses (2), cap and plug lines and fittings.
STEP 10
BD06F208
BD06G193
BD06F209 BD06G187
Remove the front access panel. Disconnect the electrical connectors, push
connectors out of the bottom of the cab with the
STEP 15 rubber gromment
STEP 20
BD06F210
STEP 17
Put identification tags on each hose and disconnect
one at a time from the remote control valve. Install
plugs in the hoses and caps on the fittings to prevent
entry of foreign matter into hydraulic system.
STEP 18
Push the hoses out of the bottom of the cab with the
rubber gromment.
BD06G185
BD06G184
STEP 23
Connect lifting equipment to cab at lifting eyes. Take
up all slack in lifting equipment.
STEP 24
Remove nuts, bolts, and washers securing cab to
rear chassis.
9007-8
2 1
4
4
5
5
6
6
BC06G031
Installation STEP 32
STEP 26
Check rubber mounts (3 an 4) for deterioration, tears,
defor mation, or other damage; replace rubber
mounts as necessary.
STEP 27
BD06G188
STEP 33
BD01D388
STEP 28
Install washers, bolts, and nuts to secure cab to rear BD06G192
chassis. Tighten bolts to a torque of 773 to 854 Nm
Remove plugs from hoses and caps from fittings.
(570 to 630 pound feet)
Connect hoses to steering control valve following
tags installed during removal. Remove and discard
STEP 29 tags.
Disconnect lifting equipment from cab.
STEP 34
STEP 30
Remove lifting eyes.
STEP 31
BD06G193
BD06G185
2 3
BD06G186 BD06G205
1. TRANSMISSION FILTER
Install the ducts on the machine.
2. AIR CONDITIONING HOSES
3. HEATER HOSES
STEP 36
If machine is equipped with a heater, remove plugs
from hoses and caps from fittings, connect heater
hoses (3), if machine is equipped with air
conditioning, remove plugs from hoses and caps
from fittings, connect air conditioning hoses (2),
charge the air conditioning system, see section 9003.
STEP 39
Remove plugs from hoses and caps from fittings.
Connect hoses to joystick and two-lever controller
and install in hose mounting grommet halves as
shown on pages 11, 12, and 13.
BD06G189
STEP 37
BD06G194
3
8
6
7
1
5
7 8
7 5
1 2
8 3
6 4
BC05M092
5 5
7 1 4 7
3
4
6 3
2 1
6
2
7 7
7 7
1 1
2 2
6 6
3 3
4 5 4 5
BC05M091
1
5
4 5 4 6
6 3 2
3 1
2
2 1 2 1
6 6
3 3
4 5 4 5
BC05M090
BD06F210 BD06F208
Connect the electrical connectors for the remote Install and close the access panel.
control valve.
STEP 44
STEP 41
BD06F209 BD06F207
Place the access panel into position, install and Close the right hand window.
tighten the screw.
STEP 42 STEP 45
BD06G187
BD06G191
Connect wiring harness connectors.
Install skirting under each side and front of cab.
9007-15
STEP 46 STEP 49
Start engine and run engine at low idle. Run engine
at operating temperature for approximately five
minutes to completely mix Ethylene Glycol and water.
When coolant is at operating temperature, stop
engine. When engine has cooled, check coolant level
at reservoir.
WARNING: Hot coolant can spray out if radiator cap
is removed. To remove radiator cap: let system cool,
turn to first notch, then wait until all pressure is
released. Scalding can result from fast removal of
radiator cap.
BD01F184
STEP 50
If machine is equipped with a heater and coolant was
drained, check that coolant drain cap is tight. Put articulation lock in OPERATING position.
STEP 47
Fill engine coolant system with a solution of 50%
Ethylene Glycol and 50% water. Cooling system
capacity is 36.9 liters (9.75 U.S. Gallons). Install
radiator cap. Fill coolant reservoir up to FULL mark
on reservoir.
STEP 48
Put battery disconnect switch in ON position.
9007-16
NOTES
Section
9010
9010
9010-2
TABLE OF CONTENTS
PREPARATION FOR GLASS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GLASS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SILICONE SEALANT APPLICATION - FRONT WINDOWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
9010-3
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.
adhesive (345-135) to the pr imed surface
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
9010-5
2
1
3
4
2
1
497L93
9020
9020-2
TABLE OF CONTENTS
Rear view camera . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation - Camera . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation - Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
9020-3
STEP 1
STEP 4
Assemble and mount the camera brackets as shown
in Camera mounting - Ilustration 1. Route the camera
harness through the screen.
Route cable down left side and under fan to the right
side of the Wheel Loader. Pull cable and tie wrap
through firewall to the bottom of the fuse box.
9020-4
STEP 8 STEP 11
Pull cable up through existing hole into the fuse box. In the fuse box connect the extension cable from the
camera to the CA1 cable from the monitor. Tie wrap
STEP 9 to secure cable.
STEP 12
MONITOR MOUNTING
monitor as shown and tighten all nuts. Connect the remaining monitor connector to the
“MON” connector in the fuse box. Tie wrap to secure
cable.
STEP 10 STEP 13
Install the 5A fuse to F19 in the ECA fuse panel.
Always install the correct fuse size.
Install the access plate and route the cable with the
engine harness. The monitor cable will run through
the grommet on the access plate and up to the
monitor per Plate access mounting - Illustration 3.
9020-5
Installation - Monitor
Camera mounting - Illustration 1
84336466(1)
84336466(2)
9020-6
Plate access mounting - Illustration 3
84336466(3)
84336466(4)
9020-7
Removal STEP 4
STEP 1
STEP 2 STEP 5
Raise the engine hood and turn the master switch to Unplug the monitor cable and loosen the handle on
the off position. display arm. Remove monitor.
STEP 3
BACKUP ALARM 6
, 14
COLOR ABBREVIATIONS
70
62
SHT SHT SHT SHT SHT
SHT
71
SHT
3 18
21 13 14 15
20
2
8
158
1
10
Relay in
4 location F5/F6
160
Relay in
location
F3\F4
6 11
16 17
159
92
90
161
Relay in
location F7\F8 Relay in
Relay in location
location 93 F9\F10
F1/F2
95
78
CAN_L3 G-0.8
CAN_H3 Y-0.8
91
23 Turn
Signal
163
Driving
Lights
Light/
Horn
79
Horn
169 94
164
168
103
165 96 97
167
166 102
89 172
54
173 171
57
81 55
59
56
88
87
174
80
86
46
47
45
61
48
58
49
85
50
84
51
52
170
53
83
60
82
35
36
26
63 29
33
64
31
32
68 98
74
27
72
37
67
65
99
75
69
73 39
28
76
40
38 34 30
66
41
42
44
43
121
113
122
155 129
154 122
104 126
128
108
105 130
114
106 125
124 123
115 119
107
117
109
156
111
116
BLUE BROWN
112
DOWN
LIMIT
UP
LIMIT
113 Note: Telematics for future models
SWITCH SWITCH
127
157
110
NO
COM 118
NC
R R
S S
144
143
146
184
177
175
147
8
8
148
185
176
179
153
149 150
152
151
178
181
182
180
183
186
16
21
11 YPP
A1
UNLOCK
20
P
T X1
LOCK
8 16B
MX
16A B1
20D
12 T 20A
280 bar
14
16C
20C
R R1 F
4 13A 13
2 20B
X 13F
16D
3
1
13E
5 P
2 B A
3 13D 16E
13B 1
T1
T1'
N B
240±8% L/min
240±8% L/min
280±8% L/min
20±8% L/min
B1 280±8% L/min
OPTION
22K
BOOM
BUCKET
22K
a3
a2
6 13C
T2
868050
868050
ø0.8
ø2.0
ø2.0
ø0.8
pst
22A
0.6
R2
a1
A1
A3
A2
B3
B2
P
17
765876
LS
Mp
1.2
Pst
22F
11
R901075585
898999
7
528789
528789
528789
30 bar
22C
T
22C )( 22H
22C
22G
847160
TP11: REAR BRAKE TO AXLE 10
224±3 bar
R901007569
R901075587
859551
TP10: FRONT BRAKE TO AXLE 22J
22D
8-10.8 bar
329140
TP6: FRONT BRAKE ACCUMULATOR
MT1
22B
S1
TP7: REAR BRAKE ACCUMULATOR
737012
290 bar
290 bar
936718
936718
290 bar
290 bar
936718
936718
TP2: IMPLEMENT LOAD SENSE
936725
TP5: STEERING PUMP PRESSURE
22D
TP1: UNLOADING PUMP PRESSURE 22E 22E 22D 22E
22E
S2
TP9: PILOT PRESSURE SUPPLY
22
A2
280±8% A1
b1
B2
899039
868050
ø2.0
ø2.0
ø0.8
ø0.8
L/min
45C
M2 P
22K 22K
b3
b2
45B
44 45A
45
43
42 234
M2 162 bar IN bar
35 LS EF LS IMPL 24
23cc 234
M1 TANK CF
bar .64
L
.8 24A
P 24B
46
45B 45D
Note 2 T 24C
35A T 30 LS 23
M1 LS SLS ST CF 32
G1
0.7
35B 35C 27
G2 X2
R
34 X1 30A 2
33 T
240 bar 0.31 1 46
0.31
34A 33A 30B
36 29
R L
34B 33B 3
30C
40 28
Note 1 0.75 LS
23cc 34C 33C T P
P T
28A
41 P
34D 33D
1.8
28B 28C
L1 L2 S1 S2 L4 L3 p
31 26
39 11 cc
T
25
38
COMPONENTS
1 Rear Axle Brakes 11 Redundant Accumulator Pressure Switches 16C Lift Pilot Control 22F Pilot Pressure Reducing Valve 30A Auxiliary Steering Activation Solenoid 35A Priority Spool 44 Standard Fan Valve
Modulation Pressure Electrical Connectors PRB1, PRB2 16D Auxiliary Hydraulics Pilot Control 1 29 to 40 bar (420 to 580 PSI) Electrical Connector YSS 35B Differential Pressure Relief 162 bar (2350 PSI)
68 to 75 bar (985 to 1090 PSI) Rising < 91 bar (< 1320 PSI) 16E Auxiliary Hydraulics Pilot Control 2 22G Pilot Pressure Relief 30B Relief Valve 40 bar (580 PSI) 45 Fan Reversing and Variable Valve
2 Front Axle Brakes Falling 70 to 84 bar (1015 to 1220 PSI) 17 Pilot Control Accumulator 22H Load Sense Signal Bleed Down Orifice 240 bar (3480 PSI) 35C Steering Relief 45A Crossover Relief 234 bar (3395 PSI)
Modulation Pressure 12 Low Brake Pressure Warning Switch 0.75 liter (0.79 quart) 22J Loader Main Relief 30C Priority Spool 216 bar (3130 PSI) 45B Reversing Spools
70 to 77 bar (1015 to 1115 PSI) Alarm OFF 138 bar (2000 PSI) Increasing 13.8 bar (200 PSI) Precharge 22K Shuttle Check Valve 31 Auxiliary Steering Pump 36 Brake Pump 45C Pulse Width Modulation (PWM) Relief Valve
37 37 3 Brake Damping Accumulators Alarm ON 115 to 129 bar (1670 to 1870 PSI) Decreasing 18 Bucket Cylinder Z-Bar 23 Steering Cylinders 32 Auxiliary Steering Pressure Switch 37 100 Mesh Strainers 165 bar (2390 PSI)
0.16 liter (0.17 quart) 13 Brake Valve 19 Lift Cylinders 24 Steering Control Valve Electrical Connector PSS 38 Hydraulic Reservoir 45D ON/OFF Reversing Solenoid
7 bar (102 PSI) Precharge 13A Parking Brake Solenoid 20 Ride Control Valve 24A Steering Spool 33 Second Pump (Farthest from Transmission) 90 liter Electrical Connector YFR
4 Parking Brake Electrical Connector YPB 20A Ride Control Solenoid 24B Gerotor Pump 120 LPM (31.6 GPM) 39 Reservoir Vent 46 Steering Cylinder Relief Valves
5 Brake Signal, 5-speed transmission 13B Front Brake Valve Electrical Connector YRC 24C Circuit Relief Valve Cut Off 280 bar (4060 PSI) 100 mesh 345 bar (5000 PSI)
6 Brake Declutch Switch, 4-speed transmission 13C Rear Brake Valve 20B Ride Control Spool Valve 25 Steering Back Pressure Valve Delta 24 to 26 bar (350 to 375 PSI) 0.03 bar check
Electrical Connector PBD 13D Accumulator Isolation Check Valve 20C Manual Bleed Valve 8 to 10 bar (115 to 145 PSI) 33A Compensator Differential Pressure Spool 0.35 bar relief
24 bar (350 PSI) 13E Accumulator Charging Spool 20D Pressure Relief Valve 26 Steering Back Pressure Sensor 33B Compensator High Pressure Cutoff Spool 40 Filter
7 Brake Light Switch 13F Priority Valve 280 bar (4060 PSI) Joystick Steering Only 33C Control Piston with Spring Electrical Connector PHF
4.1 bar (60 PSI) Increasing Cut-In Pressure 21 Ride Control Accumulator 27 Joystick Steering Load Sense Resolver 33D Rotating Group with Swash Plate 10 micron media
8 Parking Brake Accumulator 157 to 167 bar (2275 to 2420 PSI) 3.78 liter (4 quart) 28 Joystick Steering Valve 34 First Pump (Closest to Transmission) Bypass 3.4 bar (50 PSI)
0.16 liter (0.17 quart) Cut-Out Pressure 14.5 bar (210 PSI) Precharge 28A Control Spool 120 LPM (31.6 GPM) Warning Switch 2.7 bar (40 PSI)
96 bar (1390 PSI) Precharge 190 to 196 bar (2755 to 2845 PSI) 22 Loader Valve 28B Pressure Reducer Cut Off 280 bar (4060 PSI) 41 Oil Cooler Thermal Valve
9 Front Brake Accumulator 14 Coupler Locking Valve 22A Load Sense Shuttle Valve 28C Pilot Dump Valve Delta 28 to 30 bar (405 to 435 PSI) 2.4 to 3.6 bar (35 to 52 PSI) Bypass
3.5 liter (3.7 quart) 15 Coupler Locking Cylinders 22B Regeneration Relief Valve 29 Auxiliary Steering Accumulator 34A Compensator Differential Pressure Spool 42 Hydraulic Oil Cooler
70 bar (1015 PSI) Precharge 16 Pilot Control Valve 22C Flow Compensator Spool 0.32 liter (0.34 quart) 34B Compensator High Pressure Cutoff Spool 43 Oil Cooler Fan
10 Rear Brake Accumulator, 3.5 liter, 70 bar precharge 16A Pilot ON/OFF Solenoid 22D Regeneration Check Valve 60 bar (870 PSI) Precharge 34C Control Piston with Spring
3.5 liter (3.7 quart) Electrical Connector YPP 22E Circuit Relief Valve with Anti-Cavitation 30 Auxiliary Steering Control Valve 34D Rotating Group with Swash Plate
70 bar (1015 PSI) Precharge 16B Bucket Pilot Control 35 Priority Valve
16 21
11 A1
UNLOCK
P 20 T X1
LOCK
16B
8
MX
16A B1
20D
12 T
20A 280 bar
14
16C
20C
R R1 F
4 13
13A 2
20B
X 13F 16D
3
1
13E
5 P
2 B A
3 13D 16E
13B 1
T1
T1'
N B
B1 280±8% L/min
B3 240±8% L/min
B2 280±8% L/min
A3 240±8% L/min
20±8% L/min
22K 22K
BOOM
BUCKET
a3
a2
OPTION
6
13C
T2
868050
868050
ø0.8
ø2.0
ø2.0
ø0.8
pst
0.6 22A
R2
A1
A2
a1
17
P
765876
LS
Mp
1.2
Pst
22F
11
R901075585
7
898999
528789
528789
528789
30 bar
22C
T
)( 22H 22C
22C
22G
847160
TP11: REAR BRAKE TO AXLE 10
224±3 bar
R901075587
R901007569
859551
TP10: FRONT BRAKE TO AXLE
22D 22J
8-10.8 bar
329140
TP6: FRONT BRAKE ACCUMULATOR
MT1
22E
S1
TP7: REAR BRAKE ACCUMULATOR
737012
290 bar
290 bar
290 bar
290 bar
936718
936718
936718
936718
TP5: STEERING PUMP PRESSURE
936725
TP1: UNLOADING PUMP PRESSURE
22D
22E 22E 22D 22E
TP9: PILOT PRESSURE SUPPLY
22E
S2
22
A2
280±8% A1
b1
B2
899039
868050
ø2.0
ø2.0
ø0.8
ø0.8
L/min
M2 45C
P
22K 22K
b3
b2
45B
44 45A 45
42 43
M2 IN 234
162 BAR bar
23cc 35 LS EF LS IMPL 24
234 CF
M1 TANK bar 0.64
L
0.47
LS1 24A
P 24B 46
LS2
45B 45D
Note 2
T 35A 24C
T 30 LS
M1 23
G1 LS SLS ST CF 32
35B 0.7
35C 27
X1 G2 X2
R
34 30A 2 T
33
240 bar 0.31 1 46
0.31
34A 33A 30B
36 29
R L
34B 33B
30C 3
40 28
Note 1 0.75 LS
23cc 34C 33C T P
P T
28A
41 P
34D 33D
1.8
28B 28C
p
L1 L2 S1 S2 L4 L3
31 26
39 11 cc
25 T
38
COMPONENTS
1 Rear Axle Brakes 11 Redundant Accumulator Pressure Switches 16C Lift Pilot Control 22F Pilot Pressure Reducing Valve 30 Auxiliary Steering Control Valve 35 Priority Valve 42 Hydraulic Oil Cooler
Modulation Pressure Electrical Connectors PRB1, PRB2 16D Auxiliary Hydraulics Pilot Control 1 29 to 40 bar (420 to 580 PSI) 30A Auxiliary Steering Activation Solenoid 35A Priority Spool 43 Oil Cooler Fan
68 to 75 bar (985 to 1090 PSI) Rising < 91 bar (< 1320 PSI) 16E Auxiliary Hydraulics Pilot Control 2 22G Pilot Pressure Relief Electrical Connector YSS 35B Differential Pressure Relief 44 Standard Fan Valve
2 Front Axle Brakes Falling 70 to 84 bar (1015 to 1220 PSI) 17 Pilot Control Accumulator 22H Load Sense Signal Bleed Down Orifice 30B Relief Valve 40 bar (580 PSI) 162 bar (2350 PSI)
Modulation Pressure 12 Low Brake Pressure Warning Switch 0.75 liter (0.79 quart) 22J Loader Main Relief 240 bar (3480 PSI) 35C Steering Relief 45 Fan Reversing and Variable Valve
37 37 70 to 77 bar (1015 to 1115 PSI) Alarm OFF 138 bar (2000 PSI) Increasing 13.8 bar (200 PSI) Precharge 22K Shuttle Check Valve 30C Priority Spool 216 bar (3130 PSI) 45A Crossover Relief 234 bar (3395 PSI)
3 Brake Damping Accumulators Alarm ON 115 to 129 bar (1670 to 1870 PSI) Decreasing 18 Bucket Cylinder Z-Bar 23 Steering Cylinders 31 Auxiliary Steering Pump 36 Brake Pump 45B Reversing Spools
0.16 liter (0.17 quart) 13 Brake Valve 19 Lift Cylinders 24 Steering Control Valve 32 Auxiliary Steering Pressure Switch 37 100 Mesh Strainers 45C Pulse Width Modulation (PWM) Relief Valve
7 bar (102 PSI) Precharge 13A Parking Brake Solenoid 20 Ride Control Valve 24A Steering Spool Electrical Connector PSS 38 Hydraulic Reservoir 165 bar (2390 PSI)
4 Parking Brake Electrical Connector YPB 20A Ride Control Solenoid 24B Gerotor Pump 33 Second Pump (Farthest from Transmission) 108.5 liter 45D ON/OFF Reversing Solenoid
5 Brake Signal, 5-speed transmission 13B Front Brake Valve Electrical Connector YRC 24C Circuit Relief Valve 120 LPM (31.6 GPM) 39 Reservoir Vent Electrical Connector YFR
6 Brake Declutch Switch, 4-speed transmission 13C Rear Brake Valve 20B Ride Control Spool Valve 25 Steering Back Pressure Valve Cut Off 280 bar (4060 PSI) 100 mesh 46 Steering Cylinder Relief Valves
Electrical Connector PBD 13D Accumulator Isolation Check Valve 20C Manual Bleed Valve 8 to 10 bar (115 to 145 PSI) Delta 21 to 23 bar (305 to 335 PSI) 0.03 bar check 345 bar (5000 PSI)
24 bar (350 PSI) 13E Accumulator Charging Spool 20D Pressure Relief Valve 26 Steering Back Pressure Sensor 33A Compensator Differential Pressure Spool 0.35 bar relief
7 Brake Light Switch 13F Priority Valve 280 bar (4060 PSI) Joystick Steering Only 33B Compensator High Pressure Cutoff Spool 40 Filter
4.1 bar (60 PSI) Increasing Cut-In Pressure 21 Ride Control Accumulator 27 Joystick Steering Load Sense Resolver 33C Control Piston with Spring Electrical Connector PHF
8 Parking Brake Accumulator 157 to 167 bar (2275 to 2420 PSI) 3.78 liter (4 quart) 28 Joystick Steering Valve 33D Rotating Group with Swash Plate 10 micron media
0.16 liter (0.17 quart) Cut-Out Pressure 14.5 bar (210 PSI) Precharge 28A Control Spool 34 First Pump (Closest to Transmission) Bypass 3.4 bar (50 PSI)
96 bar (1390 PSI) Precharge 190 to 196 bar (2755 to 2845 PSI) 22 Loader Valve 28B Pressure Reducer 162 LPM (42.7 GPM) Warning Switch 2.7 bar (40 PSI)
9 Front Brake Accumulator 14 Coupler Locking Valve 22A Load Sense Shuttle Valve 28C Pilot Dump Valve Cut Off 280 bar (4060 PSI) 41 Oil Cooler Thermal Valve
3.5 liter (3.7 quart) 15 Coupler Locking Cylinders 22B Regeneration Relief Valve 29 Auxiliary Steering Accumulator Delta 24 to 26 bar (350 to 380 PSI) 2.4 to 3.6 bar (35 to 52 PSI) Bypass
70 bar (1015 PSI) Precharge 16 Pilot Control Valve 22C Flow Compensator Spool 0.32 liter (0.34 quart) 34A Compensator Differential Pressure Spool
10 Rear Brake Accumulator, 3.5 liter, 70 bar precharge 16A Pilot ON/OFF Solenoid 22D Regeneration Check Valve 60 bar (870 PSI) Precharge 34B Compensator High Pressure Cutoff Spool
3.5 liter (3.7 quart) Electrical Connector YPP 22E Circuit Relief Valve with Anti-Cavitation 34C Control Piston with Spring
70 bar (1015 PSI) Precharge 16B Bucket Pilot Control 34D Rotating Group with Swash Plate