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SERVICE MANUAL

WHEEL LOADER
821E
TIER 3

84299244
(Replaces 87364100)

Revised December 2009


Issued September 2006

SECTION INDEX

GENERAL
Section Title

Section Number

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


Fluids and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1002
Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1003

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

Bur 5-3090

Copyright 2006 CNH Ameica LLC.


All rights reserved.
Printed in U.S.A.
Issued August, 2006

1001
Section
1001
GENERAL TORQUE SPECIFICATIONS

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

Bur 8-71603

Copyright 2004 CNH America LLC.


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

1001-2

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

Bur 8-71603

Revised 7-05

3
4
5
6

Printed in U.S.A.

1001-3

TORQUE SPECIFICATIONS - DECIMAL HARDWARE


Use the torques in this chart when special torques
are not given. These torques apply to fasteners with
both UNC and UNF threads as received from
suppliers dry, or when lubricated with engine oil. Not
applicable if special graphities, Molydisulfide
greases, or other extreme pressure lubricants are
used.

Grade 5 Bolts, Nuts, and Studs

Grade 8 Bolts, Nuts, and Studs

PoundInches

Newton
metres

1/4 inch

144 to 180

16 to 20

5/16 inch

288 to 348

33 to 39

3/8 inch

540 to 648

61 to 73

Size

PoundInches

Newton
metres

Size

PoundFeet

Newton
metres

1/4 inch

108 to 132

12 to 15

7/16 inch

70 to 84

95 to 114

5/16 inch

204 to 252

23 to 28

1/2 inch

110 to 132

149 to 179

3/8 inch

420 to 504

48 to 57

9/16 inch

160 to 192

217 to 260

5/8 inch

220 to 264

298 to 358

Newton
metres

3/4 inch

380 to 456

515 to 618

Size

PoundFeet

7/8 inch

600 to 720

814 to 976

7/16 inch

54 to 64

73 to 87

1.0 inch

900 to 1080

1220 to 1465

1/2 inch

80 to 96

109 to 130

1-1/8 inch

1280 to 1440

1736 to 1953

9/16 inch

110 to 132

149 to 179

1-1/4 inch

1820 to 2000

2468 to 2712

5/8 inch

150 to 180

203 to 244

1-3/8 inch

2380 to 2720

3227 to 3688

3/4 inch

270 to 324

366 to 439

1-1/2 inch

3160 to 3560

4285 to 4827

7/8 inch

400 to 480

542 to 651

1.0 inch

580 to 696

787 to 944

1-1/8 inch

800 to 880

1085 to 1193

1-1/4 inch

1120 to 1240

1519 to 1681

1-3/8 inch

1460 to 1680

1980 to 2278

1-1/2 inch

1940 to 2200

2631 to 2983

Size

Bur 8-71603

NOTE: Use thick nuts with Grade 8 bolts.

Revised 7-05

Printed in U.S.A.

1001-4

TORQUE SPECIFICATIONS - METRIC HARDWARE


Use the following torques when specifications are not
given.
These values apply to fasteners with coarse threads
as received from supplier, plated or unplated, or
when lubricated with engine oil. These values do not
apply if graphite or Molydisulfide grease or oil is
used.

Grade 8.8 Bolts, Nuts, and Studs


8.8

Size

PoundInches

Grade 10.9 Bolts, Nuts, and Studs


10.9

Size

PoundInches

Newton
metres

M4

36 to 48

4 to 5

M5

84 to 96

9 to 11

M6

132 to 156

15 to 18

M8

324 to 384

37 to 43

PoundFeet

Newton
metres

Newton
metres

M4

24 to 36

3 to 4

Size

M5

60 to 72

7 to 8

M10

54 to 64

73 to 87

M6

96 to 108

11 to 12

M12

93 to 112

125 to 150

M8

228 to 276

26 to 31

M14

149 to 179

200 to 245

M10

456 to 540

52 to 61

M16

230 to 280

310 to 380

M20

450 to 540

610 to 730

Newton
metres

M24

780 to 940

1050 to 1275

Size

PoundFeet

M30

1470 to 1770

2000 to 2400

M12

66 to 79

90 to 107

M36

2580 to 3090

3500 to 4200

M14

106 to 127

144 to 172

M16

160 to 200

217 to 271

M20

320 to 380

434 to 515

M24

500 to 600

675 to 815

M30

920 to 1100

1250 to 1500

M36

1600 to 1950

2175 to 2600

Bur 8-71603

Grade 12.9 Bolts, Nuts, and Studs


12.9

Usually the torque values specified for grade 10.9


fasteners can be used satisfactorily on grade 12.9
fasteners.

Revised 7-05

Printed in U.S.A.

1001-5

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS


37 Degree Flare Fitting

Straight Threads with O-ring

Tube OD
Hose ID

Thread
Size

PoundInches

Newton
metres

Tube OD
Hose ID

Thread
Size

PoundInches

Newton
metres

1/4 inch
6.4 mm

7/16-20

72 to 144

8 to 16

1/4 inch
6.4 mm

7/16-20

144 to 228

16 to 26

5/16 inch
7.9 mm

1/2-20

96 to 192

11 to 22

5/16 inch
7.9 mm

1/2-20

192 to 300

22 to 34

3/8 inch
9.5 mm

9/16-18

120 to 300

14 to 34

3/8 inch
9.5 mm

9/16-18

300 to 480

34 to 54

1/2 inch
12.7 mm

3/4-16

180 to 504

20 to 57

1/2 inch
12.7 mm

3/4-16

540 to 804

57 to 91

5/8 inch
15.9 mm

7/8-14

300 to 696

34 to 79
Tube OD
Hose ID

Thread
Size

PoundFeet

Newton
metres

Tube OD
Hose ID

Thread
Size

PoundFeet

Newton
metres

5/8 inch
15.9 mm

7/8-14

58 to 92

79 to 124

3/4 inch
19.0 mm

1-1/16-12

40 to 80

54 to 108

3/4 inch
19.0 mm

1-1/16-12

80 to 128

108 to 174

7/8 inch
22.2 mm

1-3/16-12

60 to 100

81 to 135

7/8 inch
22.2 mm

1-3/16-12

100 to 160

136 to 216

1.0 inch
25.4 mm

1-5/16-12

75 to 117

102 to 158

1.0 inch
25.4 mm

1-5/16-12

117 to 187

159 to 253

1-1/4 inch
31.8 mm

1-5/8-12

125 to 165

169 to 223

1-1/4 inch
31.8 mm

1-5/8-12

165 to 264

224 to 357

1-1/2 inch
38.1 mm

1-7/8-12

210 to 250

285 to 338

1-1/2 inch
38.1 mm

1-7/8-12

250 to 400

339 to 542

Split Flange Mounting Bolts


PoundInches

Newton
metres

5/16-18

180 to 240

20 to 27

3/8-16

240 to 300

27 to 34

7/16-14

420 to 540

47 to 61

Size

PoundFeet

Newton
metres

1/2-13

55 to 65

74 to 88

5/8-11

140 to 150

190 to 203

Size

Bur 8-71603

Revised 7-05

Printed in U.S.A.

1001-6

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS


O-ring Boss End
Fitting or Lock Nut

O-ring Face Seal End


Nom.
SAE
Dash
Size

Tube OD

Thread
Size

PoundInches

Newton
metres

Thread
Size

PoundInches

Newton
metres

-4

1/4 inch
6.4 mm

9/16-18

120 to 144

14 to 16

7/16-20

204 to 240

23 to 27

-6

3/8 inch
9.5 mm

11/16-16

216 to 240

24 to 27

9/16-18

300 to 360

34 to 41

-8

1/2 inch
12.7 mm

13/16-16

384 to 480

43 to 54

3/4-16

540 to 600

61 to 68

Thread
Size

PoundFeet

Newton
metres

7/8-14

60 to 65

81 to 88

1-1/16-12

85 to 90

115 to 122

-10

Nom.
SAE
Dash
Size

5/8 inch
15.9 mm

Tube OD

1-14

552 to 672

62 to 76

Thread
Size

PoundFeet

Newton
metres

1-3/16-12

95 to 100

129 to 136

-12

3/4 inch
19.0 mm

1-3/16-12

65 to 80

90 to 110

1-5/16-12

115 to 125

156 to 169

-14

7/8 inch
22.2 mm

1-3/16-12

65 to 80

90 to 110

1-5/8-12

150 to 160

203 to 217

-16

1.0 inch
25.4 mm

1-7/16-12

92 to 105

125 to 140

1-7/8-12

190 to 200

258 to 271

-20

1-1/4 inch
31.8 mm

1-11/16-12

125 to 140

170 to 190

-24

1-1/2 inch
38.1 mm

2-12

150 to 180

200 to 254

Bur 8-71603

Revised 7-05

Printed in U.S.A.

1002

Section
1002
FLUIDS AND LUBRICANTS

CNH America LLC.


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

Bur 5-3100

Copyright 2006 CNH Ameica LLC.


All rights reserved.
Printed in U.S.A.
Issued August, 2006

1002-2

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

Bur 5-3100

Issued 8-06

3
4
5
5
5
5
6
6
7
7

Printed in U.S.A.

1002-3

CAPACITIES AND LUBRICANTS


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

Bur 5-3100

Issued 8-06

Printed in U.S.A.

1002-4

ENGINE OIL RECOMMENDATIONS


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

RH99K130

BD03A102

NOTE: Do not put performance


additives or other oil additive
products
in
the
engine
crankcase. The oil change
intervals given in this manual
are according to tests with Case
AKCELA lubricants.

BC02N250

Bur 5-3100

Issued 8-06

Printed in U.S.A.

1002-5

TRANSMISSION TEMPERATURE CHART

BC04F193

DIESEL FUEL SYSTEM


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

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

The diesel fuel used in this machine must meet the


specifications as shown below in, Specifications for
Acceptable No. 2 Diesel Fuel, or Specification
D975-81 of the American Society for Testing and
Materials.

Specifications for Acceptable No. 2 Diesel Fuel


API gravity, minimum ............................................................................................................................................. 34
Flash point, minimum ............................................................................................................................60C (140F)
Cloud point (wax appearance point), maximum ...........................................................-20C (-5F) See Note above
Pour point, maximum ..................................................................................................-26C (-15F) See Note above
Distillation temperature, 90% point ................................................................................282 to 338C (540 to 640F)
Viscosity, at 38C (100F)
Centistokes ......................................................................................................................................... 2.0 to 4.3
Cetane number, minimum .......................................................................... 43 (45 to 55 for winter or high altitudes)
Water and sediment, by volume, maximum ..................................................................................................... 0.05%

Bur 5-3100

Issued 8-06

Printed in U.S.A.

1002-6

MAINTENANCE SCHEDULE
Model 821E

Variable
Periodic
(*)

13

Radiator Coolant Level

14

Tires

19

Hydraulic Filter

22

Alternator, AC, Drive Belt

29

Air cleaner

XX

Fire extinguisher

Every 10 Hours 1

Check Engine Oil Level

10

Check Engine Coolant Level

50

Check Transmission Oil Level

50

Check Hydraulic Oil Level

50

5&6

Grease Bucket Mounting Fittings

18

Bleed Fuel Filter of Condensation

Every 500
Hours

Every 1000
Hours

Every 2000
Hours
Every 6000
hours
Bur 5-3100

50
50

Change Engine Oil and Filters

100

18 & 26

Replace Fuel Filters

100

19

Change Hydraulic Filter

100

21

Change Oil in Axles

100

Lubricate The Steering Cylinder Pivots - Rod And


Closed End (4 Fittings)

100

Grease Front Drive Shaft Support Bearing

100

10

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

100

11

Lubricate Loader Lift & Cylinder Pivots (18) XT

100

12 & 23

Check Cab Air Filter

13

Check Radiator Coolant Level

14

Check Tire Pressure & Wheel Torque

22

Check Drive Belt

XX

Trans Clutch Calibration (See Section 6002)

250
250
4

250

250

1000

250

15

Check Axle Oil Level

500

16

Check Battery Electrolyte Level

500

17

Change Engine Oil and Filter

500

17

Change Crankcase Filter

500

18

Drain Fuel Tank Condensation & Water Separator

26

Replace Fuel Filter

500

19

Replace Hydraulic Oil filter

1000

20

Grease Articulation Fittings

21

Change Front & Rear Axle Oil

ADJUST

REPLACE

LUBRICATE

DRAIN

CHANGE

CLEAN

17

Every 100 Hours 9

Every 250
Hours

*
*
*
*
*
*

Every 50 Hours 4

First 100 Hours

SERVICE POINTS

CHECK

ITEM
NUMBER

SERVICE
INTERVAL

Initial Service

FREQUENCY IN HOURS

500

1000
1000

22

Replace Drive Belt

23

Replace Cab Air Filter

1000

25

Change Transmission Oil and Filter

XX

Check Injector Calibration

XX

Check Valve Adjustment (Engine Manual)

1000

XX

Trans Clutch Calibration (See Section 6002)

1000

1000
1000
1000

27

Change Hydraulic Oil

2000

28

Change Coolant

2000

29

Replace Engine Air Cleaner

XX

Valve Clearance (Engine Manual)

2000

XX

Engine Injectors (Engine Manual)

6000

XX

Fuel Pump (Engine Manual)

6000

2000
6000
Issued 8-06

Printed in U.S.A.

1002-7

MAINTENANCE POINTS
Model 821E
1

29

12 23

17

11

10

26
18
14
21 15

19 25 24

10

21 15

13

16

22

11
5

17

20

18

17

28

27
BC06F531

See your Operators manual for maintenance of


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

Bur 5-3100

If you operate the machine in severe conditions,


lubricate and service the machine more frequently.

Issued 8-06

Printed in U.S.A.

1002-8

NOTES

Bur 5-3100

Issued 8-06

Printed in U.S.A.

1003

Section
1003
METRIC CONVERSION CHART

CNH America LLC.


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

Bur 7-52590

Copyright 2003 CNH Ameica LLC.


All rights reserved.
Printed in U.S.A.
Issued April, 2003

1003-2

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

Bur 7-52590

Issued 4-03

Printed in U.S.A.

1003-3

CONVERSION FACTORS
Metric to U.S.
MULTIPLY

BY

TO OBTAIN

Area:

sq. meter
hectare

10.763 91
2.471 05

square foot
acre

Force:

newton
newton

3.596 942
0.224 809

ounce force
pound force

Length:

millimeter
meter
kilometer

0.039 370
3.280 840
0.621 371

inch
foot
mile

Mass:

kilogram

2.204 622

pound

Mass/Area:

kilogram/hectare

0.000 466

ton/acre

Mass/Energy:

gr/kW/hr.

0.001 644

lbs/hp/hr.

Mass/Volume:

kg/cubic meter

1.685 555

lb/cubic yd.

Power:

kilowatt

1.341 02

horsepower

Pressure:

kilopascal
bar

0.145 038
14.50385

lb/sq. inch
lb/sq. inch

Temperature:

degree C

1.8 x C +32

degree F

Torque:

newton meter
newton meter

8.850 748
0.737 562

lb/inch
lb/foot

Velocity:

kilometer/hr.

0.621 371

miles/hr.

Volume:

cubic centimeter
cubic meter
cubic meter
milliliter
litre
litre
litre
litre

0.061 024
35.314 66
1.307 950
0.033 814
1.056 814
0.879 877
0.264 172
0.219 969

cubic inch
cubic foot
cubic yd.
ounce (US fluid)
quart (US liquid)
quart (Imperial)
gallon (US liquid)
gallon (Imperial)

Volume/Time:

litre/min.
litre/min.

0.264 172
0.219 969

gallon/min. (US liquid)


gallon/min. (Imperial)

Bur 7-52590

Issued 4-03

Printed in U.S.A.

1003-4

U.S. to Metric
MULTIPLY

BY

TO OBTAIN

Area:

square foot
acre

0.092 903
0.404 686

square meter
hectare

Force:

ounce force
pound force

0.278 014
4.448 222

newton
newton

Length:

inch
foot
mile

25.4 *
0.304 8 *
1.609 344 *

millimeter
meter
kilometer

Mass:

pound
ounce

0.453 592
28.35

kilogram
gram

Mass/Area:

ton/acre

2241 702

kilogram/hectare

Mass/Energy:

lb/hp/hr

608.277 4

gr/kW/hr

Mass/Volume:

lb/cubic yd.

0.593 276

kg/cubic meter

Power:

horsepower

0.745 700

kilowatt

Pressure:

lbs/sq. in.
lbs/sq. in.
lbs/sq. in.

6.894 757
0.069
0.070 303

kilopascal
bar
kg/sq. cm

Temperature:

degree F

1.8 F - 32

degree C

Torque:

pound/inch
pound/foot

0.112 985
1.355 818

newton meter
newton meter

Velocity:

miles/hr.

1.609 344 *

kilometer/hr.

Volume:

cubic inch
cubic foot
cubic yard
ounce (US fluid)
quart (US liquid)
quart (Imperial)
gallon (US)
gallons (Imperial)

16.387 06
0.028 317
0.764.555
29.573 53
0.946 353
1.136 523
3.785 412
4.546 092

cubic centimeter
cubic meter
cubic meter
milliliter
litre
litre
litre
litre

Volume/Time:

gallon/min.

3.785 412

litre/min.

* = exact

Bur 7-52590

Issued 4-03

Printed in U.S.A.

SECTION INDEX

ENGINES
Section Title

Section Number

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


Stall Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2002
After Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2003

FOR ENGINE REPAIR, SEE THE ENGINE SERVICE MANUAL


87519803

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

Bur 5-3110

Copyright 2006 CNH Ameica LLC.


All rights reserved.
Printed in U.S.A.
Issued August, 2006

Section
2000

CNH America LLC.


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

Bur 5-2700

Copyright 2006 CNH Ameica LLC.


All rights reserved.
Printed in U.S.A.
Issued August, 2006

2000

ENGINE AND RADIATOR REMOVAL AND INSTALLATION

2000-2

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

Bur 5-2700

Issued 8-06

3
3
10
18
18
20

Printed in U.S.A.

2000-3

ENGINE
Removal

STEP 5

STEP 1

BD02N160

Park machine on a level surface and lower bucket to


ground. Put articulation lock in LOCKED position.

Put a 37 liter (10 gallon) container below radiator


drain. Remove radiator cap. Remove cap and drain
coolant into container. Install cap after coolant has
drained. Install radiator cap.

STEP 2

STEP 6

BD03A040

Stop engine. Actuate brake pedal several times to


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

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

STEP 4
BD02N160

Put a 14.2 liter (15 U.S. quarts) container below


engine oil drain. Remove cap and drain oil into
container. Install cap after oil has drained.
NOTE: After draining oil disconnect drain hose from
frame for removal with engine.

BD06F108

The master and hood raise switch are located in the


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

Bur 5-2700

Issued 8-06

Printed in U.S.A.

2000-4

STEP 7

STEP 10

BD03A231

BD06F109

Double up a nylon lifting strap (1) and slide through


the exhaust stack (2) on the hood.

Tag and disconnect hood wiring harness connector


from rear chassis wiring harness connector.

STEP 8

STEP 11

1
BD03A230

BD03A227

Place a solid steel bar through the strap, raise the


hood and release tension on the lifting motor.

STEP 9
2

BD03A226

BD03A228

Remove mount bolt (1) and backup alarm wiring


harness clamp from cooler housing. Have another
person balance the hood and remove the hood hinge
mounting bolts (2) from the cooler frame.

Remove the pin from the top of the lifting motor.

Bur 5-2700

Issued 8-06

Printed in U.S.A.

2000-5

STEP 12

STEP 15

BD03A232

BD06F110

Carefully raise and remove hood from loader. Lower


hood onto suitable platform and disconnect lifting
equipment.

Loosen clamps on turbocharger and air cleaner,


remove the intake hose.

STEP 16
STEP 13

BD06F110
BD03A224

Tag and disconnect engine wiring harness connector


from air filter restriction switch.

Loosen the clamp on the turbocharger for the after


cooler inlet hose.

STEP 17
STEP 14

BD03A115
BD03A225

Loosen clamp on air cleaner intake hose and remove


the crankcase ventilation hose.

Bur 5-2700

Loosen the clamp on the after cooler and remove the


after cooler inlet hose from the machine.

Issued 8-06

Printed in U.S.A.

2000-6

STEP 18

STEP 21

BD06F111

BD06F112

Loosen the clamp on the intake manifold for the after


cooler output hose.

Remove the air cleaner and muffler from the bracket.

STEP 22

STEP 19

BD06F113
BD03A118

Loosen the clamp on the after cooler and remove the


after cooler outlet hose from the machine.

STEP 20

BD06F114

Remove the four mounting bolts from the belt cover,


remove the cover.
NOTE: After removing the belt cover remove the
cover mounting brackets from the machine frame.
BD06F110

Loosen the exhaust clamp from the turbocharger.

Bur 5-2700

Issued 8-06

Printed in U.S.A.

2000-7

STEP 23

STEP 26

BD06F115

BD06F118

Remove the drive belt from the engine.

Tag and disconnect the wiring from the alternator.

STEP 24

STEP 27

BD06F116

BD06F119

Loosen clamps and remove lower cooler hose from


the engine.

Remove bolt securing wiring harness clamp to


engine.

STEP 25

STEP 28
1

1
2

BD06F117

BD06F120

If loader is equipped with air conditioning, identify,


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

Remove bolt securing wiring harness clamp (1) to the


engine. Remove ground wires (2) from the engine.

Bur 5-2700

Issued 8-06

Printed in U.S.A.

2000-8

STEP 29

STEP 32

1
3

BD06F121

Tag and remove the wires from the starter solenoid


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

BD06F111

Tag and remove the grid heater cable.

STEP 33

NOTE: Move the starter cables away from the


engine, move the wiring harness away from the
engine.

STEP 30

BD03A142

Disconnect the wiring harness from the EDC 7


controller.
NOTE: Lifting up on the lever will release the
connector from the controller.
BD06F146

Disconnect the engine coolant vent hose and root to


the rear of the engine.

STEP 34

STEP 31
3
2
1

BD06F123

Remove the fuel line from the top of the EDC 7


controller, plug the line and cap the fitting.
BD06F122

Remove the radiator hose (1) from the rear of the


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

Issued 8-06

Printed in U.S.A.

2000-9

STEP 35

STEP 38

BD06F127

BD06F124

Tag and disconnect the fuel filter heater wires (1),


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

Remove the lower cover for the drive shaft.

STEP 39

STEP 36

BD03A172

BD06F125

Remove bolt and clamp.

Remove the drive shaft bolts from the flywheel. Move


the drive shaft clear of the flywheel.

STEP 40

STEP 37

Connect suitable lifting equipment to engine lifting


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

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

BD06F126

Connect and turn on vacuum pump to hydraulic


reservoir. Tag and remove the hydraulic lines from
the brake system pump, plug the lines and cap the
fittings.

Bur 5-2700

Issued 8-06

Printed in U.S.A.

2000-10

Installation

1
2

2
3

4
5
6

6
7

7
8

4
5
6
7
BS03B035

1. ENGINE MOUNT BOLT


2. WASHER

3. INSOLATOR UPPER
4. INSOLATOR LOWER

STEP 42

5. WASHER
6. WASHER

7. NUT
8. REMOTE OIL DRAIN HOSE

STEP 47

If engine rubber isolators require replacement,


remove and discard isolators (3 and 4). Install new
rubber isolator (4), then rubber isolator (3).

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

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

At front of engine, position drive shaft on engine


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

STEP 45
Disconnect lifting equipment from engine lifting
brackets.

STEP 46
Connect engine oil drain hose to frame bracket.

Bur 5-2700

Issued 8-06

Printed in U.S.A.

2000-11

STEP 48

STEP 51

BD06F127

Install the lower cover for the drive shaft.

BD06F124

Remove cap from fitting and plug from the hose,


connect fuel line (2). Connect fuel filter heater wires
(1). Remove and discard tag.

STEP 49

STEP 52

BD06F126

Connect and turn on vacuum pump to the hydraulic


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

BD06F123

Remove cap from fitting and plug from the hose,


connect fuel line to EDC 7.

STEP 53

STEP 50

BD03A142

Connect wiring harness to EDC 7 controller.


BD06F125

Install bolt and clamp for fuel return hose.

Bur 5-2700

NOTE: Start the connector on the EDC 7 with lever


straight out from EDC 7. Use lever to pull connector
into position.

Issued 8-06

Printed in U.S.A.

2000-12

STEP 54

STEP 57

1
2

BD06F111

BD06F121

Connect grid heater cable to grid heater. Remove


and discard tag.

Install the wires to the starter solenoid (3), install the


ground cable (2), and ground strap (1) to the starter.
Remove and discard tags.

STEP 55
STEP 58
3

1
2
2

BD06F122

Install the heater hose (2) to the rear of the engine,


mount the clamps (3), install the radiator hose (1).

STEP 56

BD06F120

Install bolt securing wiring harness (1) clamp to the


engine. Install ground wires (2) to the engine.

STEP 59

BD06F146

Connect the engine coolant vent hose.

BD06F119

Install bolt securing wiring harness clamp to engine.

Bur 5-2700

Issued 8-06

Printed in U.S.A.

2000-13

STEP 60

STEP 63

BD06F118

Connect the wiring to the alternator. Remove and


discard tags.

BD06F115

Install the drive belt.

STEP 64
STEP 61
1
2

BD06F113
BD06F117

If loader is equipped with air conditioning, mount the


compressor using the three mounting bolts (2),
connect the engine wiring harness connectors to air
compressor clutch connector (1). Remove and
discard tags.

STEP 62

BD06F114

Install the cover mounting brackets to the machine


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

BD06F116

Install lower cooler hose to the engine and tighten the


clamps to a torque of 10.1 to 11.3 Nm (90 to 100
lb-inch).

Bur 5-2700

Issued 8-06

Printed in U.S.A.

2000-14

STEP 65

STEP 68

BD06F112

BD06F111

Place the muffler and air cleaner on the bracket.


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

Tighten the clamp on the intake manifold for the after


cooler output hose.

STEP 69

STEP 66

BD03A115

BD06F110

Install and tighten the exhaust clamp on the


turbocharger, tighten the muffler mounting bolts.

Place the after cooler inlet hose on the machine.


Tighten the clamp on the after cooler.

STEP 70

STEP 67

BD06F110

BD03A118

Tighten the clamp on the turbocharger for the after


cooler inlet hose.

Place the after cooler outlet hose on the machine.


Tighten the clamp on the after cooler.

Bur 5-2700

Issued 8-06

Printed in U.S.A.

2000-15

STEP 71

STEP 74

BD06F110

Install the intake hose and tighten the clamps on


turbocharger and air cleaner.

STEP 72

BD03A232

Carefully raise and place hood over loader.


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

STEP 75

BD03A225

Install the crankcase ventilation hose and tighten the


clamp on air cleaner intake hose.

BD03A227

STEP 73

BD03A226

BD03A224

Connect engine wiring harness connector to air filter


restriction switch. Remove and discard tag.

Bur 5-2700

Have another person balance the hood, install the


hood hinge mounting bolts (2) to the cooler frame.
Install mount bolt (1) and backup alarm wiring
harness clamp to cooler housing.

Issued 8-06

Printed in U.S.A.

2000-16

STEP 76

STEP 78

1
BD03A228

BD03A221

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

NOTE: If hood strut is not adjusted properly the


hood will be damaged.
When a hood is removed and replaced an initial
adjustment on the strut is necessary. Adjust between
the top of the lift motor adjusting jam nut (1) to the top
of the threads (2) to 20 mm (X). With the motor down
to its lowest point take a measurement between the
left hand side hood bumper and the counter weight,
record this measurement (Y). Use the following table
to adjust the strut (X).

STEP 77

Hood Adjustment Table


Y
X
(MM) (MM)

BD06F109

Connect hood wiring harness connector to rear


chassis wiring harness connector. Remove and
discard tag.

Bur 5-2700

Y
X
(MM) (MM)

Y
X
(MM) (MM)

Y
X
(MM) (MM)

19

21

14

41

61

19

22

14

42

62

18

23

14

43

63

18

24

13

44

64

18

25

13

45

65

18

26

13

46

66

17

27

13

47

67

17

28

12

48

68

17

29

12

49

69

10

17

30

12

50

70

11

16

31

12

51

71

12

16

32

12

52

72

13

16

33

11

53

73

14

16

34

11

54

74

15

16

35

11

55

75

16

15

36

11

56

76

17

15

37

10

57

77

18

15

38

10

58

78

19

15

39

10

59

79

20

14

40

10

60

80

Issued 8-06

Printed in U.S.A.

2000-17

STEP 79

STEP 85

BD02N160

BD06F108

Check and make sure that drain caps are tight.

Lower the hood with the hood lift motor.

STEP 80

STEP 86

Install a new oil filter on engine. Fill engine with 14.2


liters (15 quarts) of Case AKCELA No. 1 Engine Oil
(SAE 15W-40).

Put articulation lock in OPERATING position.

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

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

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

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

Bur 5-2700

Issued 8-06

Printed in U.S.A.

2000-18

RADIATOR
Removal

STEP 5

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

STEP 2

BD06F128

Remove bolt and washer securing LH fender.


Remove LH fender.

STEP 6
BD03A040

Put articulation lock in LOCKED position.

STEP 3
Put master disconnect switch in OFF position.

STEP 4

BD02N160

Put a 37 liter (10 gallon) container below radiator


drain. Remove radiator cap then remove cap and
drain coolant into container. Install cap after coolant
has drained. Install radiator cap.

STEP 7
BD03A120

Have another person raise and hold the side panel


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

BD03A109

Release catch and tilt air conditioning condenser


core up to gain access to upper radiator hose.

Bur 5-2700

Issued 8-06

Printed in U.S.A.

2000-19

STEP 8

STEP 11

1
2

BD03A108

BD03A106

Loosen the upper radiator hose clamps, remove the


hose.

Remove screws and install lifting eyes (1). Attach


suitable lifting equipment to lifting eyes. Remove four
mounting bolts (2), remove radiator from machine.

STEP 9

BD06F129

Loose and remove the lower radiator hose from the


radiator.

STEP 10

BD03A113

Disconnect overflow hose from radiator. Disconnect


connector from coolant level sender.

Bur 5-2700

Issued 8-06

Printed in U.S.A.

2000-20

Installation

STEP 15

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

STEP 13

1
BD06F129

At bottom of radiator, install bottom radiator hose.


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

STEP 16
BD03A106

Install four lock washers and bolts (2) to secure


ra d i a t o r t o c o o li n g f ra m e. D i s c o n n e c t l i f t i n g
equipment from lifting eyes. Remove lifting eyes and
install screws (1).

STEP 14

BD03A108

At top of cooling system frame, install hose. Position


hose clamps and tighten to a torque of 10.1 to 11.3
Nm (90 to 100 lb-inch).

STEP 17

BD03A113

Connect connector to coolant level sender, connect


overflow hose to radiator.

BD06F130

When installing fender make sure it is behind the


fender mounting bolt.

Bur 5-2700

Issued 8-06

Printed in U.S.A.

2000-21

STEP 18

STEP 21

BD06F131

Align the whole in the fender on the bolt.

BD03A120

Have another person raise and hold the side panel


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

STEP 19

NOTE: Photo is of the oil cooler side of the machine,


the procedure is the same.

STEP 22

BD06F132

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

STEP 20
BD02N160

Check that coolant drain cap is tight.

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

Push the fender towards the front of the machine and


secure it using washer and bolt.

Bur 5-2700

Issued 8-06

Printed in U.S.A.

2000-22

STEP 24
Put master disconnect switch in ON position.

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

Bur 5-2700

WARNING: Hot coolant can spray out if radiator cap


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

STEP 26
Put articulation lock in OPERATING position.

Issued 8-06

Printed in U.S.A.

2002

Section
2002
STALL TEST

CNH America LLC.


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

Bur 5-3120

Copyright 2006 CNH Ameica LLC.


All rights reserved.
Printed in U.S.A.
Issued August, 2006

2002-2

TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stall Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STALL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUMENT CLUSTER DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROCEDURE TO HEAT THE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER MODE SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PERFORMING STALL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test No. 1 - Torque Converter and Hydraulic Stall Together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Understanding the Results of Test No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test No. 2 - Torque Converter Stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Understanding the Results of Test No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test No. 3 - Hydraulic Stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Understanding the Results of Test No. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 5-3120

Issued 8-06

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

Printed in U.S.A.

2002-3

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

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

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

INSTRUMENT CLUSTER DISPLAYS


1. With the engine running, press the up or down
key and scroll through the information screens
and trip screens. The following sequence is
using the down key only.
NOTE: Pressing the escape key will return the LCD
back to the normal driving screen.

BD06F183

3. Info 1 is the first information screen using the


down arrow from the driving screen. It displays
engine RPMs, speed, fuel level, and the voltage
level.

BD06F188

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


shown.

Bur 5-3120

Issued 8-06

Printed in U.S.A.

2002-4

BD06F169

BD06F027

4. Info 2 will be displayed next. The Info 2 screen


will display coolant temperature, turbocharger air
temperature, engine oil temperature in either
Fahrenheit or Celsius, as well as oil pressure
PSI.

6. Press the down button again and the Trip 1


screen will display. The LCD provides two trip
computers. These will display since last reset the
total time in hours, the total fuel, and the average
fuel consumption per hour.

BD06F170

BD06F184

5. Push the down button again and the Info 3


screen. This screen displays the temperature in
Fahrenheit or Celsius of the transmission oil,
hydraulic oil, sump oil, and radiator coolant
temperature.

Bur 5-3120

7. By continuing to scroll down, the fifth screen will


display the Trip 2 screen. Trip 1 and Trip 2
screens can be reset independently. The
previous screen can be accessed by using the
up arrow key.

Issued 8-06

Printed in U.S.A.

2002-5

PROCEDURE TO HEAT THE OIL


Torque Converter

Hydraulic System

1. Sit in the seat.

1. Apply the parking brake.

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

2. Start the engine and run at full throttle.

3. To measure the oil temperature with the


instrument cluster:

3. To measure the oil temperature with the


instrument cluster:

A. Press the up or down arrow key.

A. Press the up or down arrow key.

B. Stop at the info screen with the temperatures


that need to be monitored.

B. Stop at the info screen with the temperatures


that need to be monitored are on.

4. Place the declutch switch in the OFF position.


5. Place the automatic switch in the manual mode
position. Push down and hold the brake pedal for
the remainder of this procedure.
6. Release the parking brake.

4. Hold the bucket control lever in the ROLLBACK


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

7. Move the transmission control lever to Forward


and turn the transmission control lever to 3rd
gear.
8. Increase the engine speed to full throttle and run
the engine at this speed for 30 seconds.
9. Decrease the engine speed to low idle and move
the transmission control lever to the Neutral
position for 15 seconds.
10. Repeat steps 7, 8, and 9 until the temperature of
the torque converter oil is 82 to 104C (180 to
220F).

Bur 5-3120

Issued 8-06

Printed in U.S.A.

2002-6

POWER MODE SELECTION


1. After the oil temperatures have been raised to
operating temperatures the power mode must be
set to Auto.

3. Use down arrow to scroll through the menus.


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

BD06H038

2. Press and hold the confirmation enter button for


two seconds to arrive at the above ser vice
screen.

Bur 5-3120

Issued 8-06

Printed in U.S.A.

2002-7

PERFORMING STALL TESTS


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

Test No. 2 - Torque Converter Stall


1. Sit in the seat.
2. Start the engine and run the engine at low idle.
3. Press the brake pedal, release the park brake,
shift into Forward.
4. Run the engine at low idle.
5. Push down and hold the brake pedal for the
remainder of this test.
6. Turn the transmission control lever to third gear.

5. Turn the transmission control lever to third gear.

7. Increase the engine speed to full throttle.

6. Increase the engine speed to full throttle.

8. Check the engine speed.

7. Hold the bucket control lever in the ROLLBACK


position and raise the lift arms.

9. Decrease the engine speed to low idle.

NOTE: The stall speed must be read while the lift


arms are in motion.

10. Place the transmission in neutral and apply the


parking brake.
11. Stop the engine.

8. Check the engine speed.


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

Understanding the Results of Test


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

Understanding the Results of Test


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

2. If the engine speed was not as specified, do Test


No. 2 and 3.

Bur 5-3120

Issued 8-06

Printed in U.S.A.

2002-8

Test No. 3 - Hydraulic Stall


1. Sit in the seat.
2. Start the engine and run the engine at low idle.
3. Increase the engine speed to full throttle.
4. Hold the bucket control lever in the ROLLBACK
position and raise the lift arms.
NOTE: The stall speed must be read while the lift
arms are in motion.
5. Check the engine speed.

Understanding the Results of Test


No. 3
1. If the engine speed was as specified, the engine
and hydraulic system are good.
2. If the engine speed was more or less than
specified the main relieef setting may be too low
or too high. See Section 8002 for troubleshooting
information.
3. If the engine speed was less than specified in all
tests, the engine is probably the cause.

6. Release the bucket control lever.


7. Decrease the engine speed to low idle.
8. Lower the bucket to the ground.
9. Stop the engine.

Bur 5-3120

Issued 8-06

Printed in U.S.A.

2003

Section
2003
AFTER COOLER

CNH America LLC.


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

Bur 6-49850

Copyright 2004 CNH America LLC.


All rights reserved.
Printed in U.S.A.
Issued February, 2004

2003-2

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

Bur 6-49850

Issued 2-04

3
4
4
6
6

Printed in U.S.A.

2003-3

TROUBLESHOOTING AFTER COOLER


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

STEP 2
Raise hood. Install T fitting in waste gate valve hose.
Attach pressure gauge. Install another pressure
gauge into the intake manifold port.

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

BD03A118

Inspect the after cooler outlet flex hose for leaks or


holes and insure that the clamps are tight.

STEP 6

STEP 4

BD03A119
BD03A116

Inspect the turbocharger flex hose for leaks or holes


and insure that the clamps are tight.

Inspect the intake manifold flex hose for leaks or


holes and insure that the clamps are tight.

STEP 7

STEP 5

BD03A109
BD03A115

Inspect the after cooler inlet flex hose for leaks or


holes and insure that the clamps are tight.

Bur 6-49850

Visually inspect top of after cooler for damage or


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

Issued 2-04

Printed in U.S.A.

2003-4

AFTERCOOLER REMOVAL
Removal

STEP 4

STEP 1

BD03A118

Loosen clamps and remove air cooler outlet hose.


BD03A116

Loosen clamps and remove turbocharger outlet


components.

STEP 5

STEP 2

BD03112

BD03A115

Raise air conditioning/air cooler cover. Support cover


with appropriate lifting device. Remove cover support
latch.

Loosen clamps and remove air cooler inlet hose.

STEP 6

STEP 3

BD03A111
BD03A119

Remove three cover mounting bolts and lift cover off.

Loosen clamps and remove Intake hose.

Bur 6-49850

Issued 2-04

Printed in U.S.A.

2003-5

STEP 7

STEP 10

BD03A109

Unlatch air conditioning condenser clamp.

BD03A113

Remove two bolts, one from each side of the after


cooler mounting frame.

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

STEP 12

BD03A107

Rotate air conditioning condenser up and remove the


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

STEP 9

BD03A111

Remove four bolts that mount air cooler in the air


cooler frame. Remove air cooler from frame.

BD03A117

Remove the two bolts at the rear of the after cooler


mounting frame.

Bur 6-49850

Issued 2-04

Printed in U.S.A.

2003-6

Leak Test

Installation
STEP 1

BD03A111
BS03B028

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

Install after cooler in its frame. Install four mounting


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

STEP 2

BD03A113

Install two side mounting bolts

STEP 3

BD03A117

Install two bolts at the rear of the after cooler


mounting frame.

Bur 6-49850

Issued 2-04

Printed in U.S.A.

2003-7

STEP 4

STEP 7

BD03A107

BD03A116

Position air conditioner condenser and install


mounting bolts. Rotate the condenser down and
latch.

Install air cooler inlet hose. Tighten clamps at


turbocharger outlet.

STEP 8
STEP 5

BD03A115
BD03112

Support cover with appropriate lifting device. Raise


air conditioning/air cooler cover over machine. Install
cover support latch.

Tighten clamps at air cooler inlet.

STEP 9

STEP 6

BD03A119

Install air cooler outlet hose and tighten clamps at


engine intake.
BD03A111

Install three cover mounting bolts.

Bur 6-49850

Issued 2-04

Printed in U.S.A.

2003-8

STEP 10

STEP 11
Install T fitting in waste gate valve hose. Attach
pressure gauge. Install another pressure gauge into
the intake manifold port.

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

BD03A118

Tighten clamps at air cooler outlet.

Bur 6-49850

Issued 2-04

Printed in U.S.A.

SECTION INDEX

FUEL SYSTEM
Section Title

Section Number

FOR FUEL SYSTEM REPAIR, SEE THE ENGINE SERVICE MANUAL


87519803

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

Bur 5-3130

Copyright 2006 CNH Ameica LLC.


All rights reserved.
Printed in U.S.A.
Issued August, 2006

4001
Section
4001
REMOVAL AND INSTALLATION OF STARTER AND
ALTERNATOR

CNH America LLC.


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

Bur 5-2740

Copyright 2006 CNH Ameica LLC.


All rights reserved.
Printed in U.S.A.
Issued August, 2006

4001-2

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

Bur 5-2740

Issued 8-06

3
3
4
5
5
6
8
8
8

Printed in U.S.A.

4001-3

STARTER
Removal

STEP 4

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

STEP 2

BD06F135

Remove the ground strap from the starter, remove


the starter mounting bolts, remove the stater.

BD06F133

Raise the engine compartment with lifting motor.


Place the master disconnect switch in the OFF
position.

STEP 3

BD06F134

Place identification tags on the positive cables and


remove the positive cables from the starter.

Bur 5-2740

Issued 8-06

Printed in U.S.A.

4001-4

Installation

STEP 7

STEP 5

1
BD06F134

Install and tighten the wires on the starter solenoid.


Remove and discard tags.

STEP 8
BC05G047

1. STUDS
2. NUTS

Place the master disconnect switch in the ON


position. Lower the engine compartment with lifting
motor.

Apply Loctite 747 primer to studs and holes, apply 2


drops of Loctite 271 to each hole and stud.
Immediately install and torque studs to 19 to 29 Nm
(14 to 21 pound-feet). Allow adhesive to cure for 20
minutes before installing starter.

STEP 6

2
BD06F135

Position the star ter on the machine, attach the


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

Bur 5-2740

Issued 8-06

Printed in U.S.A.

4001-5

ALTERNATOR
Removal

STEP 4

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

STEP 2

BD06F137

BD06F133

Raise the engine compartment with lifting motor.


Place the master disconnect switch in the OFF
position.

STEP 3

BD06F138

Remove four belt cover mounting bolts, remove


cover.

STEP 5

BD06F136

Disconnect wires from the alternator.

BD06F139

Use a wrench to move the belt tensioner to loosen


the tension on the belt. Remove the belt.

Bur 5-2740

Issued 8-06

Printed in U.S.A.

4001-6

Installation

STEP 6

STEP 7

BD06F140

Remove mounting bolts for alternator, remove


alternator.

BD06F140

Place alternator onto engine, install mounting bolts


for alternator and tighten.

STEP 8

BD06F139

Use a wrench to move the belt tensioner, install the


belt.
NOTE: Belt routing instructions are on belt cover.

Bur 5-2740

Issued 8-06

Printed in U.S.A.

4001-7

STEP 9

STEP 10

BD06F137

BD06F136

Connect wires to the alternator, place rubber boot


over positive post.

STEP 11

BD06F138

Install belt cover, install four belt cover mounting


bolts and tighten.

BD06F133

Place the master disconnect switch in the ON


position. Lower the engine compartment with lifting
motor.

Bur 5-2740

Issued 8-06

Printed in U.S.A.

4001-8

BELT INSTALLATION

BC05G045

WITH OUT AIR CONDITIONING

BC05G046

WITH AIR CONDITIONING

Bur 5-2740

Issued 8-06

Printed in U.S.A.

4002

Section
4002
ELECTRICAL SPECIFICATIONS AND
TROUBLESHOOTING

CNH America LLC.


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

Bur 5-2750

Copyright 2006 CNH Ameica LLC.


All rights reserved.
Printed in U.S.A.
Issued August, 2006

4002-2

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

Issued 8-06

7
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Printed in U.S.A.

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

Issued 8-06

Printed in U.S.A.

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

Issued 8-06

Printed in U.S.A.

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

Bur 5-2750

Issued 8-06

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

Printed in U.S.A.

4002-6

NOTES

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-7

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-8

ELECTRICAL WIRE IDENTIFICATION


Wire Identification Codes

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

Bk = Black
T = Tan
LU = Light Blue

1.0 mm 2.0 mm 5.0 mm


DU = Dark Blue
W = White
Or = Orange

Wire Identification
Wire

Circuit

14

Alternator D+

42

S = Gray
N = Brown
R = Red

LG = Light Green
G = Green
P = Purple

From Connector
Color, Size,
and Material

Connector

K = Pink
U = Blue
Y = Yellow

To Connector
Cavity

Connector

Cavity

AD, Alternator D+

ENG, Engine Cab

26

Work Lights Switched Fused Pwr R2.0 GXL

SPL-WL, Ultrasonic

ECC, Work Lights

23

44

Brake Lt Control Power

T 1.0 SXL

FRONT, Cab Front Chassis

23

PBL, Brake Light Press Switch

49

Back Lt Power

DU1.0 GXL

D-OR, Diode OR

SPL-BCK-LGT, Spl Back Lgt Pwr

52

Fan Reverse LSD

W 0.8 TXL

AIC-1, Adv Instr Clust 1

23

ECB, Electrical Center B

B8

56

Fan Control PWM

W 0.8 TXL

CAB-E, Cab Engine

23

AIC-1, Adv Instr Clust 1

26

57

Pin Engage Sol Pwr

W 1.0 SXL

FRONT, Cab Front Chassis

20

YPE, Pin Engage Option

58

Ride Control Sol Pwr

W 1.0 SXL

PRBF, Rollback Press Sw

YRC, Ride Control Option

64

Horn Power

Or 1.0 SXL

FRONT, Cab Front Chassis

13

HN1, Horn Power

0 29

RTT/Float Ground

Bk 0.8 GXL

SFL, Return To Travel Sw

SPL-BCK-LT-GD2, Spl Back Lgt


Gnd

0 AA

Proximity Switch Grnd

Bk 1.0 SXL

PXH, Height Control RTT

SPL-A2, Ultrasonic

0 AB

Proximity Switch Grnd

Bk 1.0 SXL

SPL-A2, Ultrasonic

GND-FC, Ground A

0 AC

Proximity Switch Grnd

Bk 1.0 SXL

PXF, RTD

SPL-A2, Ultrasonic

0 AD

Ride Control Ground

Bk 1.0 SXL

YRC, Ride Control Option

SPL-A1, Ultrasonic

0 AE

Pin Engage Ground

Bk 1.0 SXL

SPL-A1, Ultrasonic

YPE, Pin Engage Option

0 AF

Horn Ground

Bk 1.0 SXL

HN2, Horn Ground

SPL-A1, Ultrasonic

0 AG

Front Chassis Ground

Bk 2.0 SXL

SPL-A1, Ultrasonic

GND-FC, Ground A

0 AH

RH Front Lights Ground

Bk 1.0 SXL

SPL-A1, Ultrasonic

LRF, Lights RH

0 AJ

LH Front Lights Ground

Bk 1.0 SXL

SPL-A1, Ultrasonic

LLF, Lights LH

0 AK

Park Brake/Warning Ground

Bk 1.0 SXL

SPL-A4, Ultrasonic

GND-FC, Ground A

0 AL

Brake Warning Press Sw Gnd

Bk 1.0 SXL

PBW, Brake Warn Press Sw

SPL-A4, Ultrasonic

0 AM

RTD Grnd

Bk 1.0 SXL

PXM, RTD

PXT, RTD

0 AN

Park Brake Solenoid Ground

Bk 1.0 SXL

YPB, Park Brake Solenoid

SPL-A4, Ultrasonic

0 AP

Front To Rear Chassis Ground

Bk 5.0 SXL

GND-S1, Ground A

GND-S2, Ground A

0 AQ

Comfort Steering Solenoid Gnd

Bk 1.0 SXL

YCS, Comfort Steer Solenoid

SPL-A4, Ultrasonic

0 AR

Front Axle Temp Sensor Ground Bk 1.0 SXL

FRONT, Cab Front Chassis

HOT-FA, Front Axle Oil Temp

0B

Front Washer Ground

Bk 1.0 SXL

FWW, Front Washer

SPL-ENG-GRD, Gnd Spl 6 Pck

0 B1

Back Light Ground

Bk 0.8 GXL

SPC, Pilot Control Switch

SPL-PED-BL-GD, Spl Bk Lgt


Grnd 6 Pck

Bur 5-2750

Lg 1.0 SXL

Issued 8-06

Printed in U.S.A.

4002-9

Wire Identification Codes

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

Bk = Black
T = Tan
LU = Light Blue

1.0 mm 2.0 mm 5.0 mm


DU = Dark Blue
W = White
Or = Orange

Wire Identification
Wire

Circuit

S = Gray
N = Brown
R = Red

LG = Light Green
G = Green
P = Purple

From Connector
Color, Size,
and Material

K = Pink
U = Blue
Y = Yellow

To Connector

Connector

Cavity

Connector

Cavity

0 B2

Back Light Ground

Bk 0.8 GXL

SFL, Return To Travel Switch

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

0 B3

Back Light Ground

Bk 0.8 GXL

SHC, Height Control Switch

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

0 B4

Back Light Ground

Bk 0.8 GXL

SRTD, Detent Switch

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

0 B5

Back Light Ground

Bk 0.8 GXL

SPE, Pin Engage Switch

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

0 B6

Cab2 Ground

Bk 1.0 GXL

GND-CAB2, Ground A

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

0 B7

Back Light Ground

Bk 0.8 GXL

SFC, Fan Control Switch

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

0 B8

Front Wiper Motor Ground

Bk 0.8 GXL

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

FWMG, Wiper Ground

0 B9

Back Light Ground

Bk 0.8 GXL

SCS, Comfort Steering Sw

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


6 Pck

0 B10 Hood Ground

Bk 1.0 GXL

SPL-HOOD-GRND, Hood
Grnd 6 Pck

GND-CAB2, Ground A

0 B11 Back Light Ground

Bk 0.8 GXL

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

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


6 Pck

0 B12 Hood Down Relay Ground

Bk 1.0 GXL

SPL-HOOD-GRND, Hood
Grnd 6 Pck

ECC, Work Lights

C4

0 B13 Back Light Ground

Bk 1.0 GXL

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

GND-CAB2, Ground A

0 B14 Back Light Ground

Bk 0.8 GXL

SWL, Work Lights Switch

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

0 B15 Back Light Ground

Bk 0.8 GXL

SBE, Beacon Switch

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

0 B16 Hood Down Control Ground

Bk 1.0 GXL

SPL-HOOD-GRND, Hood
Grnd 6 Pck

ECC, Work Lights

B4

0 B17 Back Light Ground

Bk 0.8 GXL

STA, Trans Auto Switch

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

0 B18 Back Light Ground

Bk 0.8 GXL

SDC, Declutch Switch

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

0 B19 Back Light Ground

Bk 0.8 GXL

SDR, Driving Lights Switch

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

0 B20 Back Light Ground

Bk 0.8 GXL

SRC, Ride Control Switch

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

0 B21 Back Light Ground

Bk 1.0 GXL

SBU, Backup Alarm Disc Sw

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

0 B22 Hood Up Relay Ground

Bk 1.0 GXL

SPL-HOOD-GRND, Hood
Gnd 6 Pck

ECC, Work Lights

Bur 5-2750

Issued 8-06

C2

Printed in U.S.A.

4002-10

Wire Identification Codes

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

Bk = Black
T = Tan
LU = Light Blue

1.0 mm 2.0 mm 5.0 mm


DU = Dark Blue
W = White
Or = Orange

Wire Identification
Wire

Circuit

S = Gray
N = Brown
R = Red

LG = Light Green
G = Green
P = Purple

From Connector
Color, Size,
and Material

Connector

K = Pink
U = Blue
Y = Yellow

To Connector
Cavity

Connector

Cavity

0 B23 Back Light Ground

Bk 0.8 GXL

SRWP, Rear Wiper Switch

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

0 B24 Back Light Ground

Bk 0.8 GXL

SHZ, Hazard Switch

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


6 Pck

0 B25 Hood Up Control Ground

Bk 1.0 GXL

SPL-HOOD-GRND, Hood
Gnd 6 Pck

ECC, Work Lights

B2

0 B26 Buzzer/Switch Pad Ground

Bk 0.8 GXL

SPL-BUZ, Ultrasonic

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

0 B27 Buzzer Ground

Bk 0.8 GXL

SPL-BUZ, Ultrasonic

BUZ, AIC Buzzer

0 B28 Switch Pad Ground

Bk 0.8 TXL

SW-PD, Switch Pad

10

SPL-BUZ, Ultrasonic

0 B29 RTT/Float Ground

Bk 0.8 GXL

SPB, Parking Brake Switch

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


6 Pck

0 B30 Back Light Ground

Bk 0.8 GXL

SETHR, Ether Switch

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


6 Pck

0 BA

Bk 5.0 SXL.

GND-PDST, Ground A

GND-PDST2, Ground A

0 BAC EDC7 Ground

Bk 2.0 SXL

SPL-EDC1, Ultrasonic

GND-ENG2, WIF, EDC

0 BAE EDC7 Sender Ground

Bk 1.0 SXL

RECT, Engine Coolant Temp

GND-ENG7, Tranny, Cool Temp

0 BAF Coolant Lever Sender Ground

Bk 1.0 SXL

CLS, Cool Jump-Cool Sender

GND-ENG7, Tranny, Cool Temp

0 BAG Hood Grounds (EURO)

Bk 1.0 SXL

GND-ENG4, Rear Lighting

E-HD, Trans Hood

0 BAG
Hood Grounds (NA)
N

Bk 1.0 SXL

ENG-H, Engine to Hood

GND-ENG4, Rear Lighting

0 BAH QSM11 Ground

Bk 0.8 GXL

SPL-EDC1, Ultrasonic

QSM11, Engine Controller

29

0 BAI

QSM11 Ground

Bk 0.8 GXL

SPL-EDC1, Ultrasonic

QSM11, Engine Controller

30

0 BAJ QSM11 Ground

Bk 0.8 GXL

SPL-EDC1, Ultrasonic

QSM11, Engine Controller

39

0 BAK QSM11 Ground

Bk 0.8 GXL

SPL-EDC1, Ultrasonic

QSM11, Engine Controller

40

0 BAL QSM11 Ground

Bk 0.8 GXL

SPL-EDC1, Ultrasonic

QSM11, Engine Controller

41

0 BAM Ether Relay Signal Ground

Bk 1.0 SXL

PRM-C2, PRM signal

GND-ENG2, WIF, EDC

0 BAN Ether Start Ground

Bk 1.0 SXL

ETHR, Ether Solenoid

GND-ENG3, Spl Pck Washer


Motor

0 BAP QSM11 Ground

Bk 0.8 GXL

SPL-EDC1, Ultrasonic

QSM11, Engine Controller

50

0 BAR WIF Body Ground

Bk 1.0 SXL

GND-WIF, Gnd WIF Ring


Term

GND-ENG6, Dedicated

0 BAS Rear Axle Temp Sensor Ground

Bk 1.0 SXL

HOT-RA, Rear Axle Oil Temp

GND-ENG7, Tranny, Cool Temp

0 BB

Fan Reverse Solenoid Ground

Bk 1.0 SXL

YFR, Fan Reverse Sol Opt

SPL-FAN, Ultrasonic

0 BC

EDC7 Grnd

Bk 1.0 GXL

SPL-EDC1, Ultrasonic

EDC7, Engine Controller

11

Pedestal Gnd Strap

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-11

Wire Identification Codes

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

Bk = Black
T = Tan
LU = Light Blue

1.0 mm 2.0 mm 5.0 mm


DU = Dark Blue
W = White
Or = Orange

Wire Identification
Wire

Circuit

S = Gray
N = Brown
R = Red

LG = Light Green
G = Green
P = Purple

From Connector
Color, Size,
and Material

Connector

K = Pink
U = Blue
Y = Yellow

To Connector
Cavity

Connector

Cavity

0 BD

EDC7 Grnd

Bk 1.0 GXL

SPL-EDC1, Ultrasonic

EDC7, Engine Controller

10

0 BE

EDC7 Grnd

Bk 1.0 GXL

SPL-EDC1, Ultrasonic

EDC7, Engine Controller

0 BF

EDC7 Grnd

Bk 1.0 GXL

SPL-EDC1, Ultrasonic

EDC7, Engine Controller

0 BG

AIC Power Ground

Bk 0.8 GXL

ENG, Engine Cab

19

GND-ENG6, Dedicated

0 BH

AIC Power Ground Red

Bk 0.8 GXL

ENG, Engine Cab

20

GND-ENG6, Dedicated

0 BJ

AIC Sensor Ground

Bk 0.8 GXL

ENG, Engine Cab

17

GND-ENG6, Dedicated

0 BK

Trans Splice Grounds

Bk 1.0 GXL

ENG-T, Engine to Trans

GND-ENG7, Tranny, Cool Temp

0 BL

Rear Washer Ground

Bk 1.0 SXL

RWW, Rear Washer

SPL-ENG-GRD, Grd Spl 6 Pck

0 BM

Engine Splice Grounds

Bk 1.0 SXL

SPL-ENG-GRD, Grd Spl 6


Pck

GND-ENG3, SPLC-PK, Washer


Motor

0 BN

Filter Heater Control

Bk 0.8 GXL

PRM-C2, PRM Signal

EDC7, Engine Controller

13

0 BP

WIF Sensor Ground

Bk 1.0 SXL

GND-ENG2, WIF, EDC

WIF, Water In Fuel Sensor

0 BQ

Fan Speed PWM Sol Grd

Bk 1.0 SXL

YFN, Fan PWM Solenoid

SPL-FAN, Ultrasonic

0 BR

RH Rear Light Ground (EURO)

Bk 1.0 SXL

LRR-E, RH Rear Comb Lamp

GND-ENG4, Rear Lighting

Bk 1.0 SXL

LLR-N, LH Rear Comb Lamp

SPL-J1, Ultrasonic

0 BR N LH Rear Light Ground (NA)


0 BS

Fan Control Ground

Bk 1.0 SXL

SPL-FAN, Ultrasonic

SPL-ENG-GRD, Grd Spl 6 Pck

0 BT

LH Rear Light Ground (EURO)

Bk 1.0 SXL

LLR-E, LH Rear Comb Lamp

GND-ENG4, Rear Lighting

Bk 1.0 SXL

LRR-N, RH Rear Comb Lamp

SPL-J1, Ultrasonic

0 BT N RH Rear Light Ground (NA)


0 BU

Fuel Level Sender Ground

Bk 1.0 SXL

RFLG, Fuel Send Ground

GND-ENG7, Tranny, Cool Temp

0 BV

Grid Heater Control Grnd

Bk 0.8 TXL

GHC, Grid Heater Relay

EDC7, Engine Controller

75

0 BW

Water Separator Htr Ground

Bk 2.0 SXL

GND-ENG1, Start, FFH,


WSH

WSH, Water Separator Heater

0 BX

Fuel Filter Heater Ground

Bk 2.0 SXL

FFH, Fuel Filter Heater

GND-ENG1, Start, FFH, WSH

0 BY

Air Filter Restriction Sw Grd

Bk 1.0 SXL

SPL-ENG-GRD, Grd Spl 6


Pck

PAF, Air Filter Restriction Sw

0 BZ

Sec. Steering Splice Grd

Bk 1.0 SXL

ENG-T, Engine To Trans

GND-ENG3, SPLC-PK, Washer


Motor

0 CA

Sec. Steering Signal Ground

Bk 1.0 SXL

SSM, Sec. Steering Mod

11

SPL-SEC-STR, Sec. Steer 6 Pck

0 CB

Sec. Steering Signal Ground

Bk 1.0 SXL

SSM, Sec. Steering Mod

12

SPL-SEC-STR, Sec. Steer 6 Pck

0 CC

Sec. Steering Press Sw Ground

Bk 1.0 SXL

PSS, Sec. Steer Press


Switch

SPL-SEC-STR, Sec. Steer 6 Pck

0 CD

Sec. Steering Splice Ground

Bk 1.0 SXL

SPL-SEC-STR, Sec. Steer 6


Pck

SS-TR, SS Mod Trans

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-12

Wire Identification Codes

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

Bk = Black
T = Tan
LU = Light Blue

1.0 mm 2.0 mm 5.0 mm


DU = Dark Blue
W = White
Or = Orange

Wire Identification
Wire

Circuit

S = Gray
N = Brown
R = Red

LG = Light Green
G = Green
P = Purple

From Connector
Color, Size,
and Material

Connector

K = Pink
U = Blue
Y = Yellow

To Connector
Cavity

Connector

Cavity

0 CE

Sec. Steering Chassis Ground

Bk 1.0 SXL

SSM, Sec. Steering Mod

GND-SSMOD, Sec. Str Chas Gnd

0 CF

Sec. Steering Sol Ground

Bk 1.0 SXL

YSS, Sec. Strg Sol

SPL-SEC-STR, Sec. Steer 6 Pck

0 DA

AIC Chassis Ground

Bk 0.8 TXL

GND-PDST1, Ground A

AIC-2, Advanced Inst Cluster 2

22

0 DAP Back Light Ground

S 0.8 GXL

STE, Trans Enable Switch

SPL-BCK-LT-GD, Splice Back


Light Ground

0 DAV TECM Diagnostic Ground

Bk 0.8 GXL

108F, Diagnostic connector

GND-CAB3D, Ground A

0 DB

AIC Power Ground Red

Bk 0.8 TXL

CAB-E, Cab Engine

20

AIC-2, And Instr Cluster 2

15

0 DC

Time Delay Module Ground

Bk 0.8 GXL

GND-CAB-SPL2, Spl Back


Light Ground

TDM, Time Delay Module

0 DD

Voltmeter Relay Control Ground

Bk 0.8 GXL

GND-CAB-SPL2, Spl Back


Light Ground

ECB, Elect Center B

B2

0 DE

Neutral Start Relay Control Grd

Bk 0.8 GXL

GND-CAB-SPL2, Spl Back


Light Ground

ECB, Elect Center B

B4

0 DF

Crank Request Relay Control


Ground

Bk 0.8 GXL

GND-CAB-SPL2, Spl Back


Light Ground

ECB, Elect Center B

B6

0 DG

Cab Splice Grounds

Bk 1.0 GXL

GND-CAB-SPL, Cab Grd Spl

GND-CAB3, Ground C

0 DH

Diagnostic Connector Ground

Bk 0.8 GXL

GND-CAB-SPL, Cab Grd Spl

DIA, Diagnostic

0 DJ

AC Relay Control Ground

Bk 0.8 GXL

GND-CAB-SPL, Cab Grd Spl

ECD, Elect Center D

B10

0 DK

Seat Compressor Motor Ground

Bk 0.8 GXL

GND-CAB-SPL, Cab Grd Spl

SC, Seat Comp Motor

0 DL

Power Converter Relay Control


Ground

Bk 0.8 GXL

GND-CAB-SPL, Cab Grd Spl

PRM-E2, PRM Signal

0 DM

Speed Sensor Grounds

Bk 0.8 TXL

CAB-T, Cab Transmission

11

TECM, Trans

0 DN

Output Speed Sensor Ground

Bk 0.8 TXL

CAB-T, Cab Transmission

28

TECM, Trans

0 DP

DIAG TECM Ground

Bk 0.8 TXL

GND-CAB3D, Ground A

TECM, Trans

0 DQ

DIAG TECM Ground

Bk 0.8 TXL

GND-CAB3D, Ground A

TECM, Trans

0 DR

Roof Splice Grounds

Bk 1.0 GXL

CAB-RF, Cab to Roof Conn.

GND-CAB1, Ground A

0 DS

Roof Splice Grounds

Bk 1.0 GXL

CAB-RF, Cab to Roof Conn.

GND-CAB1, Ground A

0 DT

Front Wiper/Washer Sw Grd

Bk 0.8 GXL

GND-CAB-SPL, Cab Grd Spl

SFWW, Front Wiper/Washer

0 DU

Pilot Pressure Sol Grd

Bk 0.8 GXL

GND-CAB-SPL, Cab Grd Spl

YPP, Pilot Press Sol

0 DV

Cigar Lighter Ground

Bk 3.0 SXL

CL, Cigar Lighter

GND-CAB3, Ground C

0 DW

AIC Power Ground

Bk 0.8 TXL

CAB-E, Cab Engine

19

AIC-1, Adv Instr Cluster 1

12

0 DX

AIC Sensor Ground

Bk 0.8 TXL

CAB-E, Cab Engine

17

AIC-1, Adv Instr Cluster 1

0 DY

Front Axle Temp Sensor Grnd

Bk 1.0 GXL

CAB-F, Cab Front Chassis

GND-CAB3D, Ground A

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-13

Wire Identification Codes

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

Bk = Black
T = Tan
LU = Light Blue

1.0 mm 2.0 mm 5.0 mm


DU = Dark Blue
W = White
Or = Orange

Wire Identification
Wire

Circuit

S = Gray
N = Brown
R = Red

LG = Light Green
G = Green
P = Purple

From Connector
Color, Size,
and Material

Connector

K = Pink
U = Blue
Y = Yellow

To Connector
Cavity

Connector

Cavity

0 EA

Time Delay relay Control Grnd

Bk 0.8 GXL

GND-CAB-SPL2, Spl Back


Light Ground

PRM-B2, PRM Signal

0 EB

Ignition Relay Control Ground

Bk 0.8 GXL

GND-CAB-SPL2, Spl Back


Light Ground

PRM-A1, PRM Signal

0 EC

ACC Relay Control Ground

Bk 0.8 GXL

GND-CAB-SPL2, Spl Back


Light Ground

PRM-D1, PRM Signal

0 ED

HVAC Grounds

Bk 3.0 SXL

HVAC2, HVAC2

GND-CAB4, Ground C

0 EE

DIODE Suppression Grounds

Bk 0.8 GXL

GND-CAB-SPL, Cab Grnd


Spl

140M, DIODE Module

0 EF

Brake Lights Relay Ctrl Grnd

Bk 0.8 GXL

GND-CAB-SPL2, Spl Back


Light Ground

ECC, Work Lights

B6

0 EG

Flasher Module Ground

Bk 0.8 GXL

FLSHR, Flasher Module

GND-CAB-SPL2, Spl Back Light


Ground

0 EH

Flasher Module Ground

Bk 0.8 GXL

FLSHR, Flasher Module

GND-CAB-SPL2, Spl Back Light


Ground

0 EJ

Power Converter Ground

Bk 1.0 GXL

CNV, 24V to 12V Pwr


Convert

GND-CAB4, Ground C

0 EK

AUX Power Outlet 1 Grnd

Bk 1.0 GXL

PO1, Power Outlet

GND-CAB5, Ground C

0 EL

AUX Power Outlet 2 Grnd

Bk 1.0 GXL

PO2, Power Outlet

GND-CAB5, Ground C

0 EM

Radio Ground

Bk 0.8 GXL

CAB-RF, Cab to Roof Conn.

GND-CAB-SPL, Cab Grnd Spl

0 EN

Radio Ground

Bk 0.8 GXL

ROOF, Roof to Cab Conn.

RAD, Radio Power

0 EP

Horn Switch Ground

Bk 0.8 GXL

GND-CAB-SPL, Cab Grd Spl

SRHSTLK, RH Stalk Switch

31

0 EQ

Splice Pack GND-CAB-SPL2


Grnd

Bk 0.8 GXL

GND-CAB-SPL2, Spl Back


Light Ground

GND-CAB6, Start, FFH, Water


Sep Htr

0 ER

Power Converter Grnd

Bk 1.0 GXL

CNV, 24V to 12V Pwr Conv

GND-CAB4, Ground C

0 ES

Grid Heater Ground

Bk 19.0 SXL

GH-1, Grid Heater

GND-GH1, STRT, FFH, Water


Sep Htr

0 GB

Starter Relay Control Ground

Bk 1.0 SXL

SRC-1, Relay

GND-ENG1, STRT, FFH, Water


Sep Htr

0 HC

Trans Splice Grounds

Bk 1.0 SXL

SPL-TRN-GND, Spl Trans


Ground

TRAN-E, Trans to Engine

0 HD

Speed Sensor Grounds

Bk 1.0 SXL

TRANS, Cab Transmission

11

SPL-H2, Ultrasonic

0 HE

Output Speed Sensor Grnd

Bk 1.0 SXL

TRANS, Cab Transmission

28

OSS, Out Speed Sensor

0 HF

Engine Speed Sensor Grnd

Bk 0.8 GXL
Twist

ESS, Engine Speed Sensor

SPL-H2, Ultrasonic

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-14

Wire Identification Codes

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

Bk = Black
T = Tan
LU = Light Blue

1.0 mm 2.0 mm 5.0 mm


DU = Dark Blue
W = White
Or = Orange

Wire Identification
Wire

Circuit

S = Gray
N = Brown
R = Red

LG = Light Green
G = Green
P = Purple

From Connector
Color, Size,
and Material

Connector

K = Pink
U = Blue
Y = Yellow

To Connector
Cavity

Connector

Cavity

0 HG

Inter Speed Sensor Grnd

Bk 0.8 GXL
Twist

ISS, Inter Speed Sensor

SPL-H2, Ultrasonic

0 HH

Turbine Speed Sensor Grnd

Bk 0.8 GXL
Twist

TSS, Turbine Speed Sensor

SPL-H2, Ultrasonic

0 HL

Redundant Brake Switch Grnd

Bk 1.0 SXL

PRB2, Redundant Brake Sw

SPL-TRN-GRD, Spl Trans Grd

0 HM

Redundant Brake Switch Grnd

Bk 1.0 SXL

PRB1, Redundant Brake Sw

SPL-TRN-GRD, Spl Trans Grd

0 HP

Sec. Steering Splice Grnd

Bk 1.0 SXL

TRAN-E, Trans to Engine

TR-SS, Sec. Steering Module Opt

0 HV

Coolant Level Sender Grnd

Bk 1.0 SXL

CLS, Cool Jump Cool Sender

SPL-TRN-GRD, Spl Trans Grd

0 HW

Hot Ground

Bk 1.0 SXL

HOT, Hydraulic Oil Temp


Send

SPL-TRN-GRD, Spl Trans Grd

0 JA

Hood Grounds (EURO)

Bk 1.0 SXL

HD-E, Hood Trans

SPL-J1, Ultrasonic

Bk 1.0 SXL

HD-N, Hood to Engine

SPL-J1, Ultrasonic

0 JA N Hood Grounds (NA)


0 JB

Backup Alarm Grnd

Bk 1.0 SXL

BU1, Backup Alarm Grnd

SPL-J1, Ultrasonic

0 JC

License Plate Light Grnd

Bk 1.0 SXL

LPL, Lic Plate Light

SPL-J1, Ultrasonic

0 LA

Rear Light Grnd

Bk 1.0 SXL

HD-9, Hood to Engine

SPL-B1, Ultrasonic

0 LB

Rear Light Grnd

Bk 1.0 SXL

LLR-9, LH Rear Comb Light

SPL-B1, Ultrasonic

0 LC

Rear Light Grnd

Bk 1.0 SXL

SPL-B1, Ultrasonic

LRR-9, RH Rear Comb Light

0 LD

Rear Light Grnd

Bk 1.0 SXL

SPL-B1, Ultrasonic

E-HD9, Trans Hood

0 MA

Rear Wiper Motor Grnd

Bk 1.0 GXL

SPL-ROOF, Spl Rood Grnd

RWMG, Rear Wiper Motor Grnd

0 MB

Dome Light Grnd

Bk 0.8 GXL

LDM3, Dome Light Grnd

SPL-ROOF, Spl Rood Grnd

0 MC

Beacon Light Grnd

Bk 1.0 GXL

LBEGRD, Light Beacon Grnd

SPL-ROOF, Spl Rood Grnd

0 MD

Beacon Light Grnd

Bk 1.0 GXL

LBEE, Lgt Beacon Extension

LBEG, Light Beacon Grnd

0 ME

LH Rear Work Light Grnd

Bk 1.0 GXL

LLRW, LH Rear Work Light

SPL-ROOF, Spl Rood Grnd

0 MF

RH Rear Work Light Grnd

Bk 1.0 GXL

LRRW, RH Rear Work Light

SPL-ROOF, Spl Rood Grnd

0 MJ

RH Front Work Light Grnd

Bk 1.0 GXL

LRFW, RH Front Work Light

SPL-ROOF, Spl Rood Grnd

0 MK

Roof Grounds

Bk 1.0 GXL

ROOF, Roof to Cab Conn.

SPL-ROOF, Spl Rood Grnd

0 MN

Roof Grounds

Bk 1.0 GXL

ROOF, Roof to Cab Conn.

SPL-ROOF, Spl Rood Grnd

0 MU

LH Front Work Light Grnd

Bk 1.0 GXL

LLFW, LH Front Work Light

SPL-ROOF, Spl Rood Grnd

0 NB

Master Disconnect Grnd

Bk 62.0 SGR

DC2, Discon Black Grnd

STTR-GRN, Grid Heater Fuse

0 NC

Battery Disconnect

Bk 62.0 SGR

BT4, Discon Black Grnd

DC1, Disconnect Battery

0 ND

SSM Ground

Bk 62.0 SGR

242F, Chassis Grnd Sec.


Strg Motor

GND-SSCHAS, SSM Ground


Cable

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-15

Wire Identification Codes

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

Bk = Black
T = Tan
LU = Light Blue

1.0 mm 2.0 mm 5.0 mm


DU = Dark Blue
W = White
Or = Orange

Wire Identification
Wire

Circuit

S = Gray
N = Brown
R = Red

LG = Light Green
G = Green
P = Purple

From Connector
Color, Size,
and Material

Connector

K = Pink
U = Blue
Y = Yellow

To Connector
Cavity

Connector

Cavity

0 PA

Left Speaker Grnd

Bk 0.8 GXL

LSPK, Left Speaker

SPK, Speaker

0 PB

Right Speaker Grnd

Bk 0.8 GXL

RSPK, Right Speaker

SPK, Speaker

12ACC Ignition Switch ACC Power

W 0.8 GXL

S-KEY, Ignition Switch

SPL-ACC, Ultrasonic

12ACC
ACC PRM control Power
B

W 0.8 GXL

SPL-ACC, Ultrasonic

PRM-D1, PRM Signal

12ACC Power Converter PRM Control


C
Power

W 0.8 GXL

SPL-ACC, Ultrasonic

PRM-E2, PRM Signal

12V Pwr To Outlet 1

Or 1.0 GXL

PO1, Power Outlet

ECD, Elect Center D

AA4

12V A 12V Pwr To Outlet 2

Or 1.0 GXL

PO2, Power Outlet

ECD, Elect Center D

AA5

12V B 12V Fused Pwr to Radio

Or 1.0 GXL

CAB-RF, Cab to Roof Conn.

ECD, Elect Center D

AA6

12V C 12V Switched Power

Or 2.0 GXL

CNV, 24V to 12V Pwr Conver

SPL-12V, Ultrasonic

12V D Plug 1 12V Switched Power

Or 1.0 GXL

SPL-12V, Ultrasonic

ECD, Elect Center D

A4

12V E Plug 2 12V Switched Power

Or 1.0 GXL

SPL-12V, Ultrasonic

ECD, Elect Center D

A5

12V F Radio 12V Switched Power

Or 1.0 GXL

SPL-12V, Ultrasonic

ECD, Elect Center D

A6

12V G 2 Way Radio 12V Switched Pwr

Or 1.0 GXL

SPL-12V, Ultrasonic

ECD, Elect Center D

A7

12V H 12V Fused Power to Radio

Or 0.8 GXL

ROOF, Roof to Cab Conn.

SPL-RAD, Ultrasonic

12V

12V
HA

12V Fused Power to Radio

Or 0.8 GXL

SPL-RAD, Ultrasonic

RAD, Radio Power

12V
HB

12V Fused Power to Radio

Or 0.8 GXL

SPL-RAD, Ultrasonic

RAD, Radio Power

13C

Fuel Shutoff Fused Power

Or 1.0 SXL

DC3, Fuel Solenoid Disc

DISC, Disconnect Engine

13C A Fuel Shutoff Fused Power

Or 1.0 SXL

ENG-D, Disc Harness

ENG, Engine Cab

21

13C B Fuel Shutoff Fused Power

Or 1.0 SXL

CAB-E, Cab Engine

21

ECA, Elect Center A

A9

13D

Time Delay Relay Control Pwr

Or 1.0 SXL

TDM, Time Delay Module

PRM-B2, PRM Signal

13H

Time Delay Power

Or 3.0 GXL

SPL-DLY-RL, Ultrasonic

PRM-B1 PRM Output

13H B AIC Time Delay Power

Or 0.8 GXL

SPL-DLY-RL, Ultrasonic

ECD, Elect Center D

A3

13H C Trans ECM Time Delay Power

Or 0.8 GXL

SPL-DLY-RL, Ultrasonic

ECD, Elect Center D

A1

13H D Engine ECM Time Delay Power

Or 3.0 GXL

SPL-DLY-RL, Ultrasonic

ECD, Elect Center D

A2

Ignition Switch Pwr

Or 1.0 GXL

S-KEY, Ignition Switch

SPL-PK1, Slice 3-4 Way

13K A Ignition Switch Pwr

Or 1.0 GXL

TDM, Time Delay Module

SPL-PK1, Slice 3-4 Way

13K B Ignition Switch Pwr

Or 1.0 GXL

SPL-PK1, Slice 3-4 Way

PRM-A1, PRM Signal

13K C Ignition Switch Pwr

Or 1.0 GXL

SPL-PK1, Slice 3-4 Way

ECB, Elect Center B

D1

13K

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-16

Wire Identification Codes

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

Bk = Black
T = Tan
LU = Light Blue

1.0 mm 2.0 mm 5.0 mm


DU = Dark Blue
W = White
Or = Orange

Wire Identification
Wire
13M

Circuit

S = Gray
N = Brown
R = Red

LG = Light Green
G = Green
P = Purple

From Connector
Color, Size,
and Material

Connector

K = Pink
U = Blue
Y = Yellow

To Connector
Cavity

Connector

Cavity

Fuel Shutoff Fused Power

Or 1.0 SXL

DC4, Fuel Sol Disconnect

DISC, Disconnect Engine

13M A Fuel Shutoff Fused Power

Or 0.8 TXL

ENG-D, Disconnect Harness

EDC7, Engine Controller

40

13M B Key Switch Power Disc Sw

Or 1.0 GXL

ENG-D, Disconnect Harness

QSM11, Engine Controller

38
D2

13V

Voltmeter Input ANALOG

Or 0.8 TXL

AIC-1, Adv Instr Cluster 1

ECB, Elect Center B

14 A

Alternator D+

LG 0.8 GXL

CAB-E, Cab Engine

26

215F, Alternator Resistor

SW-PD, Switch Pad

AIC-1, Advanced Instr Cluster

25
3

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


18B

LH High Beam Fused Power

Or 1.0 SXL

FRONT, Cab Front Chassis

LLF, Lights LH

18B A LH High Beam Fused Power

Or 0.8 GXL

CAB-F, Cab Front Chassis

ECB, Elect Center B

RH High Beam Fused Power

Or 1.0 SXL

FRONT, Cab Front Chassis

16

LRF, Lights RH

18C A RH High Beam Fused Power

Or 0.8 GXL

CAB-F, Cab Front Chassis

16

ECB, Elect Center B

LH Low Beam Fused Power

Or 1.0 SXL

FRONT, Cab Front Chassis

14

LLF, Lights LH

18D A LH Low Beam Fused Power

Or 0.8 GXL

CAB-F, Cab Front Chassis

14

ECB, Elect Center B

RH Low Beam Fused Power

Or 1.0 SXL

FRONT, Cab Front Chassis

15

LRF, Lights RH

18E A RH Low Beam Fused Power

Or 0.8 GXL

CAB-F, Cab Front Chassis

15

ECB, Elect Center B

LH Position/Tail Fused Power

Or 1.0 SXL

FRONT, Cab Front Chassis

LLF, Lights LH

18F A LH Position/Tail Fused Power

Or 0.8 GXL

CAB-E, Cab Engine

SPL-POS-L, Ultrasonic

LH Position/Tail Fused Power

Or 1.0 SXL

ENG, Engine Cab

ENG-H, Engine to Hood

18F B LH Position/Tail Fused Power

Or 1.0 SXL

ENG, Engine Cab

LLR-E, LH Rear Comb Light

LH Position/Tail Fused Power

Or 1.0 SXL

HD-N, Hood to Engine

LLR-N LH Rear Combination


Light

18F C LH Position/Tail Fused Power

Or 1.0 GXL

SPL-POS-L, Ultrasonic

18F E LH Position/Tail Fused Power

Or 0.8 GXL

CAB-F, Cab Front Chassis

SPL-POS-L, Ultrasonic

18F F LH Position/Tail Fused Power

Or 1.0 SXL

HD-9, Hoof to Engine

LLR-9, LH Rear Comb Light

RH Position/Tail Fused Power

Or 1.0 GXL

SPL-POS-R, Ultrasonic

18G A RH Position/Tail Fused Power

Or 1.0 SXL

FRONT, Cab Front Chassis

LRF, Lights RH

RH Position/Tail Fused Power

Or 1.0 SXL

SPL-POS-NA, Ultrasonic

LRR-N, RH Rear Combination


Light

18G D Licence Plate Light Fused Pwr

Or 1.0 SXL

SPL-POS, Ultrasonic

E-HD, Trans Hood

18G E Licence Plate Light Fused Pwr

Or 0.8 GXL

HD-E, Hood Trans

LPL, Licence Plate Light

Or 1.0 SXL

LPL, Licence Plate Light

SPL-POS-NA, Ultrasonic

18C

18D

18E

18F

18F
AN

18F
BN

18G

18G
CN

18G
EN

Licence Plate Light Fused Pwr

Bur 5-2750

AA3
3
AA4
2
AA6
2
AA5
4

AA7

ECB, Electric Center B

AA8

ECB, Elect Center B

Issued 8-06

Printed in U.S.A.

4002-17

Wire Identification Codes

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

Bk = Black
T = Tan
LU = Light Blue

1.0 mm 2.0 mm 5.0 mm


DU = Dark Blue
W = White
Or = Orange

Wire Identification
Wire

Circuit

S = Gray
N = Brown
R = Red

LG = Light Green
G = Green
P = Purple

From Connector
Color, Size,
and Material

Connector

K = Pink
U = Blue
Y = Yellow

To Connector
Cavity

Connector

Cavity

18G F RH Position/Tail Fused Power

Or 0.8 GXL

CAB-E, Cab Engine

SPL-POS-R, Ultrasonic

18G G RH Position/Tail Fused Power

Or 0.8 GXL

CAB-F, Cab Front Chassis

SPL-POS-R, Ultrasonic

18G H RH Position/Tail Fused Power

Or 1.0 SXL

ENG, Engine Cab

SPL-POS, Ultrasonic

RH Position/Tail Fused Power

Or 1.0 SXL

ENG, Engine Cab

ENG-H, Engine to Hood

18G J RH Position/Tail Fused Power

Or 1.0 SXL

LRR-E, RH Rear
Combination Light

SPL-POS, Ultrasonic

RH Position/Tail Fused Power

Or 1.0 SXL

HD-N, Hood to Engine

SPL-POS-NA, Ultrasonic

18G K RH Position/Tail Fused Power

Or 1.0 SXL

HD-N, Hood to Engine

SPL-P9, Ultrasonic

18G L RH Position/Tail Fused Power

Or 1.0 SXL

SPL-P9, Ultrasonic

E-HD9, Trans Hood

18G M RH Position/Tail Fused Power

Or 1.0 SXL

SPL-P9, Ultrasonic

LRR-9, RH Rear Combination


Light

EDC7 Time Delay Fused Power

Or 2.0 GXL

CAB-E, Cab Engine

18

SPL-D2, Ultrasonic

18J A EDC7 Time Delay Fused Power

Or 2.0 GXL

ENG, Engine Cab

18

SPL-EDC2, Ultrasonic

18J B EDC7 Time Delay Fused Power

Or 1.0 GXL

SPL-EDC2, Ultrasonic

EDC7, Engine Controller

18J C EDC7 Time Delay Fused Power

Or 1.0 GXL

SPL-EDC2, Ultrasonic

EDC7, Engine Controller

18J D EDC7 Time Delay Fused Power

Or 1.0 GXL

SPL-EDC4, Ultrasonic

EDC7, Engine Controller

18J E EDC7 Time Delay Fused Power

Or 1.0 GXL

SPL-EDC4, Ultrasonic

EDC7, Engine Controller

18J F

EDC7 Time Delay Fused Power

Or 2.0 SXL

ENG, Engine Cab

14

SPL-EDC4, Ultrasonic

18J G EDC7 Time Delay Fused Power

Or 2.0 GXL

CAB-E, Cab Engine

14

SPL-D2, Ultrasonic

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

SPL-EDC4, Ultrasonic

WIF, Water In Fuel Sensor

18J K EDC7 Time Delay Fused Power

Or 3.0 GXL

SPL-D2, Ultrasonic

ECD, Elect Center D

18J L

QSM11 Time Delay Power

Or 0.8 GXL

SPL-EDC4, Ultrasonic

QSM11, Engine controller

17

18J M QSM11 Time Delay Power

Or 0.8 GXL

SPL-EDC2, Ultrasonic

QSM11, Engine controller

18J N QSM11 Time Delay Power

Or 0.8 GXL

SPL-EDC2, Ultrasonic

QSM11, Engine controller

18J P QSM11 Time Delay Power

Or 0.8 GXL

SPL-EDC4, Ultrasonic

QSM11, Engine controller

18

18J Q QSM11 Time Delay Power

Or 0.8 GXL

SPL-EDC4, Ultrasonic

QSM11, Engine controller

28

18K A Diagnostic Fused Power

Or 0.8 GXL

DIA, Diagnostic

ECC, Work Lights

A9

18L A Comfort Steer Fused Power

Or 0.8 GXL

SPL-CSTR, Ultrasonic

ECA, Elect Center A

A2

18L B Comfort Steer Fused Power

Or 0.8 GXL

SPL-CSTR, Ultrasonic

ECC, Work Lights

D9

18L C Comfort Steer Fused Power

Or 0.8 GXL

SPL-CSTR, Ultrasonic

ECC, Work Lights

B9

18G
HN

18G
JN

18J

Bur 5-2750

Issued 8-06

AA2

Printed in U.S.A.

4002-18

Wire Identification Codes

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

Bk = Black
T = Tan
LU = Light Blue

1.0 mm 2.0 mm 5.0 mm


DU = Dark Blue
W = White
Or = Orange

Wire Identification
Wire

Circuit

18L D Comfort Steer Fused Power

S = Gray
N = Brown
R = Red

LG = Light Green
G = Green
P = Purple

From Connector
Color, Size,
and Material

Connector

Or 0.8 GXL

SCS, Comfort Steer Switch

K = Pink
U = Blue
Y = Yellow

To Connector
Cavity
2

Connector

Cavity

SPL-CSTR, Ultrasonic

18M

AC Relay Fused Power

Or 0.8 GXL

ECA, Elect Center A

C5

ECD, Elect Center D

B9

18N

Blower Motor Fused Power

Or 3.0 GXL

SPL-BLWR, Ultrasonic

ECA, Elect Center A

C1

18N A Blower Motor Fused Power

Or 0.8 GXL

SPL-BLWR, Ultrasonic

HVAC1, HVAC1

18N B Blower Motor Fused Power

Or 3.0 GXL

SPL-BLWR, Ultrasonic

HVAC2, HVAC2

Voltmeter Relay Fused Power

Or 2.0 SXL

ENG, Engine Cab

13

PRM-C1, PRM Output

18R A Voltmeter Relay Fused Power

Or 2.0 GXL

CAB-E, Cab Engine

13

ECB, Elect Center B

B1

TRANS, Cab Transmission

29

OSS, Out Speed Sensor

18R

19A

Output Speed Sensor Fused Pwr Or 1.0 SXL

19A A Brake Declutch Sw Fused Pwr

Or 1.0 SXL

FRONT, Cab Front Chassis

27

PBD, Dec. Pressure Switch

19A B FNR Switched Fused Power

Or 0.8 GXL

197M, FNR Main Cab

SPL-FNR, Ultrasonic

19A C FNR Switched Fused Power

Or 0.8 GXL

197F, Main Cab FNR

SPL-TRNS-PWR, Trans Pwr

19A D Trans Enable Switch Fused Pwr

Or 0.8 GXL

STE, Trans Enable Switch

SPL-D15, Ultrasonic

19A E Trans Enable Switch Fused Pwr

Or 0.8 GXL

STE, Trans Enable Switch

10

SPL-D15, Ultrasonic

19A F Trans Enable Switch Fused Pwr

Or 0.8 GXL

SPL-TRNS-PWR, Trans Pwr

SPL-D15, Ultrasonic

19A G FNR Sw Fused Power

Or 0.8 GXL

SPL-FNR, Ultrasonic

SFNR, FNR Switch

19A H Trans Shifter Fused Power

Or 0.8 GXL

TS1, Transmission Shifter

SPL-TRNS-PWR, Trans Pwr

19A J Pilot Control Switched Fused


Pwr

Or 0.8 GXL

SPC, Pilot Control Switch

SPL-PB1, Ultrasonic

19A K TECM Fused Power

Or 0.8 TXL

SPL-TRANS-PWR, Trans
Pwr

TECM, Trans

45

19A L Park Brake Switched Fused Pwr

Or 0.8 GXL

SPB, Parking Brake Switch

SPL-PB1, Ultrasonic

19A M Output Speed Sensor Fused Pwr Or 0.8 TXL

CAB-T, Cab Transmission

29

SPL-TRNS-PWR, Trans Power

19A N Trans Fused Power

Or 1.0 GXL

SPL-TRANS-PWR, Trans
Pwr

ECA, Elect Center A

A1

19A P Backup Alarm Relay Control


Fused Power

Bk 1.0 GXL

SPL-TRANS-PWR, Trans
Pwr

ECD, Elect Center D

AA10

19A Q Trans/Auto Switch Fused Power

Or 0.8 GXL

STA, Trans Auto Switch

SPL-TRANS-PWR, Trans Pwr

19A R Declutch Switch Fused Power

Or 0.8 GXL

SDC, Declutch Switch

SPL-TRANS-PWR, Trans Pwr

19A S Trans Fused Power

Or 0.8 GXL

SPL-TRANS-PWR, Trans
Pwr

SPL-PB1, Ultrasonic

19A T Brake Declutch Switch Fused


Power

Or 0.8 GXL

CAB-F, Cab Front Chassis

27

SPL-TRANS-PWR, Trans Pwr

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-19

Wire Identification Codes

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

Bk = Black
T = Tan
LU = Light Blue

1.0 mm 2.0 mm 5.0 mm


DU = Dark Blue
W = White
Or = Orange

Wire Identification
Wire

Circuit

S = Gray
N = Brown
R = Red

LG = Light Green
G = Green
P = Purple

From Connector
Color, Size,
and Material

Connector

K = Pink
U = Blue
Y = Yellow

To Connector
Cavity

Connector

Cavity

19A U Trans Dick Down Switch Fused


Power

Or 0.8 GXL

SPL-FNR, Ultrasonic

20M, Trans Kick Down

19A V FNR Switch Fused Power

Or 0.8 GXL

SFNR, FNR Switch

SPL-FNR, Ultrasonic

19A W Diagnostic Conn. Fused Power

Or 0.8 GXL

108F, Diagnostic Connector

SPL-TRANS-PWR, Trans Pwr

Or 0.8 GXL

SRHSTLK, RH Stalk Switch

49a

ECA, Elect Center A

A8

19C A Pilot Ctrl Fused Pwr

Or 1.0 GXL

SPL-D24, Ultrasonic

ECA, Elect Center A

A5

19C B Pilot Ctrl Fused Pwr

Or 1.0 GXL

SPL-D24, Ultrasonic

ECD, Elect Center D

B5

19C C Pilot Ctrl Fused Pwr

Or 0.8 GXL

SPL-D24, Ultrasonic

ECD, Elect Center D

D5

19C D Ride Control Fused Pwr

Or 1.0 GXL

SRC, Ride Control Switch

SPL-D24, Ultrasonic

19D A Parking Brake Relay Fused Pwr

Or 1.0 GXL

SPL-PBS, Ultrasonic

ECA, Elect Center A

A6

19D B Parking Brake Relay Fused Pwr

Or 0.8 GXL

SPL-PBS, Ultrasonic

ECB, Elect Center B

D9

19D C Parking Brake Relay Fused Pwr

Or 1.0 GXL

SPL-PBS, Ultrasonic

ECB, Elect Center B

B9

19E A AIC Wake Up Ignition

Or 0.8 TXL

AIC-2, Adv Instr Cluster 2

21

ECA, Elect Center A

A3

19B

Turn Signal Fused Power

19H

Backup Alarm Relay Fuse Pwr

Or 1.0 GXL

ECA, Elect Center A

C4

ECD, Elect Center D

A10

19J

Front Wiper Fused Pwr

Or 0.8 GXL

SPL-PK3, Splice 3-4 Way

ECA, Elect Center A

C2

19J A Front Wiper Motor Fused Pwr

Or 0.8 GXL

SPL-PK3, Splice 3-4 Way

FWM, Front Wiper Motor

19J B Front Wip Wash Sw Fused Pwr

Or 0.8 GXL

SFWW, Front Wiper/Washer

SPL-PK3, Splice 3-4 Way

19J C Front Wiper Relay Fused Power

Or 0.8 GXL

SPL-PK3, Splice 3-4 Way

SPL-FW, Ultrasonic

19J D Front Wiper Relay HS Control


Fused Power

Or 0.8 GXL

SPL-FW, Ultrasonic

ECD, Elect Center D

D1

19J E Front Wiper Relay Fused Power

Or 0.8 GXL

SPL-FW, Ultrasonic

ECD, Elect Center D

B1

Or 0.8 GXL

SPL-FW, Ultrasonic

ECD, Elect Center D

D3

Or 0.8 GXL

SPL-FW, Ultrasonic

K-WCO, Wiper Cutout

86

Or 1.0 GXL

SPL-RWW, Ultrasonic

ECA, Elect Center A

C3

19K A Rear Wiper Sw Fused Pwr

Or 1.0 GXL

SRWP, Rear Wiper Sw

SPL-RWW, Ultrasonic

19K B Rear Wip Wash Fused Pwr

Or 0.8 GXL

SRWP, Rear Wiper Sw

SPL-RWW, Ultrasonic

19K C Rear Wiper Motor Fused Pwr

Or 1.0 GXL

CAB-RF, Cab to Roof


Connect

SPL-RWW, Ultrasonic

19K D Rear Wiper Motor Fused Pwr

Or 1.0 SXL

ROOF, Roof to Cab Connect

RWM, rear Wiper Motor

Pwr Converter Fused Power

Or 2.0 GXL

PRM-E1, PRM Output

SPL-CNV, Ultrasonic

19L A Pwr Converter Fused Power

Or 2.0 GXL

CNV, 24V to 12V Pwr Conver

SPL-CNV, Ultrasonic

19J F

Front Wiper Relay LS Control


Fused Power

19J G Wiper Cutout Relay Fused Pwr


19K

19L

Rear Wiper Fused Pwr

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-20

Wire Identification Codes

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

Bk = Black
T = Tan
LU = Light Blue

1.0 mm 2.0 mm 5.0 mm


DU = Dark Blue
W = White
Or = Orange

Wire Identification
Wire

Circuit

S = Gray
N = Brown
R = Red

LG = Light Green
G = Green
P = Purple

From Connector
Color, Size,
and Material

K = Pink
U = Blue
Y = Yellow

To Connector

Connector

Cavity

Or 2.0 GXL

CNV, 24V to 12V Pwr Conver

SPL-CNV, Ultrasonic

Sec. Steering Accessory Fused


Pwr

Or 0.8 GXL

CAB-T, Cab Transmission

ECA, Elect Center A

C7

19M A Sec. Steering Accessory Fused


Pwr

Or 1.0 SXL

TRANS, Cab Transmission

TR-SS, Sec. Steering Module Opt

19M C Sec. Steering Accessory Fused


Pwr

Or 1.0 SXL

SSM, Sec. Steering Module

SS-TR, Sec. Steering Mod Trans

19L B Pwr Converter Fused Power


19M

Connector

Cavity

19N

Seat Compressor Fused Pwr

Or 1.0 GXL

SC, Seat Compressor Motor

ECA, Elect Center A

C6

19P

Pin Engage/Fan Fused Pwr

Or 0.8 GXL

SPL-PIN, Spl Back Lgt Pwr

ECA, Elect Center A

A7

19P A Pin Engage Sw Fused Pwr

Or 0.8 GXL

SPE, Pin Engage Sw

SPL-PIN, Spl Back Lgt Pwr

19P C Fan Rev Sw Fused Pwr

Or 0.8 GXL

SFC, Fan Control Switch

SPL-PIN, Spl Back Lgt Pwr

19P D Fan Rev Relay Fused Pwr

Or 0.8 GXL

SPL-PIN, Spl Back Lgt Pwr

ECB, Elect Center B

D7

19P E Fan Rev Relay Fused Pwr

Or 0.8 GXL

SPL-PIN, Spl Back Lgt Pwr

ECB, Elect Center B

B7

19R

Sec. Steering Ign Fused Pwr

Or 0.8 GXL

DM, Diode OR

SPL-2 Ultrasonic

19RR

Sec. Steering Ign Fused Pwr

Or 0.8 GXL

DM, Diode OR

ECA, Elect Center A

A4

19R A Sec. Steering Ign Fused Pwr

Or 1.0 SXL

TRANS, Cab Transmission

TR-SS, Sec. Steering Module Opt

19R C Sec. Steering Ign Fused Pwr

Or 1.0 SXL

SSM, Sec. Steering Module

SS-TR, Sec. Steering Mod Trans

19R D Alternator Resistor Fused Pwr

Or 0.8 GXL

SPL-2, Ultrasonic

216F, Alternator Resistor

19R E Sec. Steering Ign Fused Pwr

Or 0.8 GXL

SPL-2, Ultrasonic

CAB-T, Cab Transmission

19S1

Sec. Steering Fused Pwr

Or 1.0 GXL

SS, Sec. Steering Fused Pwr

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

19S1 X Sec. Steering Fused Pwr

R 1.0 SXL

SSM, Sec. Steering Module

SS-TR, Sec. Steering Module


Trans

19S B AIC Delay Fused Power

Or 0.8 GXL

SPL-DKY3, Ultrasonic

ECD, Elect Center D

19S C AIC Delay Fused Power

Or 0.8 TXL

SPL-DKY3, Ultrasonic

AIC-2, Advanced Instr Cluster 2

20

19S D AIC Delay Fused Power

Or 0.8 TXL

SPL-DKY3, Ultrasonic

AIC-2, Advanced Instr Cluster 2

14

19T A TECM Delay Fused Power

Or 0.8 TXL

TECM, Trans

23

ECD, Elect Center D

AA1

Horn Relay Fused Power

Or 0.8 GXL

SPL-HRN, Ultrasonic

ECC, Work Lights

A6

19U A Horn Relay Fused Power

Or 0.8 GXL

SPL-HRN, Ultrasonic

ECC, Work Lights

B7

19U B Beacon Dome Lt Fused Pwr

Or 1.0 GXL

SPL-LT, Ultrasonic

ECC, Work Lights

A1

19U C Dome Lt Fused Pwr

Or 0.8 GXL

ROOF, Roof to Cab


Connection

LDM1, Dome Light B+

19U

Bur 5-2750

Issued 8-06

AA3

Printed in U.S.A.

4002-21

Wire Identification Codes

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

Bk = Black
T = Tan
LU = Light Blue

1.0 mm 2.0 mm 5.0 mm


DU = Dark Blue
W = White
Or = Orange

Wire Identification
Wire

Circuit

S = Gray
N = Brown
R = Red

LG = Light Green
G = Green
P = Purple

From Connector
Color, Size,
and Material

Connector

K = Pink
U = Blue
Y = Yellow

To Connector
Cavity

Connector

Cavity

19U D Dome Lt Fused Pwr

Or 0.8 GXL

CAB-RF, Cab to Roof


Connection

SPL-LT, Ultrasonic

19U E Horn Relay Fused Power

Or 0.8 GXL

SPL-HRN, Ultrasonic

ECC, Work Lights

D7

19U F Door Sw Fused Power

Bk 0.8 GXL

ROOF, Roof to Cab


Connection

DS, Door Switch

19U G Door Sw Fused Power

Or 0.8 GXL

CAB-RF, Cab to Roof


Connection

SPL-LT, Ultrasonic

19U H Beacon Switch Fused Power

Or 1.0 GXL

SBE, Beacon Switch

SPL-LT, Ultrasonic

19W

Cigar Lighter Pwr

Or 3.0 GXL

CL, Cigar Lighter

ECC, Work Lights

A8

19Y

Hood control Fused Power

Or 1.0 GXL

SPL-HOOD, Ultrasonic

ECC, Work Lights

A7

19Y A Hood Up Relay Fused Power

Or 1.0 GXL

SPL-HOOD, Ultrasonic

ECC, Work Lights

D2

19Y B Hood Down Relay Fused Power

Or 1.0 GXL

SPL-HOOD, Ultrasonic

ECC, Work Lights

D4

19Y C Hood Switch Fused Power

Or 1.0 GXL

CAB-E, Cab Engine

35

SPL-HOOD, Ultrasonic

19Y D Hood Switch Fused Power

Or 1.0 GXL

ENG, Engine Cab

35

HD, Hood Switch

Driving Lights Sw Fused Power

Or 1.0 GXL

SPL-PK2, Splice 3-4 Way

ECC, Work Lights

A3

19Z A Driving Lights Sw Fused Power

Or 1.0 GXL

SDR, Driving Lights Sw

SPL-PK2, Splice 3-4 Way

19Z B Driving Lights Sw Fused Power

Or 1.0 GXL

SDR, Driving Lights Sw

SPL-PK2, Splice 3-4 Way

19Z C High Beam Flash Fused Power

Or 1.0 GXL

SRHSTLK, RH Stalk Switch

56d

SPL-PK2, Splice 3-4 Way

19Z

1A

Ign Switch Fused Power

R 1.0 GXL

S-KEY, Ignition Switch

SPL-DLY, Ultrasonic

1CB

Cab CB Protected Power

R 19.0 SXL

CB1A, Circuit Breaker

CBPW, Cab Power

1CB A Cab CB Protected Power

R 19.0 SXL

P-A3, B+ Power

CAB-PW, Cab Power

1DM

Time Delay/Ign Sw Fused Pwr

R 1.0 GXL

SPL-DLY, Ultrasonic

ECC, Work Lights

A5

1DN

Time Delay Fused Power

R 1.0 GXL

TDM, Time Delay Module

SPL-DLY, Ultrasonic

1NC

Cab CB PRM Power

R 19.0 SXL

B1, Starter Power Stud

CB2B, Cab B+ CB

1 AA

Brake Lt Sw Pwr

R 1.0 SXL

FRONT, Cab Front Chassis

22

PBL, Brake Light Press Switch

1 B9

PRM C Power

R 8.0 SXL

CB3B, Cab B+ CB

P-C5, B+ Power from PRMC

1 BA

Alternator B+

R 13.0 SXL

AB+, Alternator B+

B2 Starter Power

1 BB

Starter Solenoid Pwr

R 8.0 SXL

193 Starter Relay

194 Starter Signal

1 BC

Cab CB Power

R 19.0 SXL

P-C3, B+ Power From PRMC

CB1B, Cab B+ CB

1 BE

Grid Htr Pwr

R 19.0 SXL

115 Grid Htr Pwr

GH, Grid Htr

1C

ECC Bat Power

R 8.0 GXL

P-A1, B+ Power

L1-ECC, ECC Battery Power

cs01

Brake Light Switch Power

R 1.0 GXL

CAB-F, Cab Front Chassis

22

SPL-FLSHR-PWR, Ultrasonic

1 DR

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-22

Wire Identification Codes

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

Bk = Black
T = Tan
LU = Light Blue

1.0 mm 2.0 mm 5.0 mm


DU = Dark Blue
W = White
Or = Orange

Wire Identification

S = Gray
N = Brown
R = Red

LG = Light Green
G = Green
P = Purple

From Connector
Color, Size,
and Material

To Connector

Wire

Circuit

1 DU

Flasher Module Pwr

R 1.0 GXL

FLSHR, Flasher Module

SPL-FLSHR-PWR, Ultrasonic

1 DV

Brake Lights/Flasher Bat Pwr

R 2.0 GXL

SPL-FLSHR-PWR,
Ultrasonic

ECC, Work Lights

A4

1 DW

Brake Lt Relay Bat Pwr

R 1.0 GXL

SPL-FLSHR-PWR,
Ultrasonic

ECC, Work Lights

B5

Grid heater Fuse Bat Power

R 19.0 SXL

P-C2, B+ Power from PRMC

GHF1, Grid Heater Fuse

1 GA

Filter Htr Pwr

R 3.0 SXL

PRM-C1, PRM Output

SPL-HTR, Ultrasonic

1 GB

Fuel Filter Htr Pwr

R 2.0 SXL

SPL-HTR, Ultrasonic

FFH, Fuel Filter Heater

1 GC

Water Sep Htr Pwr

R 2.0 SXL

SPL-HTR, Ultrasonic

WSH, Water Separator Heater

1 KA

Hazard Switch Pwr

R 1.0 GXL

SHZ, Hazard Switch

SPL-FLSHR-PWR, Ultrasonic

1 NA

Battery Crossover

R 62.0 SGR

BT3, Starter Battery

BT2, Disconnect Battery

1 NB

Battery Starter

R 62.0 SGR

BT1, Battery Starter

B3, Starter Battery

1 NC

B+ Power PRMC

R 19.0 SXL

B1, Starter Power Stud

P-C1, B+ Power From PRMC

1 ND

SSM Power

R 62.0 SGR

244F Starter Sec. Strg Mtr

B4, Starter Power

1Y

Grid Heater Fused Power

R 19.0 SXL

GHF3, Grid heater Fuse

GHF4, Grid Heater

1Z

Starter Relay Battery Power

R 8.0 SXL

P-C4, B+, Power From PRMC

195, Starter Relay Power

20G A EDC7 ESO-K Interface

W 0.8 TXL

ENG, Engine Cab

31

EDC7, Engine Controller

89

20G B EDC7 ESO-K Interface

W 0.8 GXL

CAB-E, Cab Engine

31

DIA, Diagnostic

Neutral Start Relay Output

W 0.8 GXL

SPL-CR, Ultrasonic

ECB, Elect Center B

D4

21C A Neutral Start Relay Output

W 0.8 GXL

SPL-CR, Ultrasonic

ECB, Elect Center B

D5

21C B Neutral Start Relay Output

W 0.8 GXL

SPL-CR, Ultrasonic

ECB, Elect Center B

A10

21C C Starter Relay Signal

W 0.8 GXL

CAB-E, Cab Engine

SPL-CR, Ultrasonic

21C D Starter Relay Signal

W 1.0 SXL

SR-9, Starter Relay Signal

ENG, Engine Cab

Starter Relay Signal

W 1.0 SXL

SRC-1, Relay

ENG, Engine Cab

15

21D A Starter Relay Signal

W 0.8 GXL

SPL-4, Ultrasonic

ECB, Elect Center B

21D B Starter Relay Signal

W 0.8 GXL

140M, Diode Module

SPL-4, Ultrasonic

21D C Starter Relay Signal

W 0.8 GXL

CAB-E, Cab Engine

15

SPL-4, Ultrasonic

Key Switch Crank

W 0.8 GXL

CAB-E, Cab Engine

27

ECB, Elect Center B

D6

21E A Key Switch Crank

W 0.8 TXL

ENG, Engine Cab

27

EDC7, Engine Controller

32

EDC7 Digital Ground

W 0.8 GXL

CAB-E, Cab Engine

11

ECB, Elect Center B

B5

21F A EDC7 Digital Ground

W 0.8 GXL

ENG, Engine Cab

11

SPL-EDC3, Ultrasonic

1E

21C

21D

21E

21F

Bur 5-2750

Connector

K = Pink
U = Blue
Y = Yellow

Cavity

Connector

Issued 8-06

Cavity

AA9

Printed in U.S.A.

4002-23

Wire Identification Codes

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

Bk = Black
T = Tan
LU = Light Blue

1.0 mm 2.0 mm 5.0 mm


DU = Dark Blue
W = White
Or = Orange

Wire Identification
Wire

Circuit

S = Gray
N = Brown
R = Red

LG = Light Green
G = Green
P = Purple

From Connector
Color, Size,
and Material

Connector

K = Pink
U = Blue
Y = Yellow

To Connector
Cavity

Connector

Cavity

21F B EDC7 Digital Ground

W 0.8 TXL

SPL-EDC3, Ultrasonic

EDC7, Engine Controller

29

21F C EDC7 Digital Ground

W 0.8 TXL

RTHP, Throttle Pedal

SPL-EDC3, Ultrasonic

EDC7 Crank Control relay

W 0.8 GXL

CAB-E, Cab Engine

ECB, Elect Center B

21G A EDC7 Crank Control relay

W 0.8 TXL

ENG, Engine Cab

EDC7, Engine Controller

37

Crank control relay LSD

W 0.8 GXL

CAB-E, Cab Engine

ECB, Elect Center B

A9

21H A Crank control relay LSD

W 0.8 TXL

ENG, Engine Cab

EDC7, Engine Controller

17

Ign Sw Start Signal

W 0.8 GXL

S-KEY, Ignition Switch

SPL-CRK, Ultrasonic

21K A Ign Sw Start Signal

W 0.8 TXL

SPL-CRK, Ultrasonic

AIC-2, Adv Instrument Cluster 2

17

21K B Ign Sw Start Signal

W 0.8 GXL

SPL-CRK, Ultrasonic

ECB, Elect Center B

B3

Throttle Signal

W 0.8 TXL

RTHP, Throttle Pedal

EDC7, Engine Controller

79

24B A Throttle Signal

W 0.8 TXL

RTHP, Throttle Pedal

QSM11, Engine Controller

47

21G

21H

21K

24B

AA10

24L

Low Idle Sw

W 0.8 TXL

RTHP, Throttle Pedal

EDC7, Engine Controller

48

24R

Throttle Pos Sens Grnd

W 0.8 TXL

RTHP, Throttle Pedal

EDC7, Engine Controller

78

24R A Throttle Pos Sens Grnd

W 0.8 TXL

RTHP, Throttle Pedal

QSM11, Engine Controller

49

Throttle Supply

W 0.8 TXL

RTHP, Throttle Pedal

EDC7, Engine Controller

77

24S A Throttle Supply

W 0.8 TXL

RTHP, Throttle Pedal

QSM11, Engine Controller

48

Eng Speed Sig

W 0.8 GXL
Twist

TRANS, Cab Transmission

ESS, Engine speed Sensor

25A A Eng Speed Sig

LU 0.8 TXL

CAB-T, Cab Transmission

TECM, Trans

19

Int Speed Sig

W 0.8 GXL
Twist

TRANS, Cab Transmission

ISS, Int Speed Sensor

25B A Int Speed Sig

LU 0.8 TXL

CAB-T, Cab Transmission

TECM, Trans

42

Turbine Speed Sig

W 0.8 GXL
Twist

TRANS, Cab Transmission

TSS, Turbine Speed Sensor

25C A Turbine Speed Sig

LU 0.8 TXL

CAB-T, Cab Transmission

TECM, Trans

41

Output Speed Sig

LU 1.0 SXL

TRANS, Cab Transmission

10

OSS, Output Speed Sensor

25D A Output Speed Sig

LU 0.8 TXL

CAB-T, Cab Transmission

10

TECM, Trans

62

24S

25A

25B

25C

25D

25F

Forward Signal

LU 0.8 TXL

TS1, Transmission Shifter

TECM, Trans

43

25G

Brake Declutch Switch

LU 1.0 SXL

FRONT, Cab Front Chassis

28

PBD, Declutch Pressure Switch

25G A Brake Declutch Switch

LU 0.8 GXL

CAB-F, Cab Front Chassis

28

SPL-DC, Ultrasonic

25G B Brake Declutch Switch

LU 0.8 GXL

SDC, Declutch Switch

SPL-DC, Ultrasonic

25G C Brake Declutch Switch

LU 0.8 TXL

SPL-DC, Ultrasonic

TECM, Trans

66

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-24

Wire Identification Codes

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

Bk = Black
T = Tan
LU = Light Blue

1.0 mm 2.0 mm 5.0 mm


DU = Dark Blue
W = White
Or = Orange

Wire Identification
Wire

Circuit

S = Gray
N = Brown
R = Red

LG = Light Green
G = Green
P = Purple

From Connector
Color, Size,
and Material

Connector

K = Pink
U = Blue
Y = Yellow

To Connector
Cavity

Connector

Cavity

25H

Trans Auto Signal

LU 0.8 TXL

STA, Trans Auto Switch

TECM, Trans

29

25J

Trans Sol Valve Y6

LU 0.8 TXL

TRANS, Cab Transmission

21

TRC, Trans Control

25J A Trans Sol Valve Y6

LU 0.8 TXL

CAB-T, Cab Transmission

21

TECM, Trans

51

Trans Sol Valve Y1

LU 0.8 TXL

TRANS, Cab Transmission

16

TRC, Trans Control

25K 9 Trans Sol Valve Y2

LU 0.8 TXL

TRANS, Cab Transmission

16

TRC, Trans Control

25K A Trans Sol Valve Y1

LU 0.8 TXL

CAB-T, Cab Transmission

16

TECM, Trans

56

25K

25L

Trans Sol Valve Y2

LU 0.8 TXL

TRANS, Cab Transmission

17

TRC, Trans Control

25L 9

Trans Sol Valve Y1

LU 0.8 TXL

TRANS, Cab Transmission

17

TRC, Trans Control

25L A Trans Sol Valve Y2

LU 0.8 TXL

CAB-T, Cab Transmission

17

TECM, Trans

10

25M

Trans Sol Valve Y3

LU 0.8 TXL

TRANS, Cab Transmission

18

TRC, Trans Control

25M A Trans Sol Valve Y3

LU 0.8 TXL

CAB-T, Cab Transmission

18

TECM, Trans

32

Trans Sol Valve Y4

LU 0.8 TXL

TRANS, Cab Transmission

19

TRC, Trans Control

25N A Trans Sol Valve Y4

LU 0.8 TXL

CAB-T, Cab Transmission

19

TECM, Trans

55

Trans Sol Valve Y5

LU 0.8 TXL

TRANS, Cab Transmission

20

TRC, Trans Control

25P A Trans Sol Valve Y5

LU 0.8 TXL

CAB-T, Cab Transmission

20

TECM, Trans

25N

25P

25R

Reverse Signal

LU 0.8 TXL

TS1, Transmission Shifter

TECM, Trans

64

25S

Output Sw Power VPS1

LU 0.8 TXL

TRANS, Cab Transmission

22

TRC, Transmission Control

25S A Output Sw Power VPS1

LU 0.8 TXL

CAB-T, Cab Transmission

22

SPL D12, Ultrasonic

25S B Output Sw Power VPS1

LU 0.8 TXL

SPL D12 Ultrasonic

TECM, Trans

12

25S C Output Sw Power VPS1

LU 0.8 TXL

SPL D12 Ultrasonic

TECM, Trans

13

Neutral Signal

LU 0.8 GXL

SPL-NEU, Ultrasonic

ECB, Elect Center B

D3

25T B Neutral Signal

LU 0.8 GXL

TS1, Transmission Shifter

SPL-NEU, Ultrasonic

25T C Neutral Signal

LU 0.8 TXL

SPL-NEU, Ultrasonic

TECM, Trans

67

25W

3rd And 4th Gear Signal

LU 0.8 TXL

TS2, Transmission Shifter

TECM, Trans

65

25Y

Trans Kick Down Signal

LU 0.8 GXL

TS2, Transmission Shifter

SPL D11, Ultrasonic

25Y A Trans Kick Down Signal

LU 0.8 TXL

SPL D11, Ultrasonic

TECM, Trans

22

25Y B Trans Kick Down Signal

LU 0.8 GXL

197F, Main Cab FNR

SPL D11, Ultrasonic

25Y C Trans Kick Down Signal

LU 0.8 GXL

20M, Trans Kick Down

197M, FNR Main Cab

25T

25Z

1st And 4th Gear Signal

LU 0.8 TXL

TS2, Transmission Shifter

TECM, Trans

63

26E

Trans Enable Signal

LU 0.8 TXL

STE, Trans Enable Switch

TECM, Trans

31

26F A FNR Forward Signal

LU 0.8 GXL

197M, FNR Main Cab

SFNR, FNR Switch

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-25

Wire Identification Codes

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

Bk = Black
T = Tan
LU = Light Blue

1.0 mm 2.0 mm 5.0 mm


DU = Dark Blue
W = White
Or = Orange

Wire Identification
Wire

Circuit

26F B FNR Forward Signal

S = Gray
N = Brown
R = Red

LG = Light Green
G = Green
P = Purple

From Connector
Color, Size,
and Material

Connector

K = Pink
U = Blue
Y = Yellow

To Connector
Cavity

Connector

Cavity

LU 0.8 TXL

197F, Main Cab FNR

TECM, Trans

20

FNR Switch Jumper

LU 0.8 GXL

SFNR, FNR Switch

SFNR, FNR Switch

26N A FNR Neutral Signal

LU 0.8 GXL

SFNR, FNR Switch

197M, FNR Main Cab

26N B FNR Neutral Signal

LU 0.8 TXL

197F, Main Cab FNR

TECM, Trans

44

26R A FNR Reverse Signal

LU 0.8 GXL

SFNR, FNR Switch

197M, FNR Main Cab

26R B FNR Reverse Signal

LU 0.8 TXL

197F, Main Cab FNR

TECM, Trans

30

26J

28E

Ether Relay Signal

W 1.0 SXL

PRM-C2, PRM Signal

ENG, Engine Cab

16

28F

Filter Htrs Relay Control

W 0.8 TXL

PRM-C2,PRM Signal

EDC7, Engine Controller

36

28G

Grid Heater Source Dr.

W 1.0 GXL

GHC, Grid Htr Relay

EDC7, Engine Controller

12

28H

Ether Switch Signal

W 0.8 GXL

CAB-E, Cab Engine

16

SETHR, Ether Switch

28J

Ether AIC Ok Signal

W 0.8 GXL

SETHR, Ether Switch

AIC-1, Adv Instrument Cluster 1

19

28P

Ether Solenoid Power

W 1.0 SXL

PRM-C1, PRM Output

ETHR, Ether Solenoid

31D

Coolant Level Signal

Y 1.0 SXL

TRANS, Cab Transmission

CLS, Cool Jump-Cool Send

31D A Coolant Level Signal

Y 0.8 TXL

CAB-T, Cab Transmission

AIC-2, Adv Instrument Cluster 2

26

31D B Coolant Level Sender Eng Trans Y 1.0 SXL

TRANS, Cab Transmission

TRAN-E, Trans to Engine

31D C Coolant Level Sender Eng Trans Y 1.0 SXL

CLS, Cool Jump Cool Send

ENG-T, Engine to Trans

31F

Air Filter Rest Sw Signal

Y 1.0 SXL

ENG, Engine Cab

28

PAF, Air Filter Rest Sw

31F A Air Filter Rest Sw Signal

Y 0.8 TXL

CAB-E, Cab Engine

28

SW-PD, Switch Pad

Hyd Filter Rest Sw Signal

Y 1.0 SXL

TRANS, Cab Transmission

23

PHF, Hyd Oil Filter Rest Sw

31H A Hyd Filter Rest Sw Signal

Y 0.8 GXL

SW-PD, Switch Pad

CAB-T, Cab Transmission

23

31H

31L

Pilot Control Switch High

Y 0.8 TXL

SPC, Pilot Control Switch

AIC-2, Advance Instr Cluster 2

18

32F

Trans Filter Maint Sw

Y 1.0 SXL

TRANS, Cab Transmission

31

FM, Filter Maint Sw

32F A Trans Filter Maint Sw

Y 0.8 TXL

CAB-T, Cab Transmission

31

TECM, Trans

17

32J A Trans Enable Indiction

Y 0.8 GXL

SFNR, FNR Switch

197M FNR Main Cab

32J C Trans Enable Indiction

Y 0.8 GXL

STE, Trans Enable Switch

SPL-D16, Ultrasonic

32J D Trans Enable Indiction

Y 0.8 TXL

SPL-D16, Ultrasonic

TECM, Trans

32J E Trans Enable Indiction

Y 0.8 GXL

197F, Main Cab FNR

SPL-D16, Ultrasonic

Brake Warning Press Low

Y 1.0 SXL

FRONT, Cab Front Chassis

26

PBW, Brake Warning Press Sw

33P A Brake Warning Press Low

Y 0.8 TXL

CAB-F, Cab Front Chassis

26

AIC-2, Advance Instr Cluster 2

Y 0.8 TXL

CAB-T, Cab Transmission

AIC-2, Advance Instr Cluster 2

33P

33R

Redundant Brake Accumulator


Pressure Low

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-26

Wire Identification Codes

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

Bk = Black
T = Tan
LU = Light Blue

1.0 mm 2.0 mm 5.0 mm


DU = Dark Blue
W = White
Or = Orange

Wire Identification
Wire

Circuit

S = Gray
N = Brown
R = Red

LG = Light Green
G = Green
P = Purple

From Connector
Color, Size,
and Material

Connector

K = Pink
U = Blue
Y = Yellow

To Connector
Cavity

Connector

Cavity

33R A Redundant Brake Accumulator


Pressure Low

Y 1.0 SXL

TRANS, Cab Transmission

SPL-RD, Ultrasonic

33R B Redundant Brake Accumulator


Pressure Low

Y 1.0 SXL

SPL-RD, Ultrasonic

PRB2, Redundant Brake Switch

33R C Redundant Brake Accumulator


Pressure Low

Y 1.0 SXL

SPL-RD, Ultrasonic

PRB1, Redundant Brake Switch

Parking Brake Switch

Y 0.8 TXL

SPB, Parking Brake Switch

AIC-2, Advance Instr Cluster 2

35A 9 Backup Alarm Power

Y 1.0 SXL

HD-9, Hood to Engine

E-HD9, Transmission-Hood

35A A Backup Alarm Relay Out

Y 0.8 GXL

SPL-PK1, Splice 3-4 Way

ECD, Elect Control D

35A B Backup Alarm Disable Switch

Y 0.8 GXL

SBU, Backup Alarm Dis Sw

SPL-PK1, Splice 3-4 Way

35A C Backup Alarm Relay Out

Y 0.8 GXL

CAB-E, Cab Engine

SPL-PK1, Splice 3-4 Way

35A D Backup Alarm Relay Out

Y 0.8 GXL

209M, Backup Alarm Dis


Jump

SPL-PK1, Splice 3-4 Way

35A E Backup Alarm Relay Out

Y 0.8 SXL

209F, Backup Alarm Dis


Jump

SPL-D8-C1, Ultrasonic

35A F Backup Alarm Relay Out

Y 0.8 SXL

CAB-E, Cab Engine

40

SPL-D8-C1, Ultrasonic

35A G Backup Alarm Relay Out

Y 0.8 SXL

ENG, Engine Cab

40

E-HD, Trans Hood

Backup Alarm Relay Out

Y 1.0 SXL

ENG, Engine Cab

40

ENG-H, Engine to Hood

35A H Backup Alarm Relay Out

Y 1.0 SXL

HD-E, Hood Trans

BU2, Backup Alarm

Y 1.0 SXL

HD-N, Hood to Engine

BU2, Backup Alarm

35A J Revers Light

K 1.0 SXL

ENG, Engine Cab

SPL-A1A, Ultrasonic

35A K Revers Light

K 1.0 SXL

SPL-A1A, Ultrasonic

LRR-E, RH rear Comb Light

35A L Revers Light

K 1.0 SXL

SPL-A1A, Ultrasonic

LLR-E, LH rear Comb Light

35A M Revers Light

K 1.0 SXL

SPL-REV, Ultrasonic

HD-9, Hood to Engine

35A N Revers Light

K 1.0 SXL

SPL-REV, Ultrasonic

LLR-9, LH Rear Comb Light

35A P Revers Light

K 1.0 SXL

LRR-9, RH rear Comb Light

SPL-REV, Ultrasonic

35A R Backup Alarm Relay Out

Y 1.0 SXL

ENG, Engine Cab

ENG-H, Engine to Hood

33U

35A
GN

35A
HN

Backup Alarm Relay Out

AA9

35B

AIC Buzzer HSD

W 0.8 TXL

BUZ, AIC Buzzer

AIC-1, Advance Instr Cluster 1

13

35C

Backup Alarm Relay Control

Y 0.8 TXL

TECM, Trans

ECD, Elect Center D

A9

Y 0.8 GXL

SBU, Backup Alarm Dis Sw

SPL-D8-C1, Ultrasonic

W 0.8 TXL

WIF, Water In Fuel Sensor

EDC7, Engine Controller

42

35R C Backup Alarm Sw


35W

Water In Fuel Indicator

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-27

Wire Identification Codes

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

Bk = Black
T = Tan
LU = Light Blue

1.0 mm 2.0 mm 5.0 mm


DU = Dark Blue
W = White
Or = Orange

Wire Identification
Wire
35X

Circuit

S = Gray
N = Brown
R = Red

LG = Light Green
G = Green
P = Purple

From Connector
Color, Size,
and Material

Connector

K = Pink
U = Blue
Y = Yellow

To Connector
Cavity

Connector

Cavity

Sec. Str Low Press Sig

Y 0.8 TXL

CAB-T, Cab Transmission

AIC-2, Advance Instr Cluster 2

11

35X A Sec. Str Low Press Sig

Y 1.0 SXL

SPL-C3, Ultrasonic

PSS, Sec. Steering Press Sw

35X B Sec. Str Low Press Sig

Y 1.0 SXL

TRANS, Cab Transmission

TR-SS, Sec. Steering Mod Option

35X C Sec. Str Low Press Sig

Y 1.0 SXL

SPL-C3, Ultrasonic

SS-TR, SS Module Trans

35X D Sec. Str Low Press Sig

Y 1.0 SXL

SSM, Sec. Steering Module

SPL-C3, Ultrasonic

Rear Axle Temp

P 0.8 TXL

CAB-E, Cab Engine

32

AIC-1, Advance Instr Cluster 1

36A A Rear Axle Temp

P 1.0 SXL

ENG, Engine Cab

32

HOT-RA, Rear Axle Oil Temp

Front Axle Temp

P 0.8 TXL

AIC-1, Adv Instr Cluster 1

CAB-F, Cab Front Chassis

36B A Front Axle Temp

P 1.0 SXL

FRONT, Cab Front Chassis

HOT-FA, Front Axle Oil Temp

Radiator Cool Temp Signal

P 1.0 SXL

ENG, Engine Cab

34

RECT, Engine Coolant Temp

36C A Radiator Cool Temp Signal

W 0.8 TXL

CAB-E, Cab Engine

34

AIC-1, Advance Instr Cluster 1

11

Fuel Level Analog

P 1.0 SXL

ENG, Engine Cab

33

RFL, Fuel Sender

36F A Fuel Level Analog

P 0.8 TXL

CAB-E, Cab Engine

33

AIC-1, Advance Instr Cluster 1

Torque Conv Output Temp


Signal

P 1.0 SXL

TRANS, Cab Transmission

13

TCOT, TCO Sender

36G A Torque Conv Output Temp


Signal

P 0.8 TXL

CAB-T, Cab Transmission

13

TECM, Trans

49

P 1.0 SXL

TRANS, Cab Transmission

30

HOT, Hydraulic Oil Temp Sender

36H A Hydraulic Oil Temp

P 0.8 TXL

CAB-T, Cab Transmission

30

AIC-1, Advance Instr Cluster 1

36R A Trans Temps/Filter Return

P 1.0 SXL

TRANS, Cab Transmission

12

SPL H1, Ultrasonic

36R B Trans Filter Maint Sw Return

P 1.0 SXL

SPL H1, Ultrasonic

FM, Filter Maint Switch

36R C Valve Body Temp Return

P 0.8 TXL

SPL H1, Ultrasonic

TRC, Trans Control

36R D TCO Temp Return

P 1.0 SXL

SPL H1, Ultrasonic

TCOT, TCO Sender

36R E Trans Temps/Filter Return

P 0.8 TXL

CAB-T, Cab Transmission

12

TECM, Trans

46

Valve Body Temp Sig

P 0.8 TXL

TRANS, Cab Transmission

TRC, Trans Control

36T A Valve Body Temp Sig

P 0.8 TXL

CAB-T, Cab Transmission

TECM, Trans

39

37D A Diagnostic Signal

P 0.8 TXL

108F, Diagnostic Connector

TECM, Trans

15

P 0.8 TXL

108F, Diagnostic Connector

TECM, Trans

18

41H A High Beam Pwr

Or 1.0 GXL

SRHSTLK, RH Stalk Switch

56a

SPL-PK2, Splice 3-4 Way

41H B High Beam LH Pwr

Or 0.8 GXL

SPL-PK2, Splice 3-4 Way

ECB, Elect Center B

A3

41H C High Beam RH Pwr

Or 0.8 GXL

SPL-PK2, Splice 3-4 Way

ECB, Elect Center B

A4

36A

36B

36C

36F

36G

36H

36T

37E

Hydraulic Oil Temp Signal

Diagnostic Signal Switched

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-28

Wire Identification Codes

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

Bk = Black
T = Tan
LU = Light Blue

1.0 mm 2.0 mm 5.0 mm


DU = Dark Blue
W = White
Or = Orange

Wire Identification
Wire

Circuit

41H D High Beam Pwr

S = Gray
N = Brown
R = Red

LG = Light Green
G = Green
P = Purple

From Connector
Color, Size,
and Material

Connector

K = Pink
U = Blue
Y = Yellow

To Connector
Cavity

Connector

Cavity

Or 0.8 TXL

SW-PD, Switch Pad

SPL-PK2, Splice 3-4 Way

Or 1.0 GXL

SDR, Driving Lights Switch

SRHSTLK, RH Stalk Switch

56

41L A Low Beam Power

Or 1.0 GXL

SRHSTLK, RH Stalk Switch

56b

41L B Low Beam RH Power

Or 0.8 GXL

SPL-LB, Ultrasonic

ECB, Elect Center B

A6

41L C Low Beam LH Power

Or 0.8 GXL

SPL-LB, Ultrasonic

ECB, Elect Center B

A5

K 1.0 GXL

SDR, Driving Lights Switch

SPL-PK2, Splice 3-4 Way

41T A Position Lights RH Switched Pwr K 1.0 GXL

SPL-PK2, Splice 3-4 Way

ECB, Elect Center B

A8

41T B Position Lights LH Switched Pwr K 1.0 GXL

SPL-PK2, Splice 3-4 Way

ECB, Elect Center B

A7

41T C Position Lights Switched Pwr

K 1.0 GXL

D-OR, Diode OR

SPL-D, Ultrasonic

41T D Position Lights Switched Pwr

K 0.8 TXL

SW-PD, Switch Pad

SPL-D, Ultrasonic

41T E Position Lights Switched Pwr

K 1.0 SXL

SPL-PK2, Splice 3-4 Way

SPL-D, Ultrasonic

42C A Front Work Lights Fused Pwr

DU 1.0 GXL

CAB-RF, Cab to Roof Conn.

SPL-PK1, Splice 3-4 Way

42C C Front Work Lights Fused Pwr

DU 1.0 GXL

SPL-PK1, Splice 3-4 Way

ECB, Elect Center B

42C D Front Work Lights Fused Pwr

DU 1.0 GXL

SPL-PK1, Splice 3-4 Way

D-OR, Diode OR

42C E Front Work Lights Fused Pwr

DU 0.8 TXL

SW-PD, Switch Pad

SPL-PK1, Splice 3-4 Way

42C F Front Work Lights Fused Pwr

DU 1.0 GXL

ROOF, Roof to Cab Conn.

SPL-WRKF, Ultrasonic

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

SPL-WRKF, Ultrasonic

LRFW, RH Front Work Light

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

SPL-WRKF, Ultrasonic

LLFW, LH Front Work Light

42FS

Front Work Lights Switched Pwr

DU 1.0 GXL

SWL, Work Lights Switch

ECB, Elect Center B

A1

42RS

Rear Work Light Switched Pwr

DU 1.0 GXL

SWL, Work Lights Switch

ECB, Elect Center B

A2

42R C Rear Work Lights Fused Pwr

DU 1.0 GXL

CAB-RF, Cab to Roof Conn.

ECB, Elect Center B

AA2

42R F Rear Work Lights Fused Pwr

DU 1.0 GXL

ROOF, Roof to Cab Conn.

SPL-WRKR, Ultrasonic

42R G RH Rear Work Lt Fused Pwr

DU 1.0 SXL

SPL-WRKR, Ultrasonic

LRRW, RH Rear Work Light

42R H LH Rear Work Lt Fused Pwr

DU 1.0 SXL

SPL-WRKR, Ultrasonic

LLRW, LH Rear Work Light

41J

41T

Driving Light Power

Position Lights Switched Pwr

SPL-LB, Ultrasonic

A
AA1

42 A

Work Lights Fused Power

R 2.0 GXL

SWL, Work Lights Switch

SPL-WL, Ultrasonic

42 B

Work Lights Fused Power

R 2.0 GXL

SWL, Work Lights Switch

SPL-WL, Ultrasonic

43S A Door Open Signal

W 0.8 GXL

CAB-RF, Cab to Roof Conn.

SPL-DS, Ultrasonic

43S B Door Open Signal

W 0.8 GXL

ROOF, Roof to Cab Conn.

DS, Door Switch

43S C Door Open Signal

W 0.8 TXL

SPL-DS, Ultrasonic

AIC-2, Adv Instrument Cluster 2

43S D Time Delay Mod Door Sw Reset

W 0.8 TXL

TDM, Time Delay Module

SPL-DS, Ultrasonic

DU 0.8 TXL

CAB-RF, Cab to Roof Conn.

AIC-1, Adv Instrument Cluster 1

43 A

Dome Light Auto Mode

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-29

Wire Identification Codes

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

Bk = Black
T = Tan
LU = Light Blue

1.0 mm 2.0 mm 5.0 mm


DU = Dark Blue
W = White
Or = Orange

Wire Identification
Wire
43 B

Circuit

S = Gray
N = Brown
R = Red

LG = Light Green
G = Green
P = Purple

From Connector
Color, Size,
and Material

Connector

K = Pink
U = Blue
Y = Yellow

To Connector
Cavity

Connector

Cavity

DU 0.8 GXL

ROOF, Roof to Cab Conn.

LDM2, Dome Light Auto

44A A Brake Light Relay Out

T 0.8 GXL

SPL-BRK, Ultrasonic

ECC, Work Lights

D6

44A B Brake Light Relay Out

T 0.8 TXL

SPL-BRK, Ultrasonic

AIC-1, Adv Instrument Cluster 1

15

44A C Brake Light Relay Out

T 0.8 GXL

CAB-E, Cab Engine

SPL-BRK, Ultrasonic

44A D Brake Light Relay Out

T 1.0 SXL

ENG, Engine Cab

SPL-B8, Ultrasonic

Brake Light Relay Out

T 1.0 SXL

ENG, Engine Cab

ENG-H, Engine to Hood

44A E Brake Light Relay Out

T 1.0 SXL

LLR-E, LH Rear Comb Light

SPL-B8, Ultrasonic

Brake Light Relay Out

T 1.0 SXL

HD-N, Hood to Engine

SPL-J2-N, Ultrasonic

44A F Brake Light Relay Out

T 1.0 SXL

LRR-E, RH Rear Comb Light

SPL-B8, Ultrasonic

44A
DN

44A
EN

Dome Light Auto Mode

44A
FN

Brake Light Relay Out

T 1.0 SXL

LLR-N, LH Rear Comb Light

SPL-J2-N, Ultrasonic

44A
GN

Brake Light Relay Out

T 1.0 SXL

LRR-N, RH Rear Comb Light

SPL-J2-N, Ultrasonic

44A J Brake Light Power

T 1.0 SXL

SPL-L1, Ultrasonic

HD-9, Hood to Engine

44A K Brake Light Power

T 1.0 SXL

SPL-L1, Ultrasonic

LRR-9, RH Rear Comb Light

44A L Brake Light Power

T 1.0 SXL

LLR-9, LH Rear Comb Light

SPL-L1, Ultrasonic

44 A

T 0.8 GXL

CAB-F, Cab Front Chassis

23

ECC, Work Lights

D5

45A A Left Turn Switch Power

N 0.8 GXL

FLSHR, Flasher Module

SRHSTLK, RH Stalk Switch

45B A Right Turn Switch Power

N 0.8 GXL

FLSHR, Flasher Module

10

SRHSTLK, RH Stalk Switch

Brake Light Control Power

45H

Hazard Switch Power

N 0.8 GXL

FLSHR, Flasher Module

11

SHZ, Hazard Switch

45L

Left Turn Signal

N 1.0 SXL

FRONT, Cab Front Chassis

LLF, Lights LH

45L 9

Left Turn Signal

N 1.0 SXL

HD-9, Hood to Engine

LLR-9, LH Rear Comb Light

45L A Left Turn Signal

N 1.0 SXL

ENG, Engine Cab

10

LLR-E, LH Rear Comb Light

45L AN Left Turn Signal

N 1.0 SXL

ENG, Engine Cab

10

ENG-H, Engine to Hood

45L B Left Turn Signal

N 0.8 GXL

CAB-E, Cab Engine

10

SPL-PK3, Splice 3-4 Way

45L BN Left Turn Signal

N 1.0 SXL

HD-N, Hood to Engine

LLR-N, LH Rear Comb Light

45L C Left Turn Signal

N 0.8 GXL

CAB-F, Cab Front Chassis

SPL-PK3, Splice 3-4 Way

45L D Left Turn Signal

N 0.8 GXL

FLSHR, Flasher Module

SPL-PK3, Splice 3-4 Way

45L E Left Turn Signal

N 0.8 TXL

SPL-PK3, Splice 3-4 Way

AIC-2, Adv Instrument Cluster 2

45N A Flasher OPP Side Control

N 0.8 GXL

FLSHR, Flasher Module

64F, Flasher Connector

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-30

Wire Identification Codes

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

Bk = Black
T = Tan
LU = Light Blue

1.0 mm 2.0 mm 5.0 mm


DU = Dark Blue
W = White
Or = Orange

Wire Identification
Wire

Circuit

45N B Flasher OPP Side Control

S = Gray
N = Brown
R = Red

LG = Light Green
G = Green
P = Purple

From Connector
Color, Size,
and Material

Connector

K = Pink
U = Blue
Y = Yellow

To Connector
Cavity

Connector

Cavity

N 0.8 GXL

FLSHR, Flasher Module

12

64M, Flasher Connector

Right Turn Signal

N 1.0 SXL

FRONT, Cab Front Chassis

LRF, Lights RH

45R 9 Right Turn Signal

N 1.0 SXL

HD-9, Hood to Engine

LRR-9, RH Rear Comb Light

45R A Right Turn Signal

N 1.0 SXL

ENG, Engine Cab

12

LRR-E, RH Rear Comb Light

Right Turn Signal

N 1.0 SXL

ENG, Engine Cab

12

ENG-H, Engine to Hood

45R B Right Turn Signal

N 0.8 GXL

CAB-E, Cab Engine

12

SPL-PK3, Splice 3-4 Way

Right Turn Signal

N 1.0 SXL

HD-N, Hood to Engine

LRR-N, RH Rear Comb Light

45R C Right Turn Signal

N 0.8 TXL

SPL-PK3, Splice 3-4 Way

AIC-2, Adv Instrument Cluster 2

10

45R D Right Turn Signal

N 0.8 GXL

CAB-F, Cab Front Chassis

SPL-PK3, Splice 3-4 Way

45R E Right Turn Signal

N 0.8 GXL

FLSHR, Flasher Module

SPL-PK3, Splice 3-4 Way

46 C

Beacon Switched Power

K 1.0 GXL

CAB-RF, Cab to Roof Conn.

SBE, Beacon Switch

46 D

Beacon Switched Power

K 1.0 GXL

ROOF, Roof to Cab Conn.

LBEPWR, Light Beacon power

46 E

Beacon Switched Power

K 1.0 GXL

LBEE, Light Beacon Exten

LBEP, Light Beacon power

49A

Back Light Power

S 0.8 GXL

HVAC1, HVAC1

SPL-BCK-LGT, Spl Back Lgt Pwr

49S

Back Light Power

S 0.8 GXL

STA, Trans Auto Switch

SPL-BCK-LGT, Spl Back Lgt Pwr

49U

Back Light Power

S 0.8 GXL

SETHR, Ether Switch

SPL-PED-BL, Spl Back Lgt Pwr 6


Pck

49 A

Back Light Power

S 0.8 GXL

SWL, Work Lights Switch

SPL-BCK-LGT, Spl Back Lgt Pwr

49 B

Back Light Power

S 0.8 GXL

SBE, Beacon Switch

SPL-BCK-LGT, Spl Back Lgt Pwr

49 C

Back Light Power

S 0.8 GXL

SRWP, Rear Wiper Switch

SPL-BCK-LGT, Spl Back Lgt Pwr

49 D

Back Light Power

S 0.8 GXL

SHZ, Hazard SWitch

SPL-PED-BL, Spl Back Lgt Pwr 6


Pck

49 E

Back Light Power

S 0.8 GXL

SPL-BCK-LGT2, Spl Back


Lgt Pwr

SPL-BCK-LGT, Spl Back Lgt Pwr

49 F

Back Light Power

S 0.8 GXL

SPE, Pin Engage Switch

10

SPL-BCK-LGT2, Spl Back Lgt


Pwr

49 G

Back Light Power

S 0.8 GXL

SRC, Ride control Switch

SPL-BCK-LGT2, Spl Back Lgt


Pwr

49 H

Back Light Power

S 0.8 GXL

STE, Trans Enable Switch

SPL-BCK-LGT, Spl Back Lgt Pwr

49 J

Back Light Power

S 0.8 GXL

SRTD, Detent Switch

SPL-BCK-LGT2, Spl Back Lgt


Pwr

45R

45R
AN

45R
BN

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-31

Wire Identification Codes

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

Bk = Black
T = Tan
LU = Light Blue

1.0 mm 2.0 mm 5.0 mm


DU = Dark Blue
W = White
Or = Orange

Wire Identification
Wire

Circuit

S = Gray
N = Brown
R = Red

LG = Light Green
G = Green
P = Purple

From Connector
Color, Size,
and Material

K = Pink
U = Blue
Y = Yellow

To Connector

Connector

Cavity

Connector

Cavity

49 K

Back Light Power

S 0.8 GXL

SFL, Return to Travel Switch

SPL-BCK-LGT2, Spl Back Lgt


Pwr

49 L

Back Light Power

S 0.8 GXL

SBU, Back Up Alarm Dis Sw

SPL-BCK-LGT, Spl Back Lgt Pwr

49 M

Back Light Power

S 0.8 GXL

SHC, Height Control Switch

SPL-BCK-LGT2, Spl Back Lgt


Pwr

49 N

Back Light Power

S 0.8 GXL

SPC, Pilot Control Switch

SPL-PED-BL, Spl Back Lgt Pwr 6


Pck

49 P

Back Light Power

S 0.8 GXL

SDR, Driving Lights Switch

SPL-BCK-LGT, Spl Back Lgt Pwr

49 Q

Back Light Power

S 0.8 GXL

SFC, Fan Control Switch

SPL-BCK-LGT2, Spl Back Lgt


Pwr

49 R

Back Light Power

S 0.8 GXL

SDC, Declutch Switch

SPL-BCK-LGT, Spl Back Lgt Pwr

49 S

Back Light Power

S 0.8 GXL

SPL-PED-BL, Spl Back Lgt


Pwr 6 Pck

SPL-BCK-LGT2, Spl Back Lgt


Pwr

49 T

Back Light Power

S 0.8 GXL

SFWW, Front Wiper/Washer

SPL-BCK-LGT2, Spl Back Lgt


Pwr

49 U

Back Light Power

S 0.8 GXL

SCS, Comfort Steer Switch

SPL-PED-BL, Spl Back Lgt Pwr 6


Pck

49 V

Back Light Power

S 0.8 GXL

SPB, Parking Brake Switch

SPL-PED-BL, Spl Back Lgt Pwr 6


Pck

51B A Comfort Steer Solenoid Power

W 0.8 GXL

SCS, Comfort Steer Switch

SPL-CSS, Ultrasonic

51B B Comfort Steer Solenoid Power

W 0.8 GXL

SPL-CSS, Ultrasonic

ECC, Work Lights

51B C Comfort Steer Solenoid Power

W 0.8 GXL

SPL-CSS, Ultrasonic

CAB-F, Cab Front Chassis

51B D Comfort Steer Solenoid Power

W 1.0 SXL

FRONT, Cab Front Chassis

YCS, Comfort Steer Solenoid

D10

51C

Comfort Steer control

W 0.8 TXL

AIC-1, Adv Instrument


Cluster 1

21

ECC, Work Lights

B10

51CS

Comfort Steer Switch

W 0.8 TXL

SCS, Comfort Steer Switch

AIC-1, Adv Instrument Cluster 1

17

W 1.0 SXL

SSM, Sec. Steer Module

PSS, Sec. Steer Pressure Switch

51P A Sec. Str High Press


51S

Standard Steering Signal

W 0.8 TXL

SCS, Comfort Steer Switch

AIC-1, Adv Instrument Cluster 1

16

51 A

Sec. Str Motor Control

W 1.0 SXL

SSM, Sec. Steer Module

SPL-SS, Ultrasonic

51 B

Sec. Str Motor Control

W 1.0 SXL

SPL-SS, Ultrasonic

SSS, SS Mag Switch

51 C

Sec. Strg Sol Control

W 1.0 SXL

SPL-SS, Ultrasonic

YSS, Sec. Steering Solenoid

52AU

Fan Reverse Auto

W 0.8 TXL

SFC, Fan Control Switch

AIC-2, Adv Instrument Cluster 2

52A A Fan Reverse Relay Out

W 1.0 GXL

CAB-E, Cab Engine

22

ECB, Elect Center B

52A B Fan Reverse Relay Out

W 1.0 SXL

ENG, Engine Cab

22

YFR, Fan Rev Solenoid Option

Bur 5-2750

Issued 8-06

D8
1

Printed in U.S.A.

4002-32

Wire Identification Codes

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

Bk = Black
T = Tan
LU = Light Blue

1.0 mm 2.0 mm 5.0 mm


DU = Dark Blue
W = White
Or = Orange

Wire Identification
Wire

Circuit

S = Gray
N = Brown
R = Red

LG = Light Green
G = Green
P = Purple

From Connector
Color, Size,
and Material

Connector

K = Pink
U = Blue
Y = Yellow

To Connector
Cavity

Connector

Cavity

52C

Parking Brake Solenoid LSD

W 0.8 TXL

AIC-1, Adv Instrument


Cluster 1

14

ECB, Elect Center B

52J

Fan Control Switch Jumper

W 0.8 GXL

SFC, Fan Control Switch

SFC, Fan Control Switch

52M

Fan Reverse Manual

W 0.8 TXL

SFC, Fan Control Switch

AIC-2, Adv Instrument Cluster 2

52P

Parking Brk Relay Out

W 1.0 SXL

FRONT, Cab Front Chassis

24

YPB, Park Brake Solenoid

52P A Parking Brk Relay Out

W 0.8 GXL

CAB-F, Cab Front Chassis

24

SPL-PB, Ultrasonic

52P B Parking Brk Relay Out

W 0.8 GXL

SPL-PB, Ultrasonic

ECB, Elect Center B

D10

52P C Parking Brk Relay Out

W 0.8 TXL

SPL-PB, Ultrasonic

TECM, Trans

21

B10

53A

RTD Switch Power

W 0.8 GXL

SRTD, Detent Switch

EM, RTD Height Control RTT

53B

RTD Signal

W 1.0 SXL

FRONT, Cab Front Chassis

12

PXF, RTD

53B A RTD Signal

W 1.0 SXL

PXM, RTD

PXT, RTD

53B B RTD Signal

W 0.8 GXL

EM, RTD Height Control RTT

CAB-F, Cab Front Chassis

12

53C A Pilot Control Solenoid LSD

W 0.8 TXL

AIC-1, Adv Instrument


Cluster 1

20

ECD, Elect Center D

B6

53P A Pilot Control Relay Out

W 0.8 GXL

SPL-D25, Ultrasonic

YPP, Pilot Pressure Solenoid

53P B Pilot Control Relay Out

W 0.8 GXL

SFL, Return to Travel Switch

SPL-D25, Ultrasonic

53P C Pilot Control Relay Out

W 1.0 GXL

SPL-D25, Ultrasonic

ECD, Elect Center D

D6

53P D Pilot Control Relay Out

W 0.8 GXL

SHC, Height Control Switch

SPL-D25, Ultrasonic

53P E Pilot Control Relay Out

W 0.8 GXL

SRTD, Detent Switch

SPL-D25, Ultrasonic

53P F Pilot Control Relay Out

W 0.8 GXL

CAB-F, Cab Front Chassis

19

SPL-D25, Ultrasonic

53P G Pilot Control Relay Out

W 1.0 SXL

FRONT, Cab Front Chassis

19

SPL-A3, Ultrasonic

53P H Pilot Control Relay Out

W 1.0 SXL

SPL-A3, Ultrasonic

PXF, RTD

53P I

Pilot Control Relay Out

W 1.0 SXL

PXM, RTD

PXT, RTD

53P J Pilot Control Relay Out

W 1.0 SXL

SPL-A3, Ultrasonic

PXH, Height Control RTT

54A

Height Control Switch Power

W 0.8 GXL

SHC, Height Control Switch

EM, RTD Height Control RTT

54B

Height RTT Control Signal

W 1.0 SXL

FRONT, Cab Front Chassis

11

PXH, Height Control RTT

54B A Height RTT Control Signal

W 0.8 GXL

CAB-F, Cab Front Chassis

11

SPL-D1, Ultrasonic

54B B Height RTT Control Signal

W 0.8 GXL

EM, RTD Height Control RTT

SPL-D1, Ultrasonic

54B C Height RTT Control Signal

W 0.8 GXL

SFL, Return to Travel Switch

SPL-D1, Ultrasonic

55A A RTT Float Sw Power

W 0.8 GXL

EM, RTD Height Control RTT

SPL-RTT, Ultrasonic

55A B RTT Float Sw Power

W 0.8 GXL

SFL, Return to Travel Switch

SPL-RTT, Ultrasonic

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-33

Wire Identification Codes

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

Bk = Black
T = Tan
LU = Light Blue

1.0 mm 2.0 mm 5.0 mm


DU = Dark Blue
W = White
Or = Orange

Wire Identification
Wire

Circuit

55A C RTT Float Sw Power

S = Gray
N = Brown
R = Red

LG = Light Green
G = Green
P = Purple

From Connector
Color, Size,
and Material

K = Pink
U = Blue
Y = Yellow

To Connector

Connector

Cavity

Connector

Cavity

W 0.8 GXL

SFL, Return to Travel Switch

SPL-RTT, Ultrasonic

55B

RTT Float Switch Control

W 0.8 GXL

SFL, Return to Travel Switch

EM, RTD Height Control RTT

56 A

Fan Control PWM

W 1.0 SXL

ENG, Engine Cab

23

YFN, Fan PWM Solenoid

57 A

Pin Engage Sol Pwr

W 0.8 GXL

CAB-F, Cab Front Chassis

20

SPL-PINE, Ultrasonic

57 B

Pin Engage Sol Pwr

W 0.8 GXL

SPE, Pin Engage Switch

SPL-PINE, Ultrasonic

57 C

Pin Engage Sol Pwr

W 0.8 TXL

SPL-PINE, Ultrasonic

AIC-2, Adv Instrument Cluster 2

16

58C

Ride Control Switch Jumper

W 0.8 GXL

SRC, Ride Control Switch

SRC, Ride Control Switch

W 0.8 TXL

TECM, Trans

ECD, Elect Center D

D7

Bk 0.8 TXL

TECM, Trans

57

ECD, Elect Center D

B8

W 1.0 SXL

FRONT, Cab Front Chassis

21

YRC, Ride Control Option

58H A Ride Control Sw Pwr VPS2


58L

Ride Control Relay LSD

58S E Ride Control Sol to Front Cab


58T

Ride Control Relay Sw Pwr

W 0.8 GXL

SRC, Ride Control Switch

ECD, Elect Center D

B7

58 A

Ride Control Sol Pwr

W 1.0 SXL

202M, Rollback Jumper

202M, Rollback Jumper

58 B

Ride Control Sol Pwr

W 1.0 SXL

FRONT, Cab Front Chassis

21

PRBF, Rollback Pressure Switch

58 C

Ride Control Sol Pwr

W 0.8 GXL

CAB-F, Cab Front Chassis

21

SPL-D26, Ultrasonic

58 D

Ride Control Sol Pwr

W 0.8 GXL

140M, Diode Module

SPL-D26, Ultrasonic

58 E

Ride Control Sol Pwr

W 0.8 GXL

SPL-D26, Ultrasonic

ECD, Elect Center D

D8

58 F

Ride Control Sol Pwr

W 0.8 GXL

SRC, Ride Control Switch

SPL-D26, Ultrasonic

59D

Hood Relay Control Down

W 1.0 GXL

CAB-E, Cab Engine

37

ECC, Work Lights

D3

59D A Hood Relay Control Down

W 1.0 SXL

ENG, Engine Cab

37

HD, Hood Switch

Hood Relay Control Up

W 1.0 GXL

CAB-E, Cab Engine

39

ECC, Work Lights

D1

59U A Hood Relay Control Up

W 1.0 SXL

ENG, Engine Cab

39

HD, Hood Switch

Hood Down Relay Out

W 1.0 GXL

CAB-E, Cab Engine

36

ECC, Work Lights

B3

60D A Hood Down Relay Out

W 1.0 SXL

ENG, Engine Cab

36

HDM, Hood Lift Motor

Hood Up Relay Out

W 1.0 GXL

CAB-E, Cab Engine

38

ECC, Work Lights

B1

60U A Hood Up Relay Out

W 1.0 SXL

ENG, Engine Cab

38

HDM, Hood Lift Motor

Trinary Press Sw Input

W 1.0 SXL

ENG, Engine Cab

30

PR, Trinary Press Sw

61A B Trinary Press Sw Input

W 0.8 GXL

CAB-E, Cab Engine

30

HVAC1, HVAC1

AC Relay Out

Or 0.8 GXL

CAB-E, Cab Engine

ECD, Elect Center D

61C A AC Relay Out

Or 1.0 SXL

ENG, Engine Cab

ACT, AC Comp Clutch

61C B AC Relay Out

Or 1.0 SXL

ENG, Engine Cab

ACT-9, AC Comp Clutch

W 1.0 SXL

ENG, Engine Cab

29

PR, Trinary Press Sw

59U

60D

60U

61A

61C

61R

AC Relay Control

Bur 5-2750

Issued 8-06

D10

Printed in U.S.A.

4002-34

Wire Identification Codes

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

Bk = Black
T = Tan
LU = Light Blue

1.0 mm 2.0 mm 5.0 mm


DU = Dark Blue
W = White
Or = Orange

Wire Identification
Wire

Circuit

61R B AC Relay Control

S = Gray
N = Brown
R = Red

LG = Light Green
G = Green
P = Purple

From Connector
Color, Size,
and Material

Connector

K = Pink
U = Blue
Y = Yellow

To Connector
Cavity

Connector

Cavity

W 0.8 GXL

CAB-E, Cab Engine

29

ECD, Elect Center D

D9

63C

Front Wiper Park Control

W 0.8 GXL

FWM, Front Wiper Motor

ECD, Elect Center D

C4

63C2

Front Wiper Park Control

W 0.8 GXL

ECD, Elect Center D

D4

ECD, Elect Center D

C2

63C3

Front Wiper Park Control

W 0.8 GXL

K-WCO, Wiper Cutout

87a

ECD, Elect Center D

B3

63HC

Front Wiper High Speed Rly Ctrl

W 0.8 GXL

SFWW, Front Wiper/Washer

SPL-HC, Ultrasonic

63HC
Wiper Cutout Relay Control
A

W 0.8 GXL

SPL-HC, Ultrasonic

K-WCO, Wiper Cutout

85

63HC
Front Wiper High Speed Rly Ctrl
B

W 0.8 GXL

SPL-HC, Ultrasonic

ECD, Elect Center D

B2

63H A Front Wiper High Speed Rly Out

W 0.8 GXL

FMW, Front Wiper Motor

SPL-WHS, Ultrasonic

63H B Front Wiper High Speed Rly Out

W 0.8 GXL

SPL-WHS, Ultrasonic

ECD, Elect Center D

D2

63H C Front Wiper High Speed Rly Out

W 0.8 GXL

140M, Diode Module

SPL-WHS, Ultrasonic

63LC

Front Wiper Low Speed Rly Ctrl

W 0.8 GXL

SFWW, Front Wiper/Washer

ECD, Elect Center D

B4

63L A Front Wiper Low Speed Rly Out

W 0.8 GXL

FMW, Front Wiper Motor

SPL-WLS, Ultrasonic

63L B Front Wiper Low Speed Rly Out

W 0.8 GXL

K-WCO, Wiper Cutout

30

SPL-WLS, Ultrasonic

63L C Front Wiper Low Speed Rly Out

W 0.8 GXL

140M, Diode Module

SPL-WLS, Ultrasonic

63W

Front Washer Pump

W 0.8 GXL

CAB-E, Cab Engine

25

SFWW, Front Wiper/Washer

63W A Front Washer Pump

W 1.0 SXL

ENG, Engine Cab

25

FWW, Front Washer

64C

Horn Relay Control

Or 0.8 GXL

SRHSTLK, RH Stalk Switch

31b

ECC, Work Lights

B8

64 A

Horn Power

Or 0.8 GXL

CAB-F, Cab Front Chassis

13

ECC, Work Lights

D8

65L

Left Speaker

Or 0.8 GXL

LSPK, Left Speaker

SPK, Speaker

65R

Right Speaker

Or 0.8 GXL

RSPK, Right Speaker

SPK, Speaker

68C

Rear Wiper Park Control

Or 1.0 GXL

CAB-RF, Cab to Roof Conn.

SRWP, Rear Wiper Switch

68C A Rear Wiper Park Control

Or 1.0 GXL

ROOF, Roof to Cab Conn.

RWM, Rear Wiper Motor

Rear Wiper Switch Power

Or 1.0 GXL

SRWP, Rear Wiper Switch

SPL-3, Ultrasonic

68L A Rear Wiper Switch Power

Or 1.0 GXL

ROOF, Roof to Cab Conn.

RWM, Rear Wiper Motor

68L B Rear Wiper Switch Power

Or 1.0 GXL

CAB-RF, Cab to Roof Conn.

SPL-3, Ultrasonic

68L C Rear Wiper Switch Power

Or 1.0 GXL

140M, Diode Module

SPL-3, Ultrasonic

68W

Rear Washer Pump

W 0.8 GXL

CAB-E, Cab Engine

24

SRWP, Rear Wiper Switch

68W A Rear Washer Pump

W 1.0 SXL

ENG, Engine Cab

24

RWW, Rear Washer

CAN H CAN High

Y 0.8 TXL
TWIST

CAN2, CAN Bulk Head

EDC7, Engine Controller

35

68L

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-35

Wire Identification Codes

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

Bk = Black
T = Tan
LU = Light Blue

1.0 mm 2.0 mm 5.0 mm


DU = Dark Blue
W = White
Or = Orange

Wire Identification
Wire

Circuit

S = Gray
N = Brown
R = Red

LG = Light Green
G = Green
P = Purple

From Connector
Color, Size,
and Material

K = Pink
U = Blue
Y = Yellow

To Connector

Connector

Cavity

Connector

Cavity

CAN
HA

CAN High

Y 0.8 TXL
TWIST

SPL-CAN-HVAC, Ultrasonic

CAN, CAN Bulk Head

CAN
HB

CAN High

Y 0.8 TXL
TWIST

SPL-CAN-DIAG, Ultrasonic

DIA, Diagnostic

CAN
HC

CAN High

Y 0.8 TXL
TWIST

SPL-CAN-TRANS, Ultrasonic

SPL-CAN-DIAG, Ultrasonic

CAN
HD

CAN High

Y 0.8 TXL
TWIST

SPL-CAN-TRANS, Ultrasonic

TECM, Trans

25

CAN
HE

CAN High

Y 0.8 TXL
TWIST

SPL-CAN, Ultrasonic

SPL-CAN-TRANS, Ultrasonic

CAN
HF

CAN High

Y 0.8 TXL
TWIST

SW-PD, Switch Pad

SPL-CAN, Ultrasonic

CAN
HG

CAN High

Y 0.8 TXL
TWIST

SPL-CAN, Ultrasonic

AIC-1, Adv Instrument Cluster 1

CAN
HJ

CAN High From Engine

Y 0.8 TXL
TWIST

CAN2, CAN Bulk Head

QSM11, Engine controller

46

CAN
HK

CAN High

Y 0.8 TXL
TWIST

SPL-CAN-HVAC, Ultrasonic

HVAC-CAN1, CAN HVAC AIC

CAN
HM

CAN High

Y 0.8 TXL
TWIST

SPL-CAN-HVAC, Ultrasonic

SPL-CAN-DIAG, Ultrasonic

CAN L CAN Low

G 0.8 TXL
TWIST

CAN2, CAN Bulk Head

EDC7, Engine Controller

34

CAN
LA

CAN Low

G 0.8 TXL
TWIST

SPL-CAN-HVAC-L,
Ultrasonic

CAN, CAN Bulk Head

CAN
LB

CAN Low

G 0.8 TXL
TWIST

SPL-CAN-DIAG-L, Ultrasonic

DIA, Diagnostic

CAN
LC

CAN Low

G 0.8 TXL
TWIST

SPL-CAN-TRANS-L,
Ultrasonic

SPL-CAN-DIAG-L, Ultrasonic

CAN
LD

CAN Low

G 0.8 TXL
TWIST

SPL-D5, Ultrasonic

SPL-CAN-TRANS-L, Ultrasonic

CAN
LE

CAN Low

G 0.8 TXL
TWIST

SPL-CAN-L, Ultrasonic

SPL-CAN-TRANS-L, Ultrasonic

CAN
LF

CAN Low

G 0.8 TXL
TWIST

SW-PD, Switch Pad

SPL-CAN-L, Ultrasonic

CAN
LG

CAN Low

G 0.8 TXL
TWIST

SPL-CAN-L, Ultrasonic

AIC-1, Adv Instrument Cluster 1

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-36

Wire Identification Codes

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

Bk = Black
T = Tan
LU = Light Blue

1.0 mm 2.0 mm 5.0 mm


DU = Dark Blue
W = White
Or = Orange

Wire Identification
Wire

Circuit

S = Gray
N = Brown
R = Red

LG = Light Green
G = Green
P = Purple

From Connector
Color, Size,
and Material

Connector

K = Pink
U = Blue
Y = Yellow

To Connector
Cavity

Connector

Cavity

CAN
LJ

CAN Low

G 0.8 TXL
TWIST

SPL-D5, Ultrasonic

TECM, Trans

27

CAN
LK

CAN Low

G 0.8 TXL
TWIST

SPL-D5, Ultrasonic

TECM, Trans

26

CAN
LL

CAN Low

G 0.8 TXL
TWIST

SPL-CAN-HVAC-L,
Ultrasonic

HVAC-CAN1, CAN HVAC AIC

CAN
LM

CAN Low From Engine

G 0.8 TXL
TWIST

CAN2, CAN Bulk Head

QSM11, Engine Controller

37

CAN
LN

CAN Low

G 0.8 TXL
TWIST

SPL-CAN-HVAC-L,
Ultrasonic

SPL-CAN-DIAG-L, Ultrasonic

ECC
L1

Beacon/Dome Light L1 ECC

BUSS

L1-ECC, ECC Batt Power

cs01

ECC, Work Lights

J1

Trans ECM Power

ECA-BUSS

ECA-L1, B+ Power

cs01

ECA, Elect Center A

L1

J2

Trans ECM Comfort Steer

ECA-BUSS

ECA, Elect Center A

L1

ECA, Elect Center A

L1

J3

Comfort Steer AIC Power

ECA-BUSS

ECA, Elect Center A

L1

ECA, Elect Center A

L1

J4

Emergency Steer AIC Power

ECA-BUSS

ECA, Elect Center A

L1

ECA, Elect Center A

L1

J5

Emergency Steer Pltem Dtnts

ECA-BUSS

ECA, Elect Center A

L1

ECA, Elect Center A

L1

J6

Pltem Dtnts Park Brk Sol

ECA-BUSS

ECA, Elect Center A

L1

ECA, Elect Center A

L1

J7

Park Brake Solenoid Horn

ECA-BUSS

ECA, Elect Center A

L1

ECA, Elect Center A

L1

J8

Fan Reverse Turn Signal

ECA-BUSS

ECA, Elect Center A

L1

ECA, Elect Center A

L1

J9

Turn Signal Engine Shut Down

ECA-BUSS

ECA, Elect Center A

L1

ECA, Elect Center A

L1

J11

Blower Motor Power

ECA-BUSS

ECA-L2, B+ Power

cs01

ECA, Elect Center A

L2

J12

Blower Motor Front Wiper


Washer

ECA-BUSS

ECA, Elect Center A

L2

ECA, Elect Center A

L2

J13

Front Wiper Rear Wiper Washer

ECA-BUSS

ECA, Elect Center A

L2

ECA, Elect Center A

L2

J14

Rear Wiper Washer Backup

ECA-BUSS

ECA, Elect Center A

L2

ECA, Elect Center A

L2

J15

Backup AC

ECA-BUSS

ECA, Elect Center A

L2

ECA, Elect Center A

L2

J16

AC Seat Compressor

ECA-BUSS

ECA, Elect Center A

L2

ECA, Elect Center A

L2

J18

Seat Comp Emergency Steer

ECA-BUSS

ECA, Elect Center A

L2

ECA, Elect Center A

L2

J2
ECC

Beacon/Dome Lt Work Lights

ECA-BUSS

ECC, Work Lights

L1-1

ECC, Work Lights

L1-2

J3
ECC

Work Lights Driving Lights

ECA-BUSS

ECC, Work Lights

L1-2

ECC, Work Lights

L1-3

Bur 5-2750

Issued 8-06

L1-1

Printed in U.S.A.

4002-37

Wire Identification Codes

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

Bk = Black
T = Tan
LU = Light Blue

1.0 mm 2.0 mm 5.0 mm


DU = Dark Blue
W = White
Or = Orange

Wire Identification
Wire

Circuit

S = Gray
N = Brown
R = Red

LG = Light Green
G = Green
P = Purple

From Connector
Color, Size,
and Material

Connector

K = Pink
U = Blue
Y = Yellow

To Connector
Cavity

Connector

Cavity

J4
ECC

Driving Lights Brake Lights

ECA-BUSS

ECC, Work Lights

L1-3

ECC, Work Lights

L1-4

J5
ECC

Brake Lights Delay Power

ECA-BUSS

ECC, Work Lights

L1-4

ECC, Work Lights

L1-5

J6
ECC

Delay Power Horn

ECA-BUSS

ECC, Work Lights

L1-5

ECC, Work Lights

L1-6

J7
ECC

Horn HOD Control

ECA-BUSS

ECC, Work Lights

L1-6

ECC, Work Lights

L1-7

J8
ECC

HOD Control Cigar Lighter

ECA-BUSS

ECC, Work Lights

L1-7

ECC, Work Lights

L1-8

J9
ECC

Diagnostic Power

ECA-BUSS

ECC, Work Lights

L1-9

ECC, Work Lights

L1-8

PRM A Ignition Power Fuse Sec.


Steering

BUSS

PRM-A, Power Relay Mod A

PRM B Time Delay Fuse Ignition Pwr


Fuse

BUSS

PRM D Accessory Pwr Fuse Spare

BUSS

PRM-D, Power Relay Mod D

PRM-D, Power Relay Mod D

BUSS

PRM-A, Power Relay Mod A

PRM-D, Power Relay Mod D

RAD1 Radio Ground

W 0.8 GXL

RAD-J3, Radio Jumper

RAD-J1, Radio Power

RAD2 12V Fused Power to Radio

W 0.8 GXL

RAD-J3, Radio Jumper

12

RAD-J1, Radio Power

RAD3 12V Fused Power to Radio

W 0.8 GXL

RAD-J3, Radio Jumper

RAD-J1, Radio Power

RAD4 Left Speaker Ground

W 0.8 GXL

RAD-J3, Radio Jumper

RAD-J2, Speaker

RAD5 Left Speaker

W 0.8 GXL

RAD-J3, Radio Jumper

10

RAD-J2, Speaker

RAD6 Not Used

W 0.8 GXL

RAD-J3, Radio Jumper

RAD-J2, Speaker

RAD7 Not Used

W 0.8 GXL

RAD-J3, Radio Jumper

11

RAD-J2, Speaker

RAD8 Not Used

W 0.8 GXL

RAD-J3, Radio Jumper

RAD-J2, Speaker

RAD9 Not Used

W 0.8 GXL

RAD-J3, Radio Jumper

RAD-J2, Speaker

RAD10 Right Speaker Ground

W 0.8 GXL

RAD-J3, Radio Jumper

RAD-J2, Speaker

RAD11 Right Speaker

W 0.8 GXL

RAD-J3, Radio Jumper

RAD-J2, Speaker

PRM
PWR

Ignition Power Fuse


Accessory Power Fuse

Bur 5-2750

PRM-A, Power Relay Mod A


PRM-A, Power Relay Mod A

Issued 8-06

Printed in U.S.A.

4002-38

UNDERSTANDING THE TROUBLESHOOTING TABLES


1 Alternator

Check Points

Correct
Reading

Check the 10 ampere fuse at


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

Good
12 volts

Possible Cause of Bad Reading

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

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

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

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

LOCATING COMPONENTS ON THE SCHEMATIC POSTERS


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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-39

STARTING AND CHARGING SYSTEMS

10

5
1

7
4 11
6 12
BS06H241 / BS06H242

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

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

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

TIME DELAY MODULE


MASTER DISCONNECT SWITCH
STARTER
IGNITION SWITCH
NEUTRAL START RELAY
VOLT METER RELAY

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-40

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

Correct
Reading
Continuity

Possible Cause of Bad Reading


Bad ground circuit.

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


Terminal for wire 1-Z to ground

24 volts

Check circuit to batteries.

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

24 volts

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

Terminal for wire 1-BB to ground

24 volts

Bad starting relay.

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

Correct
Reading
75 ohms

Possible Cause of Bad Reading


Bad resistor.

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

Correct
Reading
Continuity

Possible Cause of Bad Reading

Bad ground connection.

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


Between the B+ terminal of
alternator and ground

24 volts

Check circuit to positive post of left battery. Bad master


disconnect switch.

Between terminal for wire 1-BA and


ground

24 volts

Bad wire 1-BA.

NOTE: Put the ignition switch in the ON position.


Between the B+ terminal of
alternator and ground

24 volts

Check circuit to positive post of left battery.

Terminal for wire 14 to ground

20 volts

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

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-41

4 Crank Control Relay


Located in the cab access panel for fuses and relays.
Check Points
Terminal for wire 21H to ground

Correct
Reading
Continuity

Possible Cause of Bad Reading


Bad ground circuit or bad EDC7 (24).

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

24 volts

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

Terminal for wire 21G to ground

24 volts

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

Terminal for wire 21D-A to ground

24 volts

Bad crank control relay.

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

6 Crank Request Relay


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

Correct
Reading
Continuity

Possible Cause of Bad Reading


Bad ground circuit.

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

24 volts

Check circuit 21 to neutral start relay (11).

Terminal for wire 21E to ground

24 volts

Bad crank request relay.

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-42

7 Time Delay Module


Located in the cab access panel for fuses and relays at rear of compartment.
Correct
Reading

Check Points
Terminal for wire 0-DC to ground

Continuity

Possible Cause of Bad Reading


Bad ground circuit.

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


24 volts

Terminal for wire 1DN to ground

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


and wire 1DM to fuse ECC F5.

NOTE: Put the ignition switch in the ON position.


24 volts

Terminal for wire 13K-A to ground

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

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

24 volts
Key OFF
0 volt after 30
seconds

Bad time delay module.

After 30 seconds of turning ignition


switch to the OFF position, check
terminal for wire 13D to ground

0 volt

Bad time delay module.

8 Master Disconnect Switch


Located on right side battery box cover, remove battery box cover to gain access.
Check Points

Correct
Reading

Possible Cause of Bad Reading

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

Continuity

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

NOTE: Put the master disconnect switch in the OFF position.


Between terminals of master
disconnect switch

Open Circuit

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

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-43

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

Correct
Reading
Continuity

Possible Cause of Bad Reading

Bad ground connection.

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


Starter B+ stud to ground

24 volts

Check circuit to batteries.

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

24 volts

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

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

10 Ignition Switch
Located on steering column.
Check Points

Correct
Reading

Possible Cause of Bad Reading

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


Terminal for wire 1A to ground

24 volts

Check circuit 1A to ECC-F5 fuse.

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

Continuity

Bad ignition switch.

Between Bat and Accessory

Continuity

Bad ignition switch.

NOTE: Hold the ignition switch in the START position.


Between Bat and Starter

Continuity

Bad ignition switch.

Between Bat and Ign

Continuity

Bad ignition switch.

NOTE: Put the switch in the Accessory position.


Between Bat and Accessory

Bur 5-2750

Continuity

Bad ignition switch.

Issued 8-06

Printed in U.S.A.

4002-44

11 Neutral Start Relay


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

Correct
Reading
Continuity

Possible Cause of Bad Reading


Bad ground circuit.

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

24 volts

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

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

24 volts

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

Terminal for wire 21C to ground

24 volts

Bad neutral start relay.

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

Correct
Reading
Continuity

Possible Cause of Bad Reading


Bad ground circuit.

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


Terminal for wire 18-RA to ground

24 volts

Check circuit 18R to power relay module C in engine


compartment.

NOTE: Turn ignition switch to the ON position.


Terminal for wire 13K-C to ground

24 volts

Check circuit 13K or ignition switch.

Terminal for wire 13V to ground

24 volts

Bad voltmeter relay.

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-45

POWER RELAY MODULES AND COLD STARTING SYSTEMS

20
21

17

15 19
16

13
14
18
BS06H241 / BS06H242

13.
14.
15.
16.
17.

POWER RLEAY MODULE A


POWER RELAY MODULE B
POWER RELAY MODULE C
GRID HEATER RELAY
GRID HEATER

18.
19.
20.
21.

POWER RELAY MODULE D


CIRCUIT BREAKER CAB +
WATER SEPARATOR HEATER
FUEL FILTER HEATER

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-46

13 Power Relay Module A, Ignition Power


Located in the cab access panel for fuses and relays.
Check Points
Terminal for wire 0-EB to ground

Correct
Reading
Continuity

Possible Cause of Bad Reading


Bad ground circuit.

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

24 volts

Check circuit 1CB to 105 Amp circuit breaker in engine


compartment, check circuit breaker.

Terminal for wire 13K-B to ground

24 volts

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

Terminal for wire J1 BUSS to ground

24 volts

Bad power relay module A.

14 Power Relay Module B, Ignition Power


Located in the cab access panel for fuses and relays.
Check Points
Terminal for wire 0-EA to ground

Correct
Reading
Continuity

Possible Cause of Bad Reading


Bad ground circuit.

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

24 volts

Check circuit 1CB to 105 Amp circuit breaker in engine


compartment, check circuit breaker.

Terminal for wire 13D to ground

24 volts

Check circuit 13 to Time Delay Module, check TDM (7), check


ignition switch (10).

Terminal for wire 13H to ground

24 volts

Bad power relay module B.

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

Correct
Reading

Possible Cause of Bad Reading

NOTE: Make sure engine temperature is below -0 C (32 F).


Terminal for wire 0-GA to ground

Continuity

Bad ground circuit or bad EDC7 (24).

Terminal for wire 1-NC to ground

24 volts

Check circuit 1 and circuit to batteries.

NOTE: Put the ignition switch in the ON position.


Terminal for wire 28F to ground

24 volts

Check EDC7 (24).

Terminal for wires 1-GA ground

24 volts

Check 40 ampere fuse, bad power relay module.

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-47

16 Grid Heater Relay


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

Correct
Reading
Continuity

Possible Cause of Bad Reading


Bad ground circuit or bad EDC7 (24).

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

24 volts

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

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

24 volts

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

Terminal for wire 1-BE to ground

24 volts

Bad grid heater relay.

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

Correct
Reading

Possible Cause of Bad Reading

NOTE: Disconnect terminal for wire 1-BE from grid heater.


Terminal for wire 0-ES to ground

Continuity

Bad ground circuit.

Terminal for wire 1-BE of grid heater


to ground

Resistance

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

18 Circuit breaker Cab B+


Located in the right side of the engine compartment on cooling fan housing, open engine compartment to gain access.
Check Points

Correct
Reading

Between terminal A and B on circuit


breaker

Continuity

Possible Cause of Bad Reading

Bad circuit breaker

19 Water Separator Heater


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

Correct
Reading
Continuity

Possible Cause of Bad Reading


Bad ground circuit.

NOTE: Disconnect connector WSH from water separator heater.


Between terminals A and B of heater

1.9 ohms

Bad heater.

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-48

20 Fuel Filter Heater


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

Correct
Reading
Continuity

Possible Cause of Bad Reading


Bad ground circuit.

NOTE: Disconnect connector FFH from fuel filter heater.


Between terminals A and B of heater

1.9 ohms

Bad heater.

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

21 Power Relay Module D, Accessory Power


Located in the cab access panel for fuses and relays.
Check Points
Terminal for wire 0-EC to ground

Correct
Reading
Continuity

Possible Cause of Bad Reading


Bad ground circuit.

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

24 volts

Check circuit 1CB to 105 Amp circuit breaker in engine


compartment, check circuit breaker.

Terminal for wire ACC-B to ground

24 volts

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

Terminal for wire J11 BUSS-ECA to


ground

24 volts

Bad power relay module D.

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-49

ENGINE CONTROLLER

24

22
23

BS06H241 / BS06H242

22. WATER IN FUEL SENSOR


23. THROTTLE POTENTIOMETER
24. ENGINE CONTROLLER

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-50

22 Water In Fuel Sensor


Located in the right side of the engine compartment on water separator housing, open engine compartment to gain
access.
Correct
Reading

Check Points

Continuity

Terminal for wire 0-BP to ground

Possible Cause of Bad Reading


Bad ground circuit.

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

Terminal for wire 18J-H to ground

Check fuse ECD-F2, power relay module B (14), also check


circuit 18J.

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


24 volts

Terminal for wire 35W to ground

Bad water separator sensor.

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

Correct
Reading

Possible Cause of Bad Reading

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

5 volts

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

Continuity

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

NOTE: Throttle pedal in low idle position.


Terminal for wire 24B to 24R

0.4 0.025
volts

Bad potentiometer.

NOTE: Throttle pedal in high idle position.


Terminal for wire 24B to 24R

4.0 0.1 volts

Bad potentiometer.

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

Open

Bad potentiometer.

NOTE: Throttle pedal in high idle position.

Between pin 1 and 6 at pedal

1000 400
ohms at 20 C
(68 F)

Bad potentiometer.

1200 400
ohms at 20 C
(68 F)

Bad potentiometer.

NOTE: Throttle pedal in any position.

Between pin 4 and 5 at pedal

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-51

24 Electronic Diesel Control


Located on right side of engine, open engine compartment to gain access.
Check Points

Correct
Reading

Possible Cause of Bad Reading

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

Continuity

Bad ground circuit.

Terminal for wire 0-BF pin 6 to


ground

Continuity

Bad ground circuit.

Terminal for wire 0-BD pin 10 to


ground

Continuity

Bad ground circuit.

Terminal for wire 0-BC pin 11 to


ground

Continuity

Bad ground circuit.

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

24 volts

Bad fuse ECD-F2, bad wire 18J.

Terminal for wire 18J-B pin 3 to


ground

24 volts

Bad fuse ECD-F2, bad wire 18J.

Terminal for wire 18J-D pin 8 to


ground

24 volts

Bad fuse ECD-F2, bad wire 18J.

Terminal for wire 18J-E pin 9 to


ground

24 volts

Bad fuse ECD-F2, bad wire 18J.

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-52

RETURN TO TRAVEL - RETURN TO DIG - PIN ENGAGE


28

30

25 26 31 32

29

27
33

34
BS06H241 / BS06H242

25.
26.
27.
28.
29.

RETURN TO TRAVEL FLOAT SWITCH


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

30.
31.
32.
33.
34.

HEIGHT CONTROL/RETURN TO TRAVEL PROXIMITY SWITCH


RETRUN TO DIG SWITCH
PIN ENGAGE SWITCH (OPTION)
PILOT PRESSURE SOLENOID
PIN ENGAGE SOLENOID (OPTION)

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-53

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

Correct
Reading

Possible Cause of Bad Reading

Terminal for wire 0-B2 to ground

Continuity

Bad ground circuit.

Terminal for wire 0-29 to ground

Continuity

Bad ground circuit.

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

Continuity

Bad return-to-travel/float switch.

NOTE: Put the return-to-travel/float switch in the TRAVEL position.


Between switch terminals 2 and 3

Continuity

Bad return-to-travel/float switch.

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

Terminal for wire 49-K to ground

24 volts

Bad circuit 49-K. Also check driving lamp switch (95). If


return-to-travel/float switch illumination LED is not ON with 24
volts at check point, replace return-to-travel/float switch.

Correct
Reading

Possible Cause of Bad Reading

26 Height Control Switch


Located on right side console.
Check Points
Terminals for wire 0-B3 to ground

Continuity

Bad ground circuit.

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

24 volts

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

NOTE: Turn the height control switch to the ON position.


Terminal for wire 54A to ground.

Bur 5-2750

24 volts

Bad height control switch.

Issued 8-06

Printed in U.S.A.

4002-54

27 Electromagnetic Detents
Located under right side console.
Check Points

Correct
Reading

Possible Cause of Bad Reading

NOTE: For joystick controller.


Between pins 3 and 4

74 ohms @
20 C (68 F)

Bad electromagnetic detent

Between pins 2 and 5

74 ohms @
20 C (68 F)

Bad electromagnetic detent

Between pins 1 and 6

74 ohms @
20 C (68 F)

Bad electromagnetic detent

Between pins 3 and 4

328 ohms @
20 C (68 F)

Bad electromagnetic detent

Between pins 2 and 5

328 ohms @
20 C (68 F)

Bad electromagnetic detent

Between pins 1 and 6

328 ohms @
20 C (68 F)

Bad electromagnetic detent

NOTE: For single axis controller.

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

24 volts

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

NOTE: Place the height control switch in the ON position.


Wiring harness connector EM, pin 2
to ground

24 volts

Bad height control switch. Also check wires 54A.

NOTE: Place the return to dig switch in the ON position.


Wiring harness connector EM, pin 3
to ground

24 volts

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

28 Return-To-Dig Proximity Switch


Located on bucket cylinder.
Check Points

Correct
Reading

Possible Cause of Bad Reading

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

Continuity

Terminal A for wire 53B to ground

24 volts

Bad bucket control valve detent electromagnets (27) or return


to dig switch. Also check circuit 53B.

Terminal C for wire 53P-H to ground

24 volts

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

Bad ground circuit.

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

Issued 8-06

Printed in U.S.A.

4002-55

29 Pilot Control Relay


Located in the cab access panel for fuses and relays.
Check Points

Correct
Reading

Possible Cause of Bad Reading

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

24 volts

Terminal for wire 53C-A to ground

0 volt

Terminal for wire 53P-A to ground

24 volts

Bad fuse ECA-F5, also check circuit 19C.


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

NOTE: Put the pilot control switch in ON position.


Terminal for wire 53C-A to ground

24 volts

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

30 Height Control/Return-To-Travel Proximity Switch


Located on left front frame at lift arm pivot.
Check Points

Correct
Reading

Possible Cause of Bad Reading

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

Continuity

Terminal A for wire 54B to ground

24 volts

Bad bucket control valve detent electromagnets (27) or return


to travel switch. Also check circuit 54B.

Terminal C for wire 53P-J to ground

24 volts

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

Bad ground circuit.

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

31 Return to Dig Switch


Located on right side console.
Check Points
Terminals for wire 0-B4 to ground

Correct
Reading
Continuity

Possible Cause of Bad Reading


Bad ground circuit.

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

24 volts

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

NOTE: Turn the height control switch to the ON position.


Terminal for wire 53A to ground.

Bur 5-2750

24 volts

Bad return to dig switch.

Issued 8-06

Printed in U.S.A.

4002-56

32 Pin Engage Switch (Option)


Located on right side console.
Check Points
Terminal for wire 0-B5 to ground

Correct
Reading
Continuity

Possible Cause of Bad Reading


Bad ground circuit.

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

24 volts
0 volt

Bad fuse ECA-F7 or power relay module A. Also check circuit


19P.
Bad pin engage switch.

NOTE: Put the pin engage switch in the ON position.


Terminal for wire 57-B to ground

24 volts

Bad pin engage switch.

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

Terminal for wire 49-F to ground

24 volts

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

Correct
Reading

Possible Cause of Bad Reading

33 Pilot Pressure Solenoid


Located on bottom side of pilot controls.
Check Points
Terminal for wire 0-DU to ground

Continuity

Bad ground circuit.

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

24 volts

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

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

34 Pin Engage Solenoid (Option)


Located on.
Check Points
Terminal for wire 0-AE to ground

Correct
Reading
Continuity

Possible Cause of Bad Reading


Bad ground circuit.

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

24 volts

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

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-57

PILOT CONTROL - RIDE CONTROL - FAN CONTROL

43 44

35 37 39

36
38

40
41
42
BS06H241 / BS06H242

35.
36.
37.
38.
39.

RIDE CONTROL SWITCH (OPTION)


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

40.
41.
42.
43.
44.

RIDE CONTROL SOLENOID (OPTION)


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

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-58

35 Ride Control Switch


Located on right side console.
Check Points

Correct
Reading

Possible Cause of Bad Reading

NOTE: Disconnect connector SRC from ride control switch.


Connector SRC pin 7 to ground

Continuity

Bad ground circuit.

Ride control switch terminal 6


(positive) to terminal 7 (negative)

Continuity

Bad ride control switch.

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

24 volts
0 volt

Check fuse ECA-F5 and power relay module A. Also check


circuit 19C.
Bad ride control switch.

NOTE: Put the ride control switch in the ON position.


Terminal for wire 58C to ground

24 volts

Bad ride control switch.

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

Terminal for wire 49-G to ground

24 volts

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

36 Ride Control Relay


Located in the cab access panel for fuses and relays.
Check Points

Correct
Reading

Possible Cause of Bad Reading

Terminal 85 for wire 58L to


connector TECM pin 57

Continuity

Check wire 58L.

Terminal 86 for wire 58H-A to


connector TECM pin 8

Continuity

Check wire 58H-A.

Terminal 87 for wire 58-E to ride


control switch (35) pin 6

Continuity

Check wire 58-E

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

24 volts

Bad ride control switch. Also check wire 58T.

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-59

37 Fan Reversing Switch (Option)


Located on right side console.
Check Points
Terminal for wire 0-B7 to ground

Correct
Reading
Continuity

Possible Cause of Bad Reading


Bad ground circuit.

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

24 volts

Check fuse ECA-F7, power relay module A (13), also check


circuit 19P.

NOTE: Put fan reversing switch in position 1.


Terminal for wire 52AU to ground

24 volts

Bad fan reversing switch.

NOTE: Put fan reversing switch in momentary position, hold rocker.


Terminal for wire 52M to ground

24 volts

Bad fan reversing switch.

NOTE: Put driving lamp switch in position 3.

Terminal for wire 49-Q to ground

24 volts

Check driving lamp switch. If LEDs in fan reversing switch are


not ON with 24 volts at check point, replace fan reversing
switch.

38 Fan Reverse Relay


Located in the cab access panel for fuses and relays.
Check Points

Correct
Reading

Possible Cause of Bad Reading

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


Terminal for wire 19P-D and 19P-E
to ground

24 volts

Check fuse ECA-F7 and circuit 19P.

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

Bur 5-2750

24 volts

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

Issued 8-06

Printed in U.S.A.

4002-60

39 Pilot Control Switch


Located on steering column pedestal.
Check Points
Terminal for wire 0B1 to ground

Correct
Reading
Continuity

Possible Cause of Bad Reading


Bad ground circuit.

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

24 volts

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

NOTE: Press pilot control switch to turn ON switch LED.


Terminal for wire 31L to ground

24 volts

Bad pilot control switch.

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


Terminal for wire 49-N to ground

24 volts

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

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

40 Ride Control Solenoid


Located on ride control valve inside of front frame.
Check Points

Correct
Reading

Possible Cause of Bad Reading

NOTE: Disconnect connector YRC from ride control solenoid.


Connector YRC pin 2 to ground
Between terminals 1 and 2 of ride
control solenoid

Continuity
20 to 26 ohms

Bad ground circuit.


Bad ride control solenoid.

41 Rollback Pressure Switch (Option)


Located inside of front frame.
Check Points

Correct
Reading

Possible Cause of Bad Reading

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

Continuity

Bad rollback pressure switch.

37 to 43 ohms

Bad ride control solenoid (40).

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

Terminal for wire 58-B to ground

Bur 5-2750

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

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

Issued 8-06

Printed in U.S.A.

4002-61

42 Rollback Jumper (Option)


Located inside of front frame.
Check Points
Between terminals A and B on
switch

Correct
Reading
Continuity

Possible Cause of Bad Reading

Bad rollback jumper.

43 Fan PWM Solenoid (Option)


Located on fan control valve.
Check Points

Correct
Reading

Possible Cause of Bad Reading

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

26 to 32 ohms

Pin 2 of wiring harness connector


YFN to ground

Continuity

Bad fan reversing solenoid.

Bad ground circuit.

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

24 volts

Bad instrument cluster. Also check wire 56.

44 Fan Reversing Solenoid (Option)


Located on fan control valve.
Check Points

Correct
Reading

Possible Cause of Bad Reading

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

36 to 42 ohms

Continuity

Bad fan reversing solenoid.

Bad ground circuit.

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

Bur 5-2750

24 volts

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

Issued 8-06

Printed in U.S.A.

4002-62

TRANSMISSION

46

48

52
55 56 57 60

49 50
51

45 53 54
47 61 58
BS06H241 / BS06H242

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

OUTPUT SPEED SENSOR


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

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

TRANSMISSION ENABLE SWITCH


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

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

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

45 Output Speed Sensor


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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-64

WARNING BUZZER, INSTRUMENT CLUSTER 1, PARK BRAKE

66
62 63

67
69

65

68

64
BS06H241 / BS06H242

62.
63.
64.
65.

INSTRUMENT CLUSTER CONNECTOR 1


WARNING BUZZER
PARKING BRAKE RELAY
FUEL LEVEL SENDER

66.
67.
68.
69.

AIR FILTER RESTRICTION SWITCH


PARKING BRAKE SOLENOID
RADIATOR COOLANT TEMPERATURE SENDER
BRAKE PRESSURE WARNING SWITCH

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-65

62 Instrument Cluster Connector 1


Located on instrument cluster.
Check Points

Correct
Reading

Possible Cause of Bad Reading

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

Open Circuit

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

Connector terminal SW-PD 4 to


ground

Open Circuit

Bad hydraulic filter restriction switch (72). Also check circuit


31H-A.

Connector terminal AIC-1 6 and 12


to ground

Continuity

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

Connector terminal AIC-1 11to


ground

130 to 9500
ohms

Bad engine coolant temperature sender (68). Also check circuit


circuit 36C-A and ground circuit at sender.

Connector terminal AIC-1 2 to


ground

33 to 240 ohms

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

Connector terminal AIC-1 9to


ground

130 to 9500
ohms

Bad hydraulic oil temperature sender (73). Also check circuit


36H-A and ground circuit at sender.

Connector terminal AIC-1 25 to


connector terminal SW-PD 9

Continuity

Connector terminal AIC-2 4 to


ground

Open Circuit

Bad wire 17P-A.

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

Connector terminal AIC-1 4 and


SW-PD 8 to terminals 26 and 27 on
the transmission electronic control
module (53)

Continuity

Bad circuit CAN-L.

Connector terminal AIC-1 3 and


SW-PD 7 to terminal 25 on the
transmission electronic control
module (53)

Continuity

Bad circuit CAN-H.

Connector terminal AIC-1 15 to


ground

Continuity

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


ground circuit at lamps.

NOTE: Put the parking brake switch in the ON position.


Connector terminal AIC-1 14to
ground

24 volts

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

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

Bur 5-2750

24 volts

Check fuse G, blower switch, thermostat switch, and A/C low


pressure switch. Also check circuits 61R, 61A, and 61T.

Issued 8-06

Printed in U.S.A.

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

24 volts

Check high/low beam switch, driving lamp switch, and fuse


ECC-F3. Also check circuit 41H-D.

NOTE: Press pilot control switch to turn ON switch LED.


Connector terminal AIC-1 14 to
ground

24 volts

Bad parking brake relay or fuse ECA-F6. Also check circuits


52C and 19D.

Connector terminal AIC-1 20 to


ground

24 volts

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

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

Correct
Reading

Possible Cause of Bad Reading

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

Continuity

Bad ground circuit.

NOTE: Turn the ignition switch to the ON position


Terminal for wire 35B to ground

24 volts

Bad instrument cluster

NOTE: If all readings are good, replace buzzer.

64 Parking Brake Relay


Located in the cab access panel for fuses and relays.
Check Points

Correct
Reading

Possible Cause of Bad Reading

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

24 volts
0 volt
24 volts

Bad fuse ECA-F6, also check circuit 19D.


Bad instrument cluster (62). Also check circuit 52C.
Bad parking brake relay.

NOTE: Put the parking brake switch in the ON position.


Terminal for wire 52C to ground

Bur 5-2750

24 volts

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

Issued 8-06

Printed in U.S.A.

4002-67

65 Fuel Level Sender


Located on the fuel tank top right side.
Correct
Reading

Check Points

Continuity

Terminal for wire 0-BU to ground

Possible Cause of Bad Reading


Bad ground circuit.

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

Approximately
5 volts

Check the instrument cluster (62).

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

33 to 240
ohms

Bad fuel level sender.

66 Air Filter Restriction Switch


Located on the air filter left side.
Correct
Reading

Check Points

Possible Cause of Bad Reading

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

Terminal for wire 0-BY to ground

Bad ground circuit.

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

Approximately
11.5 volts

Check the instrument cluster (62).

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

67 Parking Brake Solenoid


Located on the foot brake valve.
Check Points
Terminal for wire 0-AL to ground

Correct
Reading
Continuity

Possible Cause of Bad Reading


Bad ground circuit.

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

24 volts

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

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-68

68 Radiator Coolant Temperature Sender


Located on the lower radiator hose to engine on left side of engine compartment.
Check Points
Terminal for wire 0-BAE to ground

Correct
Reading
Continuity

Possible Cause of Bad Reading


Bad ground circuit.

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

3521 ohms
at 20 C (68 F)

Replace radiator coolant temperature sender.

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

Approximately
5 volts

Check the instrument cluster (62).

69 Brake Warning Pressure Switch


Located on the foot brake valve.
Check Points

Correct
Reading

Possible Cause of Bad Reading

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

Continuity

Bad ground circuit.

Terminal 1 for wire 33P to ground

Approximately
11.5 volts

Check circuit 33P.

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

Continuity

Bad brake warning pressure switch.

NOTE: Start and run the engine at idle two minutes.


Between terminals 1 and 2 of the
switch

Bur 5-2750

Open Circuit

Bad brake warning pressure switch or brake pressure is below


110.3 bar (1600 psi). Refer to Section 7002 to check brake
pressure.

Issued 8-06

Printed in U.S.A.

4002-69

SWITCH PAD, INSTRUMENT CLUSTER 2, PARK BRAKE


77
70 71 74

75
76

72
73
BS06H241 / BS06H242

70.
71.
72.
73.

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

74.
75.
76.
77.

PARK BRAKE SWITCH


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

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-70

70 Switch Pad
Located on steering column.
Check Points

Correct
Reading

Possible Cause of Bad Reading

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

24 volts

Bad instrument cluster (62).

NOTE: Disconnect instrument cluster connector 1.


Between terminals for wire 17P-A

Bur 5-2750

Continuity

Bad wire 17P-A.

Issued 8-06

Printed in U.S.A.

4002-71

71 Instrument Cluster Connector 2


Located on instrument cluster.
Check Points

Correct
Reading

Possible Cause of Bad Reading

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

Continuity

Bad brake warning pressure switch (69). Also check circuit


33P-A and ground circuit at brake warning pressure switch.

Connector terminal AIC-2 26 to


ground

Continuity

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

Connector terminal AIC-2 11 to


ground

Continuity

Bad secondary steering pressure switch (118). Also check


circuit 35X and ground circuit at pressure switch.

Connector terminal SW-PD 5 to


ground

Open Circuit

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

Connector terminal SW-PD 4 to


ground

Open Circuit

Bad hydraulic filter restriction switch (72). Also check circuit


31H-A.

Connector terminal AIC-2 15 and 22


to ground.
Connector terminal AIC-2 4 to
ground

Continuity

Open Circuit

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

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

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

24 volts

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

Connector terminal AIC-2 21 to


ground

24 volts

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

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

24 volts

Check fuse G, blower switch, thermostat switch, and A/C low


pressure switch. Also check circuits 61R, 61A, and 61T.

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

24 volts

Check high/low beam switch, driving lamp switch, and fuse


ECC-F3. Also check circuit 41H-D.

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

24 volts on and
off every 1-2
seconds

Check fuse ECA-F8, turn signal switch, and flasher module.


Also check wire 19B, circuit 45A-A to flasher module, and
circuit 45L from flasher module to instrument cluster.

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

24 volts on and
off every 1-2
seconds

Check fuse ECA-F8, turn signal switch, and flasher module.


Also check wire 19B, circuit 45B-A to flasher module, and
circuit 45R from flasher module to instrument cluster.

NOTE: Press pilot control switch to turn ON switch LED.


Connector terminal AIC-2 18to
ground

Bur 5-2750

24 volts

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

Issued 8-06

Printed in U.S.A.

4002-72
]

72 Hydraulic Filter Restriction Switch


Located on hydraulic filter block.
Check Points

Correct
Reading

Possible Cause of Bad Reading

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

Continuity

Bad ground connection between the hydraulic filter restriction


switch and ground.

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

Approximately
11.5 volts

Check the instrument cluster (62).

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

73 Hydraulic Oil Temperature Sender


Located on hydraulic filter block.
Check Points
Terminal for wire 0-HW to ground

Correct
Reading
Continuity

Possible Cause of Bad Reading


Bad ground circuit.

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

3521 ohms
at 20 C (68 F)

Replace hydraulic oil temperature sender.

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

Bur 5-2750

Approximately
5 volts

Check the instrument cluster (62).

Issued 8-06

Printed in U.S.A.

4002-73

74 Parking Brake Switch


Located on steering column.
Check Points
Terminal for wire 0-B29 to ground

Correct
Reading
Continuity

Possible Cause of Bad Reading


Bad ground circuit.

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

24 volts

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

24 volts

Bad parking brake switch.

NOTE: Apply parking brake switch.


Terminal for wire 33U to ground

NOTE: Put the driving lamp switch (95) in position 3, 4, or 5.


Terminal for wire 49-V to ground

24 volts

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

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

75 Redundant Brake Pressure Switch 1


Located on steel lines at accumulators.
Check Points

Correct
Reading

Possible Cause of Bad Reading

NOTE: Redundant brake switch close at 62 bar (900 psi).


Terminal for wireS 0-HM to ground

Continuity

Bad ground circuit.

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

Approximately
11.5 volts

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

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

76 Redundant Brake Pressure Switch 2


Located on steel lines at accumulators.
Check Points

Correct
Reading

Possible Cause of Bad Reading

NOTE: Redundant brake switches close at 62 bar (900 psi).


Terminal for wireS 0-HL to ground

Continuity

Bad ground circuit.

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

Approximately
11.5 volts

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

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-74

77 Coolant Level Sender


Located on radiator top tank.
Check Points
Terminal for wire 0-HV to ground

Correct
Reading
Continuity

Possible Cause of Bad Reading


Bad ground circuit.

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

Approximately
1.6 volts AC

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

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-75

BACK UP ALARM CONTROLS

79

78
BS06H241 / BS06H242

78. BACK UP ALARM RELAY

79. BACK UP ALARM DISABLE SWITCH

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-76

78 Back-up Alarm Relay


Located in the cab access panel for fuses and relays.
Check Points

Correct
Reading

Possible Cause of Bad Reading

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

Continuity

Bad wire 35C.

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

24 volts

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

Terminal for wire 19H to ground

24 volts

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

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

24 volts

Bad back-up alarm relay.

79 Back-up Alarm Disable Switch


Located on right side console.
Check Points
Terminal for wire 0-B21 to ground

Correct
Reading
Continuity

Possible Cause of Bad Reading


Bad ground circuit.

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

24 volts

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

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

Bur 5-2750

24 volts

Bad back-up alarm disable switch.

Issued 8-06

Printed in U.S.A.

4002-77

LIGHTS - 01
87
82 85
81

86
88
83
80 84

89
BS06H241 / BS06H242

80.
81.
82.
83.
84.

WORK LIGHTS SWITCH


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

85.
86.
87.
88.
89.

LEFT HAND FRONT WORK LAMP


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

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-78

80 Work Lamps Switch


Located on right side console.
Check Points
Terminal for wire 0-B14 to ground

Correct
Reading
Continuity

Possible Cause of Bad Reading


Bad ground circuit

NOTE: Put master disconnect witch in the ON position.


Terminal for wire 42-A and 42-B to
ground

24 volts

Bad fuse ECC-F2.

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

24 volts

Bad work lamps switch.

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

24 volts

Bad work lamps switch.

81 Door Switch
Located above door in cab.
Check Points

Correct
Reading

Possible Cause of Bad Reading

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


Terminal for wire 19U-F to ground

24 volts

Bad fuse ECC-F1.

NOTE: Disconnect connector DS at door switch.


Between pins on door switch with
door open

Continuity

Bad door switch.

Between pins on door switch with


door closed

Open circuit

Bad door switch

82 Rotating Beacon (Option)


Plug is located on left side front of cab.
Check Points

Correct
Reading

Possible Cause of Bad Reading

Bulb

Continuity

Bad bulb.

Terminal for wire 0-MC to ground

Continuity

Bad ground circuit.

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

24 volts

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

NOTE: If readings are good replace the rotating beacon.

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-79

83 Dome Lamp
Located in top of cab.
Correct
Reading

Check Points

Possible Cause of Bad Reading

Bulb

Continuity

Bad bulb.

Terminal for wire 0-MB to ground

Continuity

Bad ground circuit.

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

Terminal for wire 19U-C to ground


Terminal for wire 43-B to ground

24 volts
3 to 5 seconds

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


Check circuit 43, also check advanced instrument cluster (62)
and time delay module (7).

NOTE: If readings are good, replace dome lamp.

84 Beacon Switch (Option)


Located on right side console.
Check Points
Terminal for wire 0-B15 to ground

Correct
Reading
Continuity

Possible Cause of Bad Reading


Bad ground circuit.

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

24 volts

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

NOTE: Put the beacon switch in the ON position.


Terminal for wire 46-C to ground

24 volts

Bad beacon switch.

85 Left Hand Front Work Lamp


Located on left front side of cab.
Check Points

Correct
Reading

Possible Cause of Bad Reading

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

Continuity

Bad lamp bulb.

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

Continuity

Bad ground circuit.

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

Terminal for wire 42C-H to ground

Bur 5-2750

24 volts

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

Issued 8-06

Printed in U.S.A.

4002-80

86 Right Hand Front Work Lamp


Located on right front side of cab.
Check Points

Correct
Reading

Possible Cause of Bad Reading

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

Continuity

Bad lamp bulb.

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

Continuity

Bad ground circuit.

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

Terminal for wire 42C-G to ground

24 volts

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

87 Left Hand Rear Work Lamp


Located on left rear side of cab.
Check Points

Correct
Reading

Possible Cause of Bad Reading

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

Continuity

Bad lamp bulb.

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

Continuity

Bad ground circuit.

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

Terminal for wire 42R-H to ground

24 volts

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

88 Right Hand Rear Work Lamp


Located on right rear side of cab.
Check Points

Correct
Reading

Possible Cause of Bad Reading

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

Continuity

Bad lamp bulb.

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

Continuity

Bad ground circuit.

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

Terminal for wire 42R-G to ground

Bur 5-2750

24 volts

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

Issued 8-06

Printed in U.S.A.

4002-81

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

Correct
Reading

Possible Cause of Bad Reading

NOTE: Disconnect wiring harness connector D-OR from diode connector.


Multimeter positive on pin A to pin C

None

Bad diode.

Multimeter positive on pin B to pin C

None

Bad diode.

Multimeter positive on pin C to pin A

Continuity

Bad diode.

Multimeter positive on pin C to pin B

Continuity

Bad diode.

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-82

LIGHTS - 02
93 94

95

92 91 90
BS06H241 / BS06H242

90. BRAKE LIGHTS SWITCH


91. BRAKE LIGHTS RELAY
92. FLASHER MODULE

93. HAZARD SWITCH


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

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-83

90 Brake Lamp Pressure Switch


Located on the foot brake valve.
Check Points

Correct
Reading

Possible Cause of Bad Reading

NOTE: Put master disconnect switch in ON position.


Terminal for wire 1-AA to ground
Terminal for wire 44 to ground

24 volts
0 volt

Check fuse ECC-F4, also check wires 1-AA and 1-DR.


Bad brake lamp pressure switch.

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

24 volts

Bad brake lamp pressure switch.

91 Brake Lamps Relay


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

Correct
Reading
Continuity

Possible Cause of Bad Reading


Bad ground circuit.

NOTE: Put master disconnect switch in ON position.


Terminal for wire 1-DW to ground

24 volts

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

Terminal for wire 44A to ground

0 volt

Bad brake lamp pressure switch (90).

Terminal for wire 44A-A to ground

0 volt

Bad brake lamps relay.

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

24 volts

Bad brake lamp pressure switch (90).

Terminal for wire 44A-A to ground

24 volts

Bad brake lamps relay.

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-84

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

Correct
Reading

Possible Cause of Bad Reading

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

Continuity

Bad ground circuit.

Terminal for wire 0-EH to ground

Continuity

Bad ground circuit.

Terminal for wire 45N-A to terminal


for wire 45N-B (North American
machines only)

Continuity

Bad 45N circuit.

NOTE: Put master disconnect switch in ON position.


Terminal for wire 1-DU to ground

24 volts

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

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

24 volts

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

Terminal for wire 45L-D to ground

Intermittent 24
volts

Bad flasher module.

Terminal for wire 45R-E to ground

Intermittent 24
volts

Bad flasher module.

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

24 volts

Terminal for wire 45R-E to ground

Intermittent 24
volts

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

NOTE: Put turn signal switch (94) in LEFT turn position.


Terminal for wire 45A-A to ground

24 volts

Terminal for wire 45L-D to ground

Intermittent 24
volts

Bur 5-2750

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

Issued 8-06

Printed in U.S.A.

4002-85

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

Correct
Reading

Possible Cause of Bad Reading

Continuity

Bad ground circuit.

NOTE: Put master disconnect switch in ON position.


Terminal for wire 1-KA to ground

24 volts

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

NOTE: Put hazard switch in ON position.


Terminal for wire 45H to ground

Bad hazard switch. If hazard switch LED is not ON with 24 volts


at check point, replace hazard switch.

24 volts

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

Terminal for wire 49-D to ground

Check driving lamp switch (95). Also check circuit 49 to lamp


switch (95). If hazard switch LED is not ON with 24 volts at
check point, replace hazard switch.

24 volts

94 Turn Signal, High-Low Beam, and Horn Switch


Located on steering column.
Check Points

Correct
Reading

Possible Cause of Bad Reading


HORN SWITCH

Terminal for wire 0-EP to ground

Continuity

Bad ground circuit.

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


Terminal for wire 64C to ground

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

24 volts

NOTE: If readings are good, replace the switch.


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

24 volts

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

NOTE: Move turn signal lever to RIGHT turn position.


Terminal for wire 45B-A to ground

24 volts

Bad turn signal switch.

NOTE: Move turn signal lever to LEFT turn position.


Terminal for wire 45A-A to ground

24 volts

Bad turn signal switch.

HIGH-LOW BEAM SWITCH


Terminal for wire 0-EP to ground

Bur 5-2750

Continuity

Bad ground circuit.

Issued 8-06

Printed in U.S.A.

4002-86

95 Driving Lamp Switch


Located on right side console.
Check Points

Correct
Reading

Possible Cause of Bad Reading

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


Terminal for wire 19Z to ground

24 volts

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

NOTE: Put the driving lamp switch in position 2.


Terminal for wire 41T to ground

24 volts

Bad driving lamp switch.

NOTE: Put the driving lamp switch in position 3.


Terminal for wire 41J to ground

Bur 5-2750

24 volts

Bad driving lamp switch.

Issued 8-06

Printed in U.S.A.

4002-87

LIGHTS - 03 AND HORN


96 99

97

98
BS06H241 / BS06H242

96. LEFT HAND FRONT COMBINATION LAMPS


97. RIGHT HAND FRONT COMBINATION LAMPS

98. HORN RELAY


99. HORN

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-88

96 Left Hand Front Combination Lamp


Located on the left front of the machine.
Check Points

Correct
Reading

Possible Cause of Bad Reading

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

Continuity

Bad high beam lamp bulb.

Combination lamp connector pin 4 to


pin 1

Continuity

Bad position lamp bulb.

Combination lamp connector pin 2 to


pin 1

Continuity

Bad low beam lamp bulb.

Combination lamp connector pin 5 to


pin 1

Continuity

Bad turn signal lamp bulb.

NOTE: Connect wiring harness connector LF to LH front combination lamp connector.


Terminal for wire 0-AJ to ground

Continuity

Bad ground circuit.

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

24 volts

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

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

Terminal for wire 18B to ground

24 volts

Check fuse ECB-F3, high/low beam relay (80), driving lamp


switch (95), and high/low beam switch (94). Also check circuit
18B and wire 41H.

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


Terminal for wire 18D to ground

24 volts

Check fuse ECB-F6, driving lamp switch (95), and high/low


beam switch (94). Also check circuit 18D and wire 41L-A.

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

Intermittent 24
volts

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

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-89

97 Right Hand Front Combination Lamp


Located on the right front of the machine.
Check Points

Correct
Reading

Possible Cause of Bad Reading

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

Continuity

Bad high beam lamp bulb.

Combination lamp connector pin 4 to


pin 1

Continuity

Bad position lamp bulb.

Combination lamp connector pin 2 to


pin 1

Continuity

Bad low beam lamp bulb.

Combination lamp connector pin 5 to


pin 1

Continuity

Bad turn signal lamp bulb.

NOTE: Connect wiring harness connector RF to RH front combination lamp connector.


Terminal for wire 0-AH to ground

Continuity

Bad ground circuit.

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

24 volts

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

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


Terminal for wire 18C to ground

24 volts

Check fuse ECB-F4, driving lamp switch (95), and high/low


beam switch (94). Also check circuit 18C and wire 41H.

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


Terminal for wire 18E to ground

24 volts

Check fuse ECB-F5, driving lamp switch (95), and high/low


beam switch (94). Also check circuit 18E and wire 41L-C.

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

Intermittent 24
volts

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

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-90

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

Correct
Reading

Possible Cause of Bad Reading

Terminal for wire 19U-A to ground

24 volts

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

Terminal for wire 19U-E to ground

24 volts

Check wire 19U-E.

Terminal for wire 64C to ground

24 volts

Bad horn relay.

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

0 volt

Terminal for wire 64-A to ground

24 volts

Bad horn switch.


Bad horn relay.

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

Correct
Reading
Continuity

Possible Cause of Bad Reading


Bad ground circuit.

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

24 volts

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

NOTE: If the readings are good replace the horn.

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-91

LIGHTS - 04 AND BACK UP ALARM

101
103

100
102

BS06H241 / BS06H242

100.RIGHT HAND REAR COMBINATION LAMPS


101.LEFT HAND REAR COMBINATION LAMPS

102.LICENSE PLATE LAMP


103.BACK UP ALARM

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-92

100 Right Hand Rear Combination Lamp (North America Only)


Located on the right rear of the machine.
Check Points

Correct
Reading

Possible Cause of Bad Reading

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

Continuity

Bad stop lamp bulb.

Combination lamp connector pin C


to pin D

Continuity

Bad turn lamp bulb.

Combination lamp connector pin B


to pin D

Continuity

Bad tail lamp bulb.

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

Continuity

Bad ground circuit.

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

24 volts

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


lamps relay (91).

NOTE: Put turn signal lever in RIGHT turn position.


Terminal for wire 45R-BN to ground

Intermittent 24
volts

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

NOTE: Put driving lamp switch (95) in position 2 or 3.


Terminal for wire 18G-CN to ground

24 volts

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

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-93

100 Right Hand Rear Combination Lamp (Europe Only)


Located on the right rear of the machine.
Check Points

Correct
Reading

Possible Cause of Bad Reading

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

Continuity

Bad stop lamp bulb.

Combination lamp connector pin 2 to


pin 5

Continuity

Bad turn lamp bulb.

Combination lamp connector pin 3 to


pin 5

Continuity

Bad tail lamp bulb.

Combination lamp connector pin 4 to


pin 5

Continuity

Bad reverse lamp bulb.

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

Continuity

Bad ground circuit.

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

24 volts

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


lamps relay (91).

NOTE: Have assistant put transmission in reverse.


Terminal for wire 35A-K to ground

24 volts

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


backup alarm relay (78).

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

Intermittent 24
volts

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

NOTE: Put driving lamp switch (95) in position 2 or 3.


Terminal for wire 18G-A to ground

24 volts

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

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-94

101 Left Hand Rear Combination Lamp (North America Only)


Located on the left rear of the machine.
Check Points

Correct
Reading

Possible Cause of Bad Reading

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

Continuity

Bad stop lamp bulb.

Combination lamp connector pin C


to pin D

Continuity

Bad turn lamp bulb.

Combination lamp connector pin B


to pin D

Continuity

Bad tail lamp bulb.

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

Continuity

Bad ground circuit.

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

24 volts

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


lamps relay (91).

NOTE: Put turn signal lever in LEFT turn position.


Terminal for wire 45L-BN to ground

Intermittent 24
volts

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

NOTE: Put driving lamp switch (95) in position 2 or 3.


Terminal for wire 18F-BN to ground

24 volts

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

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-95

101 Left Hand Rear Combination Lamp (Europe Only)


Check Points

Correct
Reading

Possible Cause of Bad Reading

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

Continuity

Bad stop lamp bulb.

Combination lamp connector pin 2 to


pin 5

Continuity

Bad turn lamp bulb.

Combination lamp connector pin 3 to


pin 5

Continuity

Bad tail lamp bulb.

Combination lamp connector pin 4 to


pin 5

Continuity

Bad reverse lamp bulb.

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

Continuity

Bad ground circuit.

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

24 volts

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


lamps relay (91).

NOTE: Have assistant put transmission in reverse.


Terminal for wire 35A-L to ground

24 volts

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


backup alarm relay (78).

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

Intermittent 24
volts

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

102 License Plate Lamp (North America Only)


Located on the right rear of the machine with combination lamp.
Check Points

Correct
Reading

Possible Cause of Bad Reading

Bulb

Continuity

Bad bulb.

Terminal for wire 0-JC to ground

Continuity

Bad ground circuit.

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

Bur 5-2750

24 volts

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

Issued 8-06

Printed in U.S.A.

4002-96

102 License Plate Lamp (Europe Only)


Located on the right rear of the machine with combination lamp.
Check Points

Correct
Reading

Possible Cause of Bad Reading

Bulb

Continuity

Bad bulb.

Terminal for wire 0-JC to ground

Continuity

Bad ground circuit.

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

24 volts

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

103 Back-up Alarm (North America Only)


Located on the left rear of the machine inside engine compartment.
Check Points
Terminal for wire 0-JB to ground

Correct
Reading
Continuity

Possible Cause of Bad Reading


Bad ground circuit.

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

24 volts

Bad back-up alarm disable switch (79). If machine is not a TUV


model, check connector 209F and 209M is connected.

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

103 Back-up Alarm (Europe Only)


Located on the left rear of the machine inside engine compartment.
Check Points
Terminal for wire 0-JB to ground

Correct
Reading
Continuity

Possible Cause of Bad Reading


Bad ground circuit.

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

24 volts

Bad back-up alarm disable switch (79). If machine is not a TUV


model, check connector 209F and 209M is connected.

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-97

CAB WINDOW WASHER AND WIPER SYSTEM


110

109

111
107 108

112

104 106
113

105
BS06H241 / BS06H242

104.FRONT WIPER HIGH SPEED RELAY


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

109.FRONT WIPER MOTOR


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

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-98

104 Front Wiper High Speed Relay


Located in the cab access panel for fuses and relays.
Check Points

Correct
Reading

Possible Cause of Bad Reading

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

24 volts

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

NOTE: Put the front wiper switch in the HIGH position.


Terminals for wire 63HC-B to ground
Terminals for wire 63HC-B to ground

Continuity
24 volts

Bad front wiper and washer switch (108).


Bad wiper high speed relay.

NOTE: Put the front wiper switch in the LOW position.


Terminals for wire 63C2 to ground

24 volts

Bad wiper high speed relay.

105 Front Wiper Cut Out Relay


Located in the cab access panel for fuses and relays.
Check Points

Correct
Reading

Possible Cause of Bad Reading

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

24 volts

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

Terminal for wire 63L-B to ground

24 volts

Bad wiper cut out relay.

NOTE: Put the front wiper switch in the HIGH position.


Terminals for wire 63HC-A to ground
Terminals for wire 63L-B to ground

Bur 5-2750

Continuity
0 volts

Bad front wiper and washer switch (108).


Bad wiper cut out relay.

Issued 8-06

Printed in U.S.A.

4002-99

106 Front Wiper Low Speed Relay


Located in the cab access panel for fuses and relays.
Check Points

Correct
Reading

Possible Cause of Bad Reading

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

24 volts

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

NOTE: Put the front wiper switch in the LOW position.


Terminals for wire 63C to ground

24 volts

Bad wiper low speed relay.

NOTE: Put the front wiper switch in the HIGH position.


Terminals for wire 63LC to ground
Terminals for wire 63C3 to ground

Continuity
24 volts

Bad front wiper and washer switch (108).


Bad wiper low speed relay, also check high speed wiper relay
(104).

107 Rear Wiper and Washer Switch


Located on right side console.
Check Points
Terminal for wire 0-B23 to ground

Correct
Reading
Continuity

Possible Cause of Bad Reading


Bad ground circuit.

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


Terminal for wire 19K-B to ground

24 volts

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


circuit 19K.

Terminal for wire 19K-A to ground

24 volts

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


circuit 19K.

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

24 volts

Bad rear wiper and washer switch.

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

24 volts

Bad rear wiper and washer switch.

NOTE: Put the driving lamp switch in position 3.

Terminal for wire 49-C to ground

Bur 5-2750

24 volts

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

Issued 8-06

Printed in U.S.A.

4002-100

108 Front Wiper and Washer Switch


Located on right side console.
Check Points
Terminal for wire 0-DT to ground

Correct
Reading
Continuity

Possible Cause of Bad Reading


Bad ground circuit.

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

24 volts

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

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

Continuity

Bad front wiper and washer switch also check grounding


circuit.

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

Continuity

Bad front wiper and washer switch also check grounding


circuit.

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

Bur 5-2750

24 volts

Bad front wiper and washer switch.

Issued 8-06

Printed in U.S.A.

4002-101

109 Front Wiper Motor


Located in front of steering column.
Check Points
Terminal for wire 0-B8 to ground

Correct
Reading
Continuity

Possible Cause of Bad Reading


Bad ground circuit.

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

Continuity

Bad front wiper motor.

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

24 volts

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

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

24 volts
0 volt

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

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

24 volts
0 volt

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

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

24 volts pulse

Bad front wiper and washer switch (108).

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.

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-102

110 Rear Wiper Motor


Located in top of rear cab head liner.
Check Points
Terminal for wire 0-MA to ground

Correct
Reading
Continuity

Possible Cause of Bad Reading


Bad ground circuit.

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

Continuity

Bad rear wiper and washer switch (107).

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

24 volts

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

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

24 volts

Bad rear wiper and washer switch (107).

Terminal for wire 68L-A to ground

0 volt

Bad rear wiper and washer switch (107).

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

111 Rear Washer Pump Motor


Located in left side engine compartment.
Check Points
Terminal for wire 0-BL to ground

Correct
Reading
Continuity

Possible Cause of Bad Reading


Bad ground circuit.

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

24 volts

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

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

112 Front Washer Pump Motor


Located in left side engine compartment.
Check Points
Terminal for wire 0-B to ground

Correct
Reading
Continuity

Possible Cause of Bad Reading


Bad ground circuit.

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

24 volts

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

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-103

113 Wiper Diodes


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

Correct
Reading

Possible Cause of Bad Reading

NOTE: Disconnect wiring harness connector 140M from diode connector.


Multimeter positive on pin A to pin C

None

Bad diode.

Multimeter positive on pin B to pin C

None

Bad diode.

Multimeter positive on pin D to pin C

None

Bad diode.

Multimeter positive on pin E to pin C

None

Bad diode.

Multimeter positive on pin F to pin C

None

Bad diode.

Multimeter positive on pin C to pin A

Continuity

Bad diode.

Multimeter positive on pin C to pin B

Continuity

Bad diode.

Multimeter positive on pin C to pin D

Continuity

Bad diode.

Multimeter positive on pin C to pin E

Continuity

Bad diode.

Multimeter positive on pin C to pin F

Continuity

Bad diode.

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-104

SECONDARY STEERING

114 116

118

115 117
BS06H241 / BS06H242

114.SECONDARY STEERING DIODES


115.SECONDARY STEERING SOLENOID
116.SECONDARY STEERING MODULE

117.SECONDARY STEERING MOTOR


118.SECONDARY STEERING PRESSUR SWITCH

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-105

114 Secondary Steering Diodes


Located in the cab access panel for fuses and relays, rear of compartment.
Correct
Reading

Check Points

Possible Cause of Bad Reading

NOTE: Disconnect wiring harness connector DM from diode connector.


Multimeter positive on pin A to pin C

None

Bad diode.

Multimeter positive on pin B to pin C

None

Bad diode.

Multimeter positive on pin C to pin A

Continuity

Bad diode.

Multimeter positive on pin C to pin B

Continuity

Bad diode.

115 Secondary Steering Solenoid (Option)


Located in the rear frame of the machine.
Check Points

Correct
Reading

Possible Cause of Bad Reading

NOTE: Disconnect connector YSS from secondary steering solenoid.


Between pins A and B of secondary
steering solenoid

36 to 42 ohms

Between pin 2 of connector YSS and


ground

Continuity

Bad secondary steering solenoid.

Bad ground circuit.

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

Bur 5-2750

24 volts

Check secondary steering module (116) and secondary


steering pressure switch (118).

Issued 8-06

Printed in U.S.A.

4002-106

116 Secondary Steering Module (Option)


Located in the rear frame of the machine.
Check Points

Correct
Reading

Possible Cause of Bad Reading

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

Pin 2 of connector SSM to ground

Continuity

Bad relay on secondary steering motor (117) or bad secondary


steering solenoid (115). Also Check wires 51-A, 51-B, and 51-C
and ground circuit connections (wires 0-ND and 0-CF).

Pin 4 of connector SSM to ground

Continuity

Bad ground circuit.

Pin 8 of connector SSM to ground

Continuity

Bad secondary steering pressure switch (118). Also check


wires 35X-D, 35X-C, and 35X-A.

Pin 9 of connector SSM to ground

Open Circuit

Pin 11 of connector SSM to ground

Continuity

Bad ground circuit.

Pin 12 of connector SSM to ground

Continuity

Bad ground circuit.

Bad secondary steering pressure switch (118). Also check wire


51P-A.

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

24 volts

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

Pin 7 of connector SSM to ground

24 volts

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

Pin 1 of connector SSM to ground

24 volts

Check fuse ECA-F4, power relay module A (13), ignition


switch, and diode module. Also check circuit 19R.

NOTE: Start and run engine at idle speed.


Pin 9 of connector SSM to ground

Continuity

Pin 8 of connector SSM to ground

11 volts

Bad secondary steering pressure switch.


Check circuit 35X to instrument cluster. If circuit 35X okay,
problem is bad instrument cluster.

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

Bur 5-2750

24 volts

Bad secondary steering module.

Issued 8-06

Printed in U.S.A.

4002-107

117 Secondary Steering Motor (Option)


Located in the rear frame of the machine.
Check Points

Correct
Reading

Possible Cause of Bad Reading

Motor ground stud to ground

Continuity

Bad ground circuit.

Secondary steering motor relay


ground terminal to ground

Continuity

Bad ground circuit.

Terminal for wire 51-B to ground.

10 to 45 ohms

Bad secondary steering motor relay coil or secondary steering


solenoid (115). Also check relay coil and solenoid ground
circuit.

NOTE: Put the master disconnect switch in ON position.


Terminal for red wire to ground

24 volts

Check circuit to batteries.

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

Terminal for wire 51-B to ground

24 volts

Check fuses ECA-F4 and F17, secondary steering module


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

118 Secondary Steering Pressure Switch (Option)


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

Correct
Reading

Possible Cause of Bad Reading

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

Continuity

Bad secondary steering pressure switch.

Pressure switch pin B to pin A

Open Circuit

Bad secondary steering pressure switch.

Pressure switch pin A to pin C

Open Circuit

Bad secondary steering pressure switch.

NOTE: Start and run engine at idle speed.


Pressure switch pin B to pin A

Continuity

Bad secondary steering pressure switch.

Pressure switch pin B to pin C

Open Circuit

Bad secondary steering pressure switch.

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-108

CAN COMMUNICATION

119

BS06H241 / BS06H242

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.

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-109

119 CAN Communication Diagnostics Connector


Located in the cab access panel for fuses and relays.
Check Points

Correct
Reading

Terminal A for wire 0-DH to ground

Continuity

Terminal B for wire 18K-A to ground

24 volts

Bur 5-2750

Possible Cause of Bad Reading


Bad ground circuit.
Check fuse ECC-F9, check circuit 18K.

Issued 8-06

Printed in U.S.A.

4002-110

RADIO AND POWER CONVERTER


125

122 123

124

120
121
BS06H241 / BS06H242

120.POWER RELAY MODULE E


121.POWER CONVERTER 24 TO 12 VOLT
122.12 VOLT POWER OUTLETS (OPTION)

123.RADIO
124.RIGHT SPEAKER
125.LEFT SPEAKER

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-111

120 Power Relay Module E


Located in the cab access panel for fuses and relays.
Check Points
Terminal for wire 0-DL to ground

Correct
Reading
Continuity

Possible Cause of Bad Reading


Bad ground circuit.

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

24 volts

Check circuit 1CB to 105 Amp circuit breaker in engine


compartment, check circuit breaker.

Terminal for wire 19L to ground

24 volts

Bad power relay module E, bad fuse F1.

121 Power Converter 24 volts to 12 volts (Option)


Located in the cab access panel for fuses and relays.
Check Points
Terminal for wire 0-EJ to ground

Correct
Reading
Continuity

Possible Cause of Bad Reading


Bad ground circuit.

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


Terminal for wire 19L-B and 19L-A to
ground

24 volts

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

Terminal for wire 12V-C to ground

12 volts

Bad power converter.

122 Power Outlet (Option)


Located in the cab.
Check Points

Correct
Reading

Terminal for wire 0-EK or 0-EL to


ground

Continuity

Terminal for wire 12V or 12V-A to


ground

12 volts

Possible Cause of Bad Reading

Bad ground circuit.


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

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-112

123 12 Volt Radio Ready (Option)


Located in the cab.
Check Points

Correct
Reading

Terminal in radio connector for wire


0-EN to ground

Continuity

Possible Cause of Bad Reading

Bad ground circuit.

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


Terminal in radio connector for wire
12V-HA to ground

12 volts

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

124 Right Speaker (Option)


Located in the cab.
Check Points

Correct
Reading

Possible Cause of Bad Reading

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

Voltage

Pin 2 in wiring harness connector


RSPK to ground

Continuity

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

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

125 Left Speaker (Option)


Located in the cab.
Check Points

Correct
Reading

Possible Cause of Bad Reading

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

Voltage

Pin 2 in wiring harness connector


LSPK to ground

Continuity

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

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-113

AIR SEAT - CIGAR LIGHTER - AIR CONDITIONING COMPRESSOR


130

126

129
127

128
BS06H241 / BS06H242

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

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

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-114

126 Seat Compressor and Switch (Option)


Located in the cab.
Check Points
Terminal for wire 0-DK to ground

Correct
Reading
Continuity

Possible Cause of Bad Reading


Bad ground circuit.

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

24 volts

Check fuse ECA-F16 and power relay module A (13). Also


check wire 19N.

NOTE: Put the seat compressor switch in the ON position.


Terminal for wire from seat switch at
compressor

24 volts

Bad seat switch, also check circuit from seat switch to


compressor.

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

127 Cigar Lighter (Option)


Located in the cab.
Check Points

Correct
Reading

Terminal for wire 19W to ground

24 volts

Terminal for wire 0-DV to ground

Continuity

Possible Cause of Bad Reading


Check fuse ECC-F8, also check circuit 19W.
Bad ground circuit.

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

128 Compressor Clutch Relay


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

Correct
Reading
Continuity

Possible Cause of Bad Reading


Bad ground circuit.

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

24 volts

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

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

Bur 5-2750

24 volts

Check wires 61R-B and 61R.

Issued 8-06

Printed in U.S.A.

4002-115

129 A/C High/Low Pressure Switch


Located on the rear frame in front of the rear axle.
Check Points

Correct
Reading

Possible Cause of Bad Reading

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

24 volts

Check the thermostat switch, also check circuit 61A.

NOTE: Disconnect the wiring harness connector PR from the A/C trinary pressure switch.
Between terminals of trinary
pressure switch

Continuity

Bad A/C low pressure switch, also check refrigerant charge


level. (Pressure must be above 2.75 bar (40 psi) or below 26
bar (377 psi) for switch to be closed.)

130 Compressor Clutch


Located on the left side of the engine.
Check Points

Correct
Reading

Possible Cause of Bad Reading

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

Bur 5-2750

24 volts

Check the compressor clutch relay (128), also check circuit


61C.

Issued 8-06

Printed in U.S.A.

4002-116

CLIMATE CONTROL - AUTOMATIC TEMPERATURE CONTROL


135 136 137
140 141
137

131

139
132 133 134 138 142
BS06H241 / BS06H242

131.ELECTRONIC PANEL
132.EXTERNAL AIR TEMPERATURE SENSOR
133.INTERNAL AIR TEMPERATURE SENSOR
134.SUN SENSOR
135.BLOWER FAN RESISTOR
136.BLOWER MOTORS

137.THERMOCOUPLE SENSOR
138.MIXED AIR SENSOR
139.COMPRESSOR RELAY
140.RECYCLING MOTOR
141.ELETRONIC WATER VALVE
142.24 TO 12 VOLT CONVERTER

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-117

131 Electronic Panel


Check Points

Correct
Reading

Possible Cause of Bad Reading

NOTE: No information at time of print.

132 External Air Temperature Sensor


Check Points

Correct
Reading

Possible Cause of Bad Reading

NOTE: No information at time of print.

133 Internal Air Temperature Sensor


Check Points

Correct
Reading

Possible Cause of Bad Reading

Correct
Reading

Possible Cause of Bad Reading

Correct
Reading

Possible Cause of Bad Reading

Correct
Reading

Possible Cause of Bad Reading

Correct
Reading

Possible Cause of Bad Reading

Correct
Reading

Possible Cause of Bad Reading

NOTE: No information at time of print.

134 Sun Sensor


Check Points
NOTE: No information at time of print.

135 Blower Motor Resistor


Check Points
NOTE: No information at time of print.

136 Blower Motors


Check Points
NOTE: No information at time of print.

137 Thermocouple Sensor


Check Points
NOTE: No information at time of print.

138 Mixed Air Sensor


Check Points
NOTE: No information at time of print.
Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-118

139 Compressor Relay


Check Points

Correct
Reading

Possible Cause of Bad Reading

Correct
Reading

Possible Cause of Bad Reading

Correct
Reading

Possible Cause of Bad Reading

Correct
Reading

Possible Cause of Bad Reading

NOTE: No information at time of print.

140 Recycling Motor


Check Points
NOTE: No information at time of print.

141 Electronic Water Valve


Check Points
NOTE: No information at time of print.

142 24 to 12 Volt Converter


Check Points
NOTE: No information at time of print.

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-119

STANDARD CLIMATE CONTROL


143 144 145
146 147 148
137

149 150 151


152 153

BS06H241 / BS06H242

143.AIR RECIRCULATION MOTOR


144.DRIVER
145.ELETRONIC WATER VALVE
146.BLOWER FAN RESISTOR
147.BLOWER MOTOR
148.THERMOSTAT

149.FAN SPEED SWITCH


150.AIR CONDITIONING SWITCH
151.CONTROL PANEL LIGHTS
152.WATER VALVE POTENTIOMETER
153.AIR RECIRCULATING SWITCH

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-120

143 Air Recirculation Motor


Check Points

Correct
Reading

Possible Cause of Bad Reading

Correct
Reading

Possible Cause of Bad Reading

Correct
Reading

Possible Cause of Bad Reading

NOTE: No information at time of print.

144 Driver
Check Points
NOTE: No information at time of print.

145 Electronic Water Valve


Check Points
NOTE: No information at time of print.

146 Blower Motor Speed Resistors with Thermal Fuse


Check Points

Correct
Reading

Possible Cause of Bad Reading

NOTE: Disconnect the wiring harness connector DNS RESISTOR from the resistor.
Between terminals 1 and 4 of blower
motor connector

Approximately
x.x ohms

Bad blower motor resistor.

Between terminals 2 and 4 of blower


motor connector

Approximately
x.x ohms

Bad blower motor resistor.

Between terminals 3 and 4 of blower


motor connector

Approximately
x.x ohms

Bad blower motor resistor.

147 Blower Motor


Check Points

Correct
Reading

Terminals for wire DNS66 to ground

Continuity

Possible Cause of Bad Reading


Bad ground circuit.

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Turn the blower switch (149)
to position 4.
Terminal for wire DNS65 to ground

24 volts

Check the blower switch (149).

NOTE: If the readings are correct and the blower motor does not run, replace the blower motor. Turn the blower
switch (149) to position 1. If the blower motor ran in position 4 but not in position 1, 2,or 3, check the blower
motor resistor (146).

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-121

148 Thermostat
Check Points

Correct
Reading

Possible Cause of Bad Reading

Correct
Reading

Possible Cause of Bad Reading

NOTE: No information at time of print.

149 Blower Switch


Check Points

NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Terminal for wire DNS74 to ground

24 volts

Check fuse ECA-F11.

NOTE: Turn the blower switch to position 1.


Terminal for wire DNS61 to ground

24 volts

Bad blower switch.

NOTE: Turn the blower switch to position 2.


Terminal for wire DNS62 to ground

24 volts

Bad blower switch.

NOTE: Turn the blower switch to position 3.


Terminal for wire DNS63 to ground

24 volts

Bad blower switch.

NOTE: Turn the blower switch to position 4.


Terminal for wire DNS73 to ground

24 volts

Bad blower switch.

150 Air Conditioning Switch


Check Points

Correct
Reading

Possible Cause of Bad Reading

Correct
Reading

Possible Cause of Bad Reading

NOTE: No information at time of print.

151 Control Panel Lights


Check Points
NOTE: No information at time of print.

152 Water Valve Potentiometer


Check Points

Correct
Reading

Possible Cause of Bad Reading

NOTE: No information at time of print.

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-122

153 Air Recirculating Switch


Check Points

Correct
Reading

Possible Cause of Bad Reading

NOTE: No information at time of print.

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-123

HOOD RAISE AND LOWER SYSTEM

157

156

154
155
BS06H241 / BS06H242

154.HOOD UP RELAY
155.HOOD DOWN RELAY

156.HOOD SWITCH
157.HOOD MOTOR

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

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-124

154 Hood Up Relay


Located in the cab access panel for fuses and relays.
Check Points
Terminal for wire 0-B25 to ground

Correct
Reading
Continuity

Possible Cause of Bad Reading


Bad ground circuit.

NOTE: Turn the master disconnect switch ON.


Terminal for wire 19Y-A

24 volts

Check fuse ECC-F7, check circuit 19Y.

NOTE: Hold the hood switch (156) in the raise position.


Terminal for wire 59U

24 volts

Bad hood switch (156), check wire 59U.

Terminal for wire 60U

24 volts

Bad hood up relay.

155 Hood Down Relay


Located in the cab access panel for fuses and relays.
Check Points
Terminal for wire 0-B16 to ground

Correct
Reading
Continuity

Possible Cause of Bad Reading


Bad ground circuit.

NOTE: Turn the master disconnect switch ON.


Terminal for wire 19Y-B

24 volts

Check fuse ECC-F7, check circuit 19Y.

NOTE: Hold the hood switch (156) in the lower position.


Terminal for wire 59D

24 volts

Bad hood switch (156), check wire 59D.

Terminal for wire 60D

24 volts

Bad hood down relay.

156 Hood Switch


Located in the right battery compartment with the master disconnect switch.
Check Points

Correct
Reading

Possible Cause of Bad Reading

NOTE: Disconnect connector HD, turn the master disconnect ON.


Terminal for wire 19Y-D to ground

24 volts

Check fuse ECC-F7, check circuit 19Y.

Hold the hood switch in the raise


position, between pin C and B

Continuity

Bad hood switch.

Hold the hood switch in the lower


position, between pin A and B

Continuity

Bad hood switch.

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-125

157 Hood Motor


Located in the left side of the engine compartment.
Check Points

Correct
Reading

Possible Cause of Bad Reading

NOTE: Turn the master disconnect switch ON and disconnect connector HDM. Hold the hood switch (156) in the
raise position.
Terminal for wire 60U-A

24 volts

Bad hood up relay (154), bad hood switch (156), and check
fuse ECC-F7.

NOTE: Hold the hood switch (156) in the lower position.


Terminal for wire 60D-A

24 volts

Bad hood down relay (155), bad hood switch (156), and check
fuse ECC-F7.

NOTE: If all readings are good replace the hood motor.

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-126

CONNECTORS
CONNECTOR 108F - DIAGNOSTIC CONNECTOR

CONNECTOR 197F - MAIN CAB FNR

291663A1

CAV

WIRE IDENT

CIRCUIT

225350C1

CAV

WIRE IDENT

CIRCUIT

19A-W

Diagnostic Conn. Fused Power

19A-C

FNR Switch Fused Power

37D-A

Diagnostic Signal

26F-B

FNR Forward Signal

0-DAV

Diagnostic TECM Ground

26N-B

FNR Neutral Signal

37E

Diagnostic Signal Switched

26R-B

FNR Reverse Signal

Not Used

32J-E

Trans Enable Indication Lamp

Not Used

25Y-B

Trans Kick Down Signal

CONNECTOR 140M - DIODE MODULE

CONNECTOR 197M - FNR MAIN CAB

225351C1
245488C1

CAV

WIRE IDENT

CIRCUIT

CAV

WIRE IDENT

19A-B

CIRCUIT
FNR Switched Fused Power

63H-C

Front Wiper High Speed

26F-A

FNR Forward Signal

63L-C

Front Wiper Low Speed

26N-A

FNR Neutral Signal

0-EE

Diode Suppression Grounds

26R-A

FNR Reverse Signal

58-D

Ride Control Solenoid Power

32J-A

Trans Enable Indication Lamp

25Y-C

Trans Kick Down Signal

21D-B

Starter Relay Signal

68L-C

Rear Wiper Switch Power

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-127
CONNECTOR 202M - ROLLBACK JUMPER

CONNECTOR 20M - TRANSMISSION KICK-DOWN


SWITCH

245482C1

CAV

WIRE IDENT

CIRCUIT

225316C1

58-A

Ride Control Solenoid Power

CAV

58-A

Ride Control Solenoid Power

19A-U

Trans Kick Down Switched Pwr

25Y-C

Trans Kick Down Signal

CONNECTOR 209F - BACKUP ALARM DISABLE


JUMPER

WIRE IDENT

CIRCUIT

CONNECTOR 215F - ALTERNATOR RESISTOR

199436A1

245481C1

CAV
A

WIRE IDENT
35A-E

CAV

CIRCUIT

Backup Alarm Relay Out

CONNECTOR 209M - BACKUP ALARM DISABLE


JUMPER

WIRE IDENT
14-A

CIRCUIT
Alternator D+

CONNECTOR 216F - ALTERNATOR RESISTOR

199436A1
245480C1

CAV
A

WIRE IDENT
35A-D

Bur 5-2750

CIRCUIT

CAV
1

WIRE IDENT
19R-D

CIRCUIT
Alternator Resistor Fused Pwr

Backup Alarm Relay Out


Not Used

Issued 8-06

Printed in U.S.A.

4002-128
CONNECTOR 64F - FLASHER CONNECTOR

CONNECTOR AIC1 - ADV INSTRUMENT


CLUSTER 1

245481C1

CAV
1

WIRE IDENT
45N-A

CIRCUIT
Flasher Optional Side Control
87419488

CAV

CONNECTOR 64M - FLASHER CONNECTOR

245480C1

CAV
1

WIRE IDENT
45N-B

CIRCUIT
Flasher Optional Side Control

CONNECTOR ACT - AIR CONDITIONING


COMPRESSOR CLUTCH

WIRE IDENT

13V

Voltmeter Input ANALOG

36F-A

Fuel Level ANALOG

CAN-HG

CAN High

CAN-LG

CAN Low

36A

Rear Axle Temperature

0-DX

AIC Sensor Ground

43-A

Dome Light Auto Mode

36B

Front Axle Temperature

36H-A

Hydraulic Oil Temperature

10

Not Used

11

36C-A

Radiator Coolant Temp Signal

12

0-DW

AIC Power Ground

13

35B

AIC Buzzer HSD

14

52C

Park Brake Solenoid LSD

15

44A-B

Brake Light Relay Out

16

51S

Standard Steering Signal

17

51CS

Comfort Steering Switch

18

8602417

CAV
1

WIRE IDENT
61C-A

CIRCUIT
AC relay out

Not Used

19

28J

Ether AIC OK Signal

20

53C-A

Pilot Control Solenoid LSD

21

51C

Comfort Steering Control

22
23

Not Used
52

24

Bur 5-2750

CIRCUIT

Fan Reverser LSD


Not Used

25

17P-A

Switch Pad Pwr From AIC Pwr

26

56

Fan Control PWM

Issued 8-06

Printed in U.S.A.

4002-129
CONNECTOR AIC2 - ADV INSTRUMENT
CLUSTER 2

CONNECTOR BUZ - AIC BUZZER

222136A1
87410948

CAV

WIRE IDENT

1
2

CIRCUIT
Not Used

43S-C

Door Open Signal

33R

Redundant Brk Accm Press Low

33P-A

Brake Low Pressure Warning

33U

Park Brake Switch

52M

Fan Reverse Manual

52AU

Fan Reverse Auto

45L-E

Left Turn Signal

10

45R-C

Right Turn Signal

11

35X

Sec. Steering Low Press Signal

WIRE IDENT

CIRCUIT

35B

AIC Buzzer HSD

0-B27

Buzzer Ground

Not Used

12

Not Used

13

Not Used

14

19S-D

AIC Delay Fused Power

15

0-DB

AIC Power Ground Red

16

57-C

Pin Engage Solenoid Power

17

21K-A

Ignition Switch Start Signal

18

31L

Pilot Control Switch High

19

Not Used

20

19S-C

AIC Delay Fused Power

21

19E-A

AIC Wake Up Ignition

22

0-DA

AIC Chassis Ground

23

Not Used

24

Not Used

25

Not Used

26

CAV

31D-A

Bur 5-2750

Coolant Level Signal

Issued 8-06

Printed in U.S.A.

4002-130
CONNECTOR CAB-E - CAB TO ENGINE

CAV

WIRE IDENT

CIRCUIT

37

59D

Hood Down Relay Control

38

60U

Hood Up Relay Out

39

59U

Hood Up Relay Control

40

35A-F

Backup Alarm Relay Out

225415C1

CAV

WIRE IDENT

CIRCUIT

21C-C

Starter Relay Signal

61C

AC Relay Out

21G

EDC7 Crank Control Relay

21H

Crank Control Relay LSD

18F-A

LH Position/Tail Fused Power

Not Used

35A-C

Backup Alarm Relay Out

44A-C

Brake Light Relay Out

18G-F

RH Position/Tail Fused Power

10

45L-B

Left Turn Signal

11

21F

EDC7 Digital Ground

12

45R-B

Right Turn Signal

13

18R-A

Voltmeter Relay Fused Power

14

18J-G

EDC7 Time Delay Fused Power

15

21D-C

Starter Relay Signal

16

28H

Ether Switch Signal

17

0-DX

AIC Sensor Ground

18

18J

EDC7 Time Delay Fused Power

19

0-DW

AIC Power Ground

20

0-DB

AIC Power Ground Red

21

13C-B

Fuel Shutoff Fused Power

22

52A-A

Fan Reverse Relay Out

23

56

Fan Control PWM

24

68W

Rear Washer Pump

25

63W

Front Washer Pump

26

14-A

Alternator D+

27

21E

Key Switch Crank

28

31F-A

Air Filter Restriction Sw Signal

29

61R-B

AC Relay Control

30

61A-B

Trinary Pressure Switch Input

31

20G-B

EDC7 ISO-K Interface

32

36A

Rear Axle Temperature

33

36F-A

Fuel Level ANALOG

34

36C-A

Radiator Coolant Temp Signal

35

19Y-C

Hood Switch Fused Power

36

60D

Hood Down Relay Out

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-131
CONNECTOR CAB-F - CAB FRONT CHASSIS

CONNECTOR CAB-RF - CAB TO ROOF


CONNECTION

388710A1

CAV

43-A

Dome Light Auto Mode

42R-C

Rear Work Light Fused Power

Left Turn Signal

42C-A

Front Work Lights Fused Power

19U-D

Dome Light Fused Power

WIRE IDENT
45L-C

CIRCUIT

291661A1

CAV

WIRE IDENT

CIRCUIT

51B-C

Comfort Steering Solenoid Pwr

45R-D

Right Turn Signal

46-C

Beacon Switch Power

Not Used

0-DR

Roof Splice Grounds

Position RH Fused Power

0-DS

Roof Splice Grounds

19K-C

Rear Wiper Motor Fused Power

4
5

18G-G

18F-E

Position LH Fused Power

18B-A

High Beam LH Fused Power

68C

Rear Wiper Park Control

36B

Front Axle Temperature

68L-B

Rear Wiper Switch Power

O-DY

Front Axle Temperature Ground

0-EM

Radio Ground

Not Used

12V-B

12V Fused Power to Radio

10
11

54B-A

Height-RTT Signal

43S-A

Door Open Signal

12

53B-B

RTD Signal

19U-G

Door Switch Fused Power

13

64A

Horn Power

14

18D-A

Low Beam LH Fused Power

15

18E-A

Low Beam RH Fused Power

16

18C-A

High Beam RH Fused Power

17

Not Used

18

Not Used

19

53P-F

Pilot Control Relay Out

20

57-A

Pin Engage Sol Pwr

21

58-C

Ride Control Sol Pwr

22

1-DR

Brake Lamp Switch Power

23

44-A

Brake Lamp Control Power

24

52P-A

Park Brake Relay Out

25

Not Used

26

33P-A

Low Brake Pressure Warning

27

19A-T

Brake Declutch Switch Fused


Power

28

25G-A

Brake Declutch Switch Control

29

Not Used

30

Not Used

31

Not Used

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-132
CONNECTOR CAB-T - CAB TO TRANMISSION

CONNECTOR CAN - CAN BULK HEAD

380839A1

CAV

WIRE IDENT

CIRCUIT

33R

Front Brake Accumulator


Pressure Low

31D-A

Coolant Level Signal

19M

Secondary Steering Accessory


Fused Power

19R-E

Sec. Steering Ignition Fused


Power

CAN-HA

CAN High

36T-A

Valve Body Temp Signal

CAN-LA

CAN Low

35X

Secondary Steer Low Press


Signal

25A-A

Engine Speed Signal

25C-A

Turbine Speed Signal

25B-A

Intermediate Speed Signal

10

25D-A

Output Speed Signal

11

0-DM

Speed Sensor Ground

12

36R-E

Trans Temp/Filter Return

13

36G-A

TCO Temp Signal

14

CAV

WIRE IDENT

CIRCUIT

CONNECTOR CAN2 - CAN BULK HEAD

Not Used

15

Not Used

16

25K-A

Trans Solenoid Valve Y1

17

25L-A

Trans Solenoid Valve Y2

18

25M-A

Trans Solenoid Valve Y3

19

25N-A

Trans Solenoid Valve Y4

20

25P-A

Trans Solenoid Valve Y5

21

25J-A

Trans Solenoid Valve Y6

22

25S-A

Output Sw Power VPS1

23

31H-A

Hyd Filter Restriction Switch Sig

24

Not Used

25

Not Used

26

87315266

19S1

27

87315267

CAV

WIRE IDENT

CIRCUIT

CAN-H

CAN High

CAN-HJ

CAN High From Engine

CAN-L

CAN Low

CAN-LM

CAN Low From Engine

Sec. Steering Fused Power


Not Used

28

0-DN

Output Speed Sensor Ground

29

19A-M

Output Speed Sen. Fused Pwr

30

36H-A

Hydraulic Oil Temp

31

32F-A

Trans Filter Maint Switch

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-133
CONNECTOR CL - CIGAR LIGHTER

CONNECTOR D-OR - DIODE OR

245485C1

CAV
3227856R1

CAV

WIRE IDENT

CIRCUIT

19W

Cigar Lighter Fused Power

0-DV

Cigar Lighter Ground

WIRE IDENT

CIRCUIT

42C-D

Front Work Lights Fused Power

41T-C

Position Lights Switched Power

49

Back Light Power

CONNECTOR DIA - DIAGNOSTIC

CONNECTOR CLS - COOL JUMP - COOL SEND

194788A1

CAV
A

WIRE IDENT
31D

0-HV

CIRCUIT

310057A1

Coolant Level Signal

CAV

Coolant Level Sender Ground

0-DH

Ground

18K-A

Diagnostics Fused Power

CAN-HB

Controller Area Network High

CAN-LB

Controller Area Network Low

20G-B

EDC7 ISO-K Interface

CONNECTOR CNV - 24V TO 12V POWER


CONVERTER

WIRE IDENT

CIRCUIT

CONNECTOR DISC - DISCONNECT ENGINE

225351C1

CAV
1

WIRE IDENT

CIRCUIT

19L-A

Power Converter Fused Power

19L-B

Power Converter Fused Power

0-EJ

Power Converter Ground

CAV

Not Used

13C

Fuel Shutoff Fused Power

13M

Fuel Shutoff Fused Power

4
5

12V-C

12V Switched Power

0-ER

Power Converter Ground

Bur 5-2750

245482C1

WIRE IDENT

CIRCUIT

Issued 8-06

Printed in U.S.A.

4002-134
CONNECTOR DM - DIODE OR

CAV

WIRE IDENT

21

DNS7

23

DNS12

26

DNS19

CIRCUIT

CONNECTOR DNS-COMPRESSOR-RELAY

245485C1

CAV
A

WIRE IDENT
19RR

B
C

CIRCUIT
Sec. Steering Ignition Fused Pwr
Not Used

19R

Sec. Steering Ignition Fused Pwr

CAV

WIRE IDENT

85

DNS19

86

DNS20

30

DNS16

87

DNS14

CIRCUIT

CONNECTOR DNS-AC-SWITCH
CONNECTOR DNS-EXTERNAL-AIR-TEMP-SNS

CAV
1

WIRE IDENT

CIRCUIT
CAV

DNS72

DNS68

DNS71

DNS2

DNS1

WIRE IDENT

DNS48

DNS49

CIRCUIT

CONNECTOR DNS-HVAC-CAN1

CONNECTOR DNS-ACTUATOR

CAV

WIRE IDENT

CIRCUIT

CONNECTOR DNS-BLUE - ATC CONTROL PANEL


225294C1

CAV
CAV

WIRE IDENT

DNS8

DNS10

DNS11

DNS2

DNS4

DNS3

10

DNS6

14

DNS9

15

DNS31

16

DBS13

17

DNS18

Bur 5-2750

CIRCUIT

WIRE IDENT

DNS9

DNS8

CIRCUIT

Issued 8-06

Printed in U.S.A.

4002-135
CONNECTOR DNS-NOT-USED

CONNECTOR DNS-HVAC1

225326C1
225294C1

CAV

WIRE IDENT

CIRCUIT

CAV

WIRE IDENT

DNS12

DNS14

DNS10

DNS15

DNS11

DNS13

CONNECTOR DNS-YELLOW - ATC CONTROL


PANEL

CONNECTOR DNS-HVAC2

CAV

225315C1

CAV

WIRE IDENT

CIRCUIT

WIRE IDENT

DNS25

DNS24

DNS47

DNS43

DNS44

DNS21

DNS36

10

DNS23

DNS35

14

DNS28

15

DNS26

16

DNS22

17

DNS27

18

DNS29

21

DNS22

23

DNS45

24

DNS46

CONNECTOR DNS-INTERNAL-AIR-TEMP-SNS

CAV

WIRE IDENT

DNS4

DNS3

DNS17

DNS5

Bur 5-2750

CIRCUIT

CIRCUIT

CIRCUIT

Issued 8-06

Printed in U.S.A.

4002-136
CONNECTOR DNS-PWM-BLOWER-PIN4

CONNECTOR DNS-VOLTAGE-CONVERTER

CAV

WIRE IDENT

DNS34

DNS33

DNS32

DNS31

CIRCUIT

CONNECTOR DNS-ELECT-WATER-VALVE
HIRSCHMANN 772717-001

CAV

WIRE IDENT

CIRCUIT

DNS38

CAV

DNS47

DNS30

DNS37

DNS29

DNS28

DNS27

DNS26

CONNECTOR DNS-PWM-BLOWER-PIN2

CAV

WIRE IDENT

DNS41

DNS42
CAV

CAV

WIRE IDENT

DNS41

DNS42

CIRCUIT

CIRCUIT

CONNECTOR DNS-RECYCLING-MOTOR

CIRCUIT

CONNECTOR DNS-PWM-BLOWER

WIRE IDENT

WIRE IDENT

DNS21

DNS22

DNS23

DNS24

DNS25

CIRCUIT

CONNECTOR DNS-SPEED-SELECTOR
CONNECTOR DNS-THERMOCOUPLE-SENSO
CAV
CAV
1

WIRE IDENT

CIRCUIT

DNS46

DNS40

WIRE IDENT

DNS74

DNS61

DNS62

DNS63

DNS73

CIRCUIT

CONNECTOR DNS-MIXED-AIR-SENSOR

CAV

WIRE IDENT

DNS39

DNS45

Bur 5-2750

CIRCUIT

Issued 8-06

Printed in U.S.A.

4002-137
CONNECTOR DNS-CTRL-PANEL-LIGHT

CAV

WIRE IDENT

CIRCUIT

CONNECTOR DNS-RESISTOR

CAV

WIRE IDENT

DNS69

DNS61

DNS70

DNS62

DNS63

DNS64

CIRCUIT

CONNECTOR DNS-WATER-VALVE-POT
CONNECTOR DNS-ELECT-WATER-VALVE-S
CAV

WIRE IDENT

DNS55

DNS54

CIRCUIT
CAV

CONNECTOR DNS-RECIRCULATING-SWITCH

CAV

WIRE IDENT

DNS51

DNS53

WIRE IDENT

DNS60

DNS56

DNS57

DNS58

DNS59

CIRCUIT

CIRCUIT

CONNECTOR DNS-DRIVER

CONNECTOR DNS-THERMOSTAT-1

CAV
1

WIRE IDENT

CIRCUIT

DNS67

CAV

CONNECTOR DNS-THERMOSTAT-2

CAV
1

WIRE IDENT

CIRCUIT

DNS68

CONNECTOR DNS-ELECTRIC-FAN

CAV

WIRE IDENT

DNS65

DNS66

Bur 5-2750

411311A1

CIRCUIT

WIRE IDENT

DNS50

DNS52

DNS49

DNS48

DNS55

DNS57

DNS58

DNS59

11

DNS51

12

DNS53

13

DNS54

14

DNS56

CIRCUIT

Issued 8-06

Printed in U.S.A.

4002-138
CONNECTOR DNS-HVAC1-S

CONNECTOR DS - DOOR SWITCH

245482C1
225294C1

CAV
A

WIRE IDENT

CAV

CIRCUIT

DNS67

DNS76

DNS69

WIRE IDENT

CIRCUIT

19U-F

Door Switch Fused Power

43S-B

Door Open Signal

CONNECTOR E-HD - TRANSMISSION HOOD


CONNECTOR DNS-HVAC2-S

245485C1

CAV
225315C1

CAV

WIRE IDENT

DNS74

DNS75

Bur 5-2750

CIRCUIT

WIRE IDENT

CIRCUIT

18G-D

Lic Plate Light Fused Power

35A-G

Backup Alarm Relay Out

0-BAG

Hood Ground (EURO)

Issued 8-06

Printed in U.S.A.

4002-139
CONNECTOR ECA - ELECTRICAL CENTER A

87315248

CAV
CAV

WIRE IDENT

CIRCUIT

WIRE IDENT

CIRCUIT

L1

J6

Pltem Dtnts Park Brake Sol

J7

Park Brake Solenoid Horn

A1

19A-N

Transmission Fused Power

L1

A2

18L-A

Comfort Steering Fused Power

L1

J8

Fan Reverse/Turn Signal

A3

19E-A

AIC Wake Up Ignition

L1

J9

Turn Signal Engine Shutdown

A4

19RR

Sec. Steering Ignition Fused


Pwr

L2

J11

Blower Motor Power

L2

J12

Blower Mtr Front Wiper Washer

A5

19C-A

Pilot Control Relay Fused Pwr

L2

J13

Front Wiper Rear Wiper Washer

A6

19D-A

Park Brake Relay Fused Power

L2

J14

Rear Wiper Washer Backup

A7

19P

Pin Engage/Fan Fused Power

L2

J15

Backup AC

A8

19B

Turn Signal Fused Power

L2

J16

AC Seat Compressor

A9

13C-B

Fuel Shutoff Fused Power

C1

18N

Blower Motor Fused Power

L2

J18

Seat Compressor Emergency


Steering

C2

19J

Front Wiper Fused Power

C3

19K

Rear Wiper Fused Power

C4

19H

Backup Alarm Relay Fused Pwr

C5

18M

AC Relay Fused Power

C6

19N

Seat Compressor Fused Pwr

C7

19M

Sec. Steering ACC Fused Pwr

L1

J1

Transmission ECM Power

L1

J2

Trans ECM Comfort Steering

L1

J3

Comfort Steering AIC Power

L1

J4

Emergency Steering AIC Pwr

L1

J5

Emergency Strg Plt Em Dtnts

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-140
CONNECTOR ECB - ELECTRICAL CENTER B

87312843

CAV
CAV

WIRE IDENT

CIRCUIT

WIRE IDENT

CIRCUIT

B3

21K-B

Ignition Switch Start Signal


Neutral Start Relay Control Gnd

A1

42FS

Front Work Lights Power

B4

0-DE

A2

42RS

Rear Work Lights Power

B5

21F

EDC7 Digital Ground

0-DF

Crank Request Relay Ctrl Gnd

A3

41H-B

High Beam LH Power

B6

A4

41H-C

High Beam RH Power

B7

19P-E

Fan Reverse Relay Fused Pwr

A5

41L-C

Low Beam LH Power

B8

52

Fan Reverser LSD

A6

41L-B

Low Beam RH Power

B9

19D-C

Park Brake relay Fused Pwr

52C

Park Brake Solenoid LSD

A7

41T-B

Position Lights LH Sw Power

B10

A8

41T-A

Position Lights RH Sw Power

D1

13K-C

Ignition Switch Power

A9

21H

Crank Control Relay LSD

D2

13V

Voltmeter Input ANALOG

A10

21C-B

Neutral Start Relay Output

D3

25T

Neutral Signal

21C

Neutral Start Relay Output

AA1

42C-C

Front Work Lights Fused Power

D4

AA2

42R-C

Rear Work Lights Fused Power

D5

21C-A

Neutral Start Relay Output

AA3

18B-A

High Beam LH Fused Power

D6

21E

Key Switch Crank

AA4

18C-A

High Beam RH Fused Power

D7

19P-D

Fan Reverse Relay Fused Pwr

52A-A

Fan Reverse Relay Out

AA5

18E-A

Low Beam RH Fused Power

D8

AA6

18D-A

Low Beam LH Fused Power

D9

19D-B

Park Brake Relay Fused Pwr

AA7

18F-C

Pos Tail Lights LH Fused Power

D10

52P-B

Park Brake Relay Out

AA8

18G

Pos Tail Lights RH Fused Power

AA9

21D-A

Starter Relay Signal

AA10

21G

EDC7 Crank Control Relay

B1

18R-A

Voltmeter Relay Fused Power

B2

0-DD

Voltmeter Relay control Ground

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-141
CONNECTOR ECC - WORK LIGHTS

87315249

CAV

WIRE IDENT

CIRCUIT

A1

19U-B

Beacon/Dome Lt Fused Pwr

A2

42

Work Lights Sw Fused Pwr

A3

19Z

Driving Lights Sw Fused Pwr

A4

1-DV

Brake Lts/Flasher Bat Pwr

A5

1DM

Time Delay/Ign Sw Fused Pwr

A6

19U

Horn Relay Fused Power

A7

19Y

Hood Control Fused Power

A8

19W

Cigar Lighter Fused Power

A9

18K-A

Diagnostic Fused Power

B1

60U

Hood Up Relay Out

CAV
D4

WIRE IDENT
19Y-B

CIRCUIT
Hood Down Relay Fused Power

D5

44-A

Brake Light Control Power

D6

44A-A

Brake Light Relay Out

D7

19U-E

Horn relay Fused Power

D8

64-A

Horn Power

D9

18L-B

Comfort Steering Fused Power

D10

51B-B

Comfort Steering Solenoid Pwr

L1-1

ECC-L1

Beacon/Dome Lights LI ECC

L1-1

J2-ECC

Beacon/Dome Lt Work Lights

L1-2

J2-ECC

Beacon/Dome Lt Work Lights

L1-2

J3-ECC

Work Lights Driving Lights

B2

0-B25

Hood Up Control Ground

B3

60D

Hood Down Relay Out

L1-3

J3-ECC

Work Lights Driving Lights

B4

0-B16

Hood Down Control Ground

L1-3

J4-ECC

Driving Lights Brake Lights

B5

1-DW

Brake Light Relay Bat Power

L1-4

J4-ECC

Driving Lights Brake Lights

J5-ECC

Brake Lights Delay Power

B6

0-EF

Brake Light Relay Control Gnd

L1-4

B7

19U-A

Horn Relay Fused Power

L1-5

J5-ECC

Brake Lights Delay Power

B8

64C

Horn Relay Control

L1-5

J6-ECC

Delay Power Horn

B9

18L-C

Comfort Steering Fused Pwr

L1-6

J6-ECC

Delay Power horn

J7-ECC

Horn HOD Control

B10

51C

Comfort Steering Control

L1-6

C2

0-B22

Hood Up Relay Ground

L1-7

J7-ECC

Horn HOD Control

C4

0-B12

Hood Down Relay Ground

L1-7

J8-ECC

HOD Control Cigar Lighter

D1

59U

Hood Up Relay Control

L1-8

J8-ECC

HOD Control Cigar Lighter

J9-ECC

Diagnostic Power

J9-ECC

Diagnostic Power

D2

19Y-A

Hood Up Relay Fused Power

L1-8

D3

59D

Hood Down Relay Control

L1-9

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-142
CONNECTOR ECD - ELECTRICAL CENTER D

87312843

CAV
CAV

WIRE IDENT

CIRCUIT

WIRE IDENT

CIRCUIT

B5

19C-B

Pilot Control Relay Fused Pwr

53C-A

Pilot Control Solenoid LSD

A1

13H-C

Trans ECM Time Delay Pwr

B6

A2

13H-D

Engine ECM Time Delay Pwr

B7

58T

Ride Control Relay Switch Pwr

A3

13H-B

AIC Time Delay Power

B8

58L

Ride Control Relay LSD

A4

12V-D

Plug 1 12V Switched Power

B9

18M

AC Relay Fused Power

0-DJ

AC Relay Control Ground

A5

12V-E

Plug 2 12V Switched Power

B10

A6

12V-F

Radio 12V Switched Power

C2

63C2

Front Wiper Park Control

A7

12V-G

2 Way Radio 12V Sw Power

C4

63C

Front Wiper Park Control

A9

35C

Backup Alarm Relay Control

D1

19J-D

A10

19H

Backup Alarm Relay Fused Pwr

Front Wiper Relay HS Ctrl


Fused Pwr

AA1

19T-A

TECM Delay Fused Power

D2

63H-B

Front Wiper HS Relay Out

AA2

18J-K

EDC7 Time Delay Fused Power

D3

19J-F

Front Wiper Relay LS Ctrl Fused


Pwr

AA3

19S-B

AIC Delay Fused Power

D4

63C2

Front Wiper Park Control

AA4

12V

12V Power to Outlet 1

D5

19C-C

Pilot control Relay Fused Pwr

AA5

12V-A

12V Power to Outlet 2

D6

53P-C

Pilot Control Relay Out

AA6

12V-B

12V Fused Power to Radio

D7

58H-A

Ride Ctrl Switched Pwr VPS2

AA9

35A-A

Backup Alarm Relay Out

D8

58-E

Ride Control Solenoid Power

19A-P

Backup Alarm Relay Ctrl Fused


Pwr

D9

61R-B

AC Relay Control

D10

61C

AC Relay Out

AA10
B1

19J-E

Front Wiper Relay Fused Power

B2

63HC-B

Front Wiper HS Relay Control

B3

63C3

Front Wiper Park Control

B4

63LC

Front Wiper LS Relay Control

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-143
CONNECTOR EDC7 - ENGINE CONTROLLER

CAV

WIRE IDENT

CIRCUIT

42

35W

Water In Fuel Indicator

48

24L

Low Idle Switch

75

0-BV

Grid Heater Control Ground

77

24S

Throttle Supply

78

24R

Throttle Ground

79

24B

Throttle Signal

89

20G-A

EDC7 ISO-K Interface

CONNECTOR EM - HEIGHT CONTROL RTD - RTT

225351C1

CAV

BOSCH-89-POLE

CAV

WIRE IDENT

CIRCUIT

55A-A

RTT/Float Switched Power

54A

Height Control Switched Power

53A

RTD Switched Power

53B-B

RTD Control Signal

54B-B

HC-RTT Control Signal

55B

RTT Float Switch Control

CIRCUIT

18J-C

EDC7 Time Delay Fused Power

18J-B

EDC7 Time Delay Fused Power

0-BE

EDC7 Ground

0-BF

EDC7 Ground

18J-D

EDC7 Time Delay Fused Power

18J-E

EDC7 Time Delay Fused Power

10

0-BD

EDC7 Ground

11

0-BC

EDC7 Ground

12

28G

Grid Heater Source DR

13

0-BN

Filter Heater Control

17

21H-A

Crank Control Relay LSD

29

21F-B

EDC7 Digital Ground

32

21E-A

Key Switch Crank

34

CAN-L

CAN Low

35

CAN-H

CAN High

36

28F

Fuel Filter Heater Relay Control

37

21GA

EDC7 Crank Control Relay

40

13M-A

Fuel Shutoff Fused Power

Bur 5-2750

WIRE IDENT

Issued 8-06

Printed in U.S.A.

4002-144
CONNECTOR ENG - ENGINE TO CAB

CAV

225414C1

CAV

WIRE IDENT

CIRCUIT

WIRE IDENT

CIRCUIT

30

61A

Trinary Pressure Switch Input

31

20G-A

EDC7 ISO-K Interface

32

36A-A

Rear Axle Temperature

33

36F

Fuel Level ANALOG

34

36C

Radiator Coolant Temp Signal

35

19Y-D

Hood Switch Fused Power

36

60D-A

Hood Down Relay Out

37

59D-A

Hood Down Relay Control

21C-D

Starter Relay signal

38

60U-A

Hood Up Relay Out

61C-A

AC Relay Out

39

59U-A

Hood Up Relay Control

61C-B

AC Relay Out

40

35A-G

Backup Alarm Relay Out

EDC7 Crank Control Relay

40

35A-GN

Backup Alarm Relay Out

21GA

21H-A

Crank Control Relay LSD

18F-AN

LH Position/Tail Fuse Power

18F-B

LH Position/Tail Fuse Power

CONNECTOR ENG-D - DISCONECT HARNESS

Not Used

35A-R

Backup Alarm Relay Out

35A-J

Reverse Light

44A-D

Brake Light Relay Out

44A-DN

Brake Light Relay Out

18G-H

RH Position/Tail Fuse Power

18G-HN

RH Position/Tail Fuse Power

10

45L-A

Left Turn Signal

10

45L-AN

Left Turn Signal

11

21F-A

EDC7 Digital Ground

12

45R-A

Right Turn Signal

12

45R-AN

Right Turn Signal

13

18R

Voltmeter Relay Fused Power

14

18J-F

EDC7 Time Delay Fused Power

15

21D

Starter Relay Signal

16

28E

Ether Relay Signal

17

0-BJ

AIC Sensor Ground

18

18J-A

EDC7 Time Delay Fused Power

19

0-BG

AIC Power Ground

20

0-BH

AIC Power Ground Red

21

13C-A

Fuel Shutoff Fused Power

22

52A-B

Fan Reverse Relay Out

23

56-A

Fan Control PWM

24

68W-A

Rear Washer Pump

25

63W-A

Front Washer Pump

26

14

Alternator D+

27

21E-A

Key Switch Crank

28

31F

Air Filter Restriction Sw Signal

29

61R

AC Relay Control

Bur 5-2750

245483C1

CAV

WIRE IDENT

CIRCUIT

13C-A

Fuel Shutoff Fused Power

13M-A

Fuel Shutoff Fused Power

13M-B

Key Switch Power Disc Switch

Issued 8-06

Printed in U.S.A.

4002-145
CONNECTOR ENG-H - ENGINE TO HOOD

CONNECTOR ESS - ENGINE SPEED SENSOR

291718A1

CAV
225320C1

CAV

WIRE IDENT

CIRCUIT

0-BAG-N

44A-DN

Brake Light Relay Out

45L-AN

Left Turn Signal

45R-AN

Right Turn Signal

18G-HN

RH Position/Tail Fused Pwr

18F-AN

LH Position/Tail Fused Pwr

35A-GN

Backup Alarm Relay Out

35A-R

Backup Alarm Relay Out

WIRE IDENT

CIRCUIT

25A

Engine Speed Signal

0-HF

Engine Speed Sensor Ground

Hood Ground (NA)

CONNECTOR FFH - FULE FILTER HEATER

CONNECTOR ENG-T - ENGINE TO


TRANSMISSION
182069A1

CAV

WIRE IDENT

CIRCUIT

1-GB

Fuel Filter Heater Power

0-BX

Fuel Filter Heater Ground

225326C1

CAV

WIRE IDENT

CIRCUIT

0-BZ

Sec. Steering Splice Ground

0-BK

Transmission Splice Grounds

31D-C

Coolant Level Sender Eng


Transmission

Bur 5-2750

Not Used

Issued 8-06

Printed in U.S.A.

4002-146
CONNECTOR FLSHR - FLASHER MODULE

CONNECTOR FRONT - CAB FRONT CHASSIS

225389C1

CAV

WIRE IDENT

CIRCUIT
373358A1

1-DU

Flasher Module Power

45N-A

Flasher Optional Side Control

0-EH

Flasher Module Ground

0-EG

Flasher Module Ground

Not Used

6
7

45R-E

Right Turn Signal

45L-D

Left Turn Signal

45A-A

Left Turn Switch Power

10

45B-A

Right Turn Switch Power

11

45H

Hazard Switch Power

12

45N-B

Flasher Optional Side Control

CONNECTOR FM - FILTER MAINTENANCE


SWITCH

371614A1

1
2

WIRE IDENT
32F
36R-B

Bur 5-2750

WIRE IDENT

CIRCUIT
Trans Filter Maint Sw
Trans FM Switch Return

CIRCUIT

45L

Left Turn Signal

51B-D

Comfort Steering Sol Power

45R

Right Turn Signal

Not Used

CAV

CAV

Not Used

18G-A

RH Position/Tail Fused Power

18F

LH Position/Tail Fused Power

18B

LH High Beam Fused Power

36B-A

Front Axle Temperature

0-AR

Front Axle Temp Sensor GND

10

Not Used

11

54B

Height-RTT Control Signal

12

53B

RTD Control Signal

13

64

Horn Power

14

18D

LH Low Beam Fused Power

15

18E

RH Low Beam Fused Power

16

18C

RH High Beam Fused Power

17

Not Used

18

Not Used

19

53P-G

Pilot Control Relay Out

20

57

Pin Engage Sol Pwr

21

58-B

Ride Control Sol Pwr

21

58S-E

Ride Control Solenoid to Front


Cab

22

1-AA

Brake Lamp Switch Power

23

44

Brake Lamp Control Power

24

52P

25

Park Brake Relay Out


Not Used

26

33P

Low Brake Pressure Warning

27

19A-A

Brake Declutch Sw Fused Pwr

28

25G

Brake Declutch Switch Control

29

Not Used

30

Not Used

31

Not Used
Issued 8-06

Printed in U.S.A.

4002-147
CONNECTOR FWM - FRONT WIPER MOTOR

CONNECTOR FWW - FRONT WASHER

245715C1

CAV

WIRE IDENT

CIRCUIT

3227856R1

CAV

WIRE IDENT

CIRCUIT

63H-A

Front Wiper High Speed Rly Out

63W-A

Front Washer Pump

63L-A

Front Wiper Low Speed Rly Out

0-B

Front Washer Ground

19J-A

Front Wiper Motor Fused Power

63C

Front Wiper Park Control

CONNECTOR GHC - GRID HEATER RELAY

CONNECTOR FWMG - FRONT WIPER MOTOR


GROUND

3227856R1

CAV
245480C1

CAV
1

WIRE IDENT
0-B8

Bur 5-2750

CIRCUIT

WIRE IDENT

CIRCUIT

28G

Grid Heater Source DR

0-BV

Grid Heater Control Ground

Front Wiper Ground

Issued 8-06

Printed in U.S.A.

4002-148
CONNECTOR GND-CAB-SPL - CAB GROUND
SPLICE

CAV

WIRE IDENT

CIRCUIT

0-DD

Voltmeter Relay Control Gnd

0-DF

Crank Request Relay Control


Gnd

0-DE

Neutral Start Relay Control Gnd

0-EQ

Splice Pack Gnd Cab SPL2


GND

Not Used

0-EH

Flasher Module Ground

0-EG

Flasher Module Ground

0-EF

Brake Lights Relay Control Gnd

CONNECTOR HD - HOOD SWITCH


87324393

CAV

WIRE IDENT

CIRCUIT

0-EE

Diode Suppression Grounds

0-EM

Radio Ground

0-EP

Horn Switch Ground

Not Used

Not Used

0-DG

Cab Splice Grounds

0-DT

Front Wiper/Washer Sw Gnd

0-DL

Power Converter Relay Ctrl Gnd

CAV

59D-A

Hood Relay Control Down

245485C1

WIRE IDENT

CIRCUIT

0-DK

Seat Compressor Motor Ground

0-DJ

AC Relay Control Ground

19Y-D

Hood Switch Fused Power

0-DU

Pilot Pressure Solenoid Gnd

59U-A

Hood Relay Control Up

0-DH

Diagnostic Connector Ground

CONNECTOR HD-E - HOOD HARNESS TO


TRANSMISSION HARNESS

CONNECTOR GND-CAB-SPL2 - SPLICE BACK


LIGHT GROUND

245484C1

CAV

87324393

CAV

WIRE IDENT

CIRCUIT

18G-E

License Plate Light Fused Pwr

35A-H

Backup Alarm Relay Out

0-JA

Hood Ground (EURO)

CIRCUIT

0-DC

Time Delay Module Ground

0-EA

Time Delay Relay Control Gnd

0-EB

Ignition Relay Control Ground

0-EC

ACC Relay Control Ground

Bur 5-2750

WIRE IDENT

Issued 8-06

Printed in U.S.A.

4002-149
CONNECTOR HD-N - HOOD TO ENGINE

CONNECTOR HOT - HYDRAULIC OIL


TEMPERATURE SENDER

194788A1

CAV

225319C1

CAV

WIRE IDENT

WIRE IDENT

36H

0-HW

CIRCUIT
Hydraulic Oil Temp Signal
Hydraulic Oil Temp Ground

CIRCUIT

CONNECTOR HVAC1 - HVAC1

0-JA-N

Hood Grounds (NA)

44A-EN

Brake Light relay Out

45L-BN

Left Turn Signal

45R-BN

Right Turn Signal

18G-JN

RH Position/Tail Fused Power

18F-BN

LH Position/Tail Fused Power

35A-HN

Backup Alarm Relay Out

225295C1

CONNECTOR HDM - HOOD LIFT MOTOR


CAV
1

WIRE IDENT

CIRCUIT

61A-B

Trinary Pressure Switch Input

18N-A

Blower Motor Fused Power

49A

Back Light Power

CONNECTOR HVAC2 - HVAC2

225316C1

CAV

WIRE IDENT

CIRCUIT

60U-A

Hood Up Relay Out

60D-A

Hood Down Relay Out

87552622

CAV

Bur 5-2750

WIRE IDENT

CIRCUIT

0-ED

HVAC Grounds

18N-B

Blower Motor Fused Power

Issued 8-06

Printed in U.S.A.

4002-150
CONNECTOR HVAC-CAN1 - CAN-HVAC-ATC

CONNECTOR K-WCO - WIPER CUTOUT

245731C1

CAV
87315267

CAV

WIRE IDENT

CIRCUIT

CAN-HK

CAN High

CAN-LL

CAN Low

WIRE IDENT

CIRCUIT

30

63L-B

Front Wiper LS Relay Out

85

63HC-A

Wiper Cut Out Relay Control

86

19J-G

Wiper Cut Out Relay Fused Pwr

87
87A

Not Used
63C3

Front Wiper Park Control

CONNECTOR ISS - INT-SPEED-SENSOR


CONNECTOR LBEE - LIGHT BEACON EXTESION

291718A1

CAV

WIRE IDENT

CIRCUIT

25B

INT Speed Signal

0-HG

INT Speed Sensor Ground

Bur 5-2750

291730A1

CAV

WIRE IDENT

CIRCUIT

46-E

Beacon Light Power

0-MD

Beacon Light Ground

Issued 8-06

Printed in U.S.A.

4002-151
CONNECTOR LLF - LH FRONT LIGHTS

CONNECTOR LLR-E - LH REAR COMBINATION


LAMP

225351C1

CAV

WIRE IDENT

225351C1

CIRCUIT

0-AJ

Lights Ground LH

CAV

WIRE IDENT

CIRCUIT

18D

Low Beam LH

44A-E

Brake Light Relay Out

45L-A

Left Turn Signal

18B

High Beam LH

18F

Position LH Fused Power

18F-B

Left Tail Fused Power

45L

Left Turn Signal

35A-L

Reverse Lamp

Not Used

0-BT

LH Ground (EURO)
Not Used

CONNECTOR LLFW - LH FRONT WORK LAMP


CONNECTOR LLR-N - LH REAR COMBINATION
LAMP

245483C1

CAV

WIRE IDENT

CIRCUIT

42C-H

LH Front Work Lamp Power

0-MU

LH Front Work Lamp Ground

245715C1

CAV

Bur 5-2750

WIRE IDENT

CIRCUIT

44A-FN

Brake Lamp Relay Out

18F-BN

LH Tail Lamp Fused Pwr

45L-BN

Left Turn Signal

0-BR-N

LH Rear Light Ground (NA)

Issued 8-06

Printed in U.S.A.

4002-152
CONNECTOR LLRW- LH REAR WORK LAMP

CONNECTOR LRF - RH FRONT COMBINATION


LAMP

245483C1

CAV

WIRE IDENT

CIRCUIT

42R-H

LH Rear Work Lamp Fused Pwr

0-ME

LH Rear Work Lamp Ground

CONNECTOR LPL - LICENSE PLATE LAMP

225351C1

CAV

WIRE IDENT

CIRCUIT

0-AH

RH Front Lights Ground

18E

RH Low Beam Fused Pwr

18C

RH High Beam Fused Pwr

18G-A

RH Position/Tail Fused Pwr

45R

Right Turn Signal

Not Used

CONNECTOR LRFW - RH FRONT WORK LAMP

245482C1

CAV

WIRE IDENT

CIRCUIT

18G-E

License Plate Lamp Fused Pwr

18G-EN

License Plate Lamp Fused Pwr

0-JC

License Plate Lamp Ground


245483C1

CAV

Bur 5-2750

WIRE IDENT

CIRCUIT

42C-G

RH Front Work Lamp Fused Pwr

0-MJ

RH Front Work Lamp Ground

Issued 8-06

Printed in U.S.A.

4002-153
CONNECTOR LRR-E - RH REAR COMBINATION
LAMP

CONNECTOR LRRW - RH REAR WORK LAMP

245483C1

CAV
225351C1

CAV

WIRE IDENT

CIRCUIT

44A-F

Brake Light Relay Out

45R-A

Right Turn Signal

18G-J

Right Position/Tail Fused Pwr

35A-K

Reverse Lamp

0-BR

WIRE IDENT

CIRCUIT

42R-G

RH Rear Work Lamp Fused Pwr

0-MF

RH Rear Work Lamp Ground

CONNECTOR LSPK - LEFT SPEAKER

Ground (EURO)
Not Used

CONNECTOR LRR-N - RH REAR COMBINATION


LAMP
195552A1

CAV

WIRE IDENT

CIRCUIT

65L

Left Speaker Signal

0-PA

Left Speaker Ground

CONNECTOR OSS - OUTPUT SPEED SENSOR

245715C1

CAV

WIRE IDENT

CIRCUIT

44A-GN

Brake Lamp Relay Out

18G-CN

RH Position/Tail Lamp Fused


Pwr

45R-BN

Right Turn Signal

0-BT-N

RH Rear Light Ground (NA)


291719A1

CAV
1

Bur 5-2750

WIRE IDENT
0-HE

CIRCUIT
Output Speed Ground

25D

Output Speed Signal

19A

Output Speed Fused Pwr

Issued 8-06

Printed in U.S.A.

4002-154
CONNECTOR PAF - AIR FILTER RESTRICTION
SWITCH

CONNECTOR PBL - BRAKE LAMP PRESSURE


SWITCH

222136A1
291718A1

CAV

WIRE IDENT

CAV

CIRCUIT

31F

Air Filter Restriction Switch


Signal

0-BY

Air Filter Restriction Switch


Grnd

WIRE IDENT

CIRCUIT

1-AA

Brake Lamp Switch Power

44

Brake Lamp Control Power

CONNECTOR PBW - BRAKE PRESSURE


WARNING SWITCH
CONNECTOR PBD - BRAKE DECLUTCH
PRESSURE SWITCH

225316C1
245482C1

CAV

WIRE IDENT

CIRCUIT

19A-A

Brake Declutch Sw Fused Pwr

25G

Brake Declutch Switch Control

Bur 5-2750

CAV

WIRE IDENT

CIRCUIT

33P

Low Brake Press Warning

0-AL

Brake Press Warn Sw Ground

Issued 8-06

Printed in U.S.A.

4002-155
CONNECTOR PO1 - POWER OUTLET

CONNECTOR PR - TRINARY PRESSURE SWITCH

182068A1

CAV

WIRE IDENT

CIRCUIT

12176446

CAV
A

WIRE IDENT
12V

B
C

CIRCUIT
12V Pwr to Outlet 1

61-A

Trinary Pressure Switch Input

61R

AC Relay Control

Not Used
0-EK

CONNECTOR PRB1 - REDUNDANT BRAKE


SWITCH

Aux Power Outlet 1 Gnd

CONNECTOR PO2 - POWER OUTLET

245483C1

CAV

WIRE IDENT

CIRCUIT

33R-C

RDNT Brake Accumulator Press


Low

0-HM

Ground

12176446

CAV
A

WIRE IDENT
12V

B
C

CIRCUIT

CONNECTOR PRB2 - REDUNDANT BRAKE


SWITCH

12V Pwr to Outlet 2


Not Used

0-EK

Aux Power Outlet 2 Gnd

245483C1

CAV

Bur 5-2750

WIRE IDENT

CIRCUIT

33R-B

RDNT Brake Accumulator Press


Low

0-HL

Ground

Issued 8-06

Printed in U.S.A.

4002-156
CONNECTOR PRBF - ROLLBACK PRESSURE
SWITCH

CONNECTOR PRM-B2 - PRM SIGNAL

245483C1

CAV

WIRE IDENT

CIRCUIT

256340A1

58

Ride Control Solenoid Power

CAV

58-B

Ride Control Solenoid Power

13D

Time Delay Relay Control Pwr

0-EA

Time Delay Relay Control Gnd

WIRE IDENT

CIRCUIT

CONNECTOR PRM-A1 - PRM SIGNAL


CONNECTOR PRM-C1 - PRM OUTPUT

409084A1
256340A1

CAV

WIRE IDENT

CIRCUIT

CAV

WIRE IDENT

CIRCUIT

18R

Voltmeter Relay Fused Pwr

13K-B

Ignition Switch Power

28P

Ether Solenoid Power

0-EB

Ignition Relay Control Ground

1-GA

Filter Heater Power

CONNECTOR PRM-B1 - PRM SIGNAL

409084A1

CAV

WIRE IDENT

A
C

CIRCUIT
Not Used

13H

Bur 5-2750

Time Delay Power

Issued 8-06

Printed in U.S.A.

4002-157
CONNECTOR PRM-C2 - PRM SIGNAL

ONNECTOR PRM-E1 - PRM SIGNAL

409084A1

CAV
256340A1

CAV

WIRE IDENT

A
C

CIRCUIT

28E

Ether Relay Signal

28F

Fuel Filter Heater Relay Control

0-BAM

Ether Relay Signal Ground

0-BN

Filter Heater Control

WIRE IDENT

CIRCUIT
Not Used

19L

Power Converter FSD Power

CONNECTOR PRM-E2 - PRM SIGNAL

CONNECTOR PRM-D1 - PRM SIGNAL

256340A1

CAV

WIRE IDENT

CIRCUIT

12ACC-C

Pwr Converter PRM Control Pwr

0-DL

Pwr Converter Relay Ctrl Gnd

256340A1

CAV

WIRE IDENT

CIRCUIT

12ACC-B

ACC PRM Control Power

0-EC

ACC Relay Control Ground

CONNECTOR PSS - SECONDARY STEERING


PRESSURE SWITCH

245485C1

CAV

Bur 5-2750

WIRE IDENT

CIRCUIT

51P-A

Secondary Steer High Pressure

0-CC

Sec. Steer Press Switch Ground

35X-A

Secondary Steer Low Press Sig

Issued 8-06

Printed in U.S.A.

4002-158
CONNECTOR PXF - RTD

CONNECTOR PXT - RTD

245485C1

CAV

WIRE IDENT

CIRCUIT

245485C1

CAV

WIRE IDENT

CIRCUIT

53B

RTD Signal

53B-A

RTD Control Signal

0-AC

Proximity Switch Ground

0-AM

RTD Ground

53P-H

Pilot Control Relay Out

53P-I

Pilot Control Relay Out

CONNECTOR PXH - HEIGHT CONTROL RTT

CONNECTOR RAD - RADIO POWER

245485C1

CAV

WIRE IDENT

CIRCUIT

54B

RTT Signal

0-AA

Proximity Switch Ground

CAV

53P-J

Pilot Control Relay Out

Not Used

Not Used

Not Used

292495A1

CONNECTOR PXM - RTD

WIRE IDENT

12V-HB

CIRCUIT

12V Fused Power to Radio


Not Used

Not Used

12V-HA

12V Fused Power to Radio

0-EN

Radio Ground

245485C1

CAV
A

WIRE IDENT
53B-A

CIRCUIT
RTD Control Signal

0-AM

RTD Ground

53P-I

Pilot Control Relay Out

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-159
CONNECTOR RAD-J1 - RADIO POWER

CONNECTOR RAD-J3 - RADIO JUMPER

411311A1

CAV

292497A1

CAV

WIRE IDENT

CIRCUIT

WIRE IDENT

CIRCUIT

RAD10

Right Speaker Ground

RAD8

Not Used

RAD4

Left Speaker Ground

RAD6

Not Used

RAD1

Not Used

Not Used

Not Used

RAD3

12V Fused Power to Radio

12V Fused Power to Radio

RAD11

Right Speaker

Not Used

RAD9

Not Used

Not Used

10

RAD5

Left Speaker

RAD3

Radio Ground
Not Used

RAD2

12V Fused Power to Radio

11

RAD7

Not Used

RAD1

Radio Ground

12

RAD2

12V Fused Power to Radio

CONNECTOR RAD-J2 - SPEAKER

13

Not Used

14

Not Used

CONNECTOR RECT - ENGINE COOLANT


TEMPERATURE

194788A1
292501A1

CAV

WIRE IDENT

CIRCUIT

RAD11

Right Speaker

RAD10

Right Speaker Ground

RAD9

Not Used

RAD8

Not Used

RAD7

Not Used

RAD6

Not Used

RAD5

Left Speaker

RAD4

Left Speaker Ground

Bur 5-2750

CAV

WIRE IDENT

CIRCUIT

36C

Radiator Coolant Temp Signal

0-BAE

EDC7 Sender Ground

Issued 8-06

Printed in U.S.A.

4002-160
CONNECTOR ROOF - ROOF TO CAB
CONNECTION

CONNECTOR RTHP - THROTTLE PEDAL

388708A1

CAV

WIRE IDENT

CIRCUIT

225351C1

43-B

Dome Light Auto Mode

CAV

42R-F

Rear Work Light Fused Power

WIRE IDENT
21F-C

CIRCUIT
EDC7 DIGITAL Ground

42C-F

Front Work Lights Fused Power

Not Used

19U-C

Done Light Fused Power

24B

Throttle Signal

46-D

Beacon Switch Power

24B-A

Throttle Signal

0-MN

Roof Grounds

24R

Throttle Position Sensor Ground

24R-A

Throttle Position Sensor Ground

0-MK

Roof Grounds

19K-D

Rear Wiper Motor Fused Power

24S

Throttle Supply

68C-A

Rear Wiper Park Control

24S-A

Throttle Supply

68L-A

Rear Wiper Switched Power

24L

Low Idle Switch

0-EN

Radio Ground

12V-H

12V Fused Power to Radio

43S-B

Door Open Signal

19U-F

Door Switch Fused Power

CONNECTOR RWM - REAR WIPER MOTOR

CONNECTOR RSPK - RIGHT SPEAKER

245715C1

CAV
195552A1

CAV

WIRE IDENT

WIRE IDENT

CIRCUIT
Not Used

CIRCUIT

68L-A

Rear Wiper Switch Power

65R

Right Speaker Signal

19K-D

Rear Wiper Motor Fused Power

0-PB

Right Speaker Ground

68C-A

Rear Wiper Park Control

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-161
CONNECTOR RWMG - REAR WIPER MOTOR
GROUND

CONNECTOR S-KEY - IGNITION SWITCH TO


PEDESTAL HARNESS

245480C1

CAV
1

WIRE IDENT
0-MA

225253C1

CIRCUIT
Rear Wiper Motor Ground

CONNECTOR RWW - REAR WASHER

CAV

WIRE IDENT

CIRCUIT

1A

Ign Sw Fused Power

21K

Ign Switch Start Signal

13K

Ignition Switch Power

12ACC

Ign Switch Accessory Power

Not Used

Not Used

CONNECTOR SBE - BEACON SWITCH

3227856R1

CAV

WIRE IDENT

CIRCUIT

68W-A

Rear Washer Pump

0-BL

Rear Washer Ground

382391A1

CAV

WIRE IDENT

Not Used

19U-H

Beacon Switch Fused Power

46-C

Beacon Switched Power

Not Used

Not Used

Bur 5-2750

CIRCUIT

Not Used

0-B15

Back Light Ground

49-B

Back Light Power

Not Used

10

Not Used

Issued 8-06

Printed in U.S.A.

4002-162
CONNECTOR SBU - BACKUP ALARM DISABLE
SWITCH

CONNECTOR SCS - COMFOR STEER SWITCH

382391A1
382391A1

CAV

WIRE IDENT

CIRCUIT

35R-C

Backup Alarm Switch

35A-B

Backup Alarm Disable Switch

CAV

WIRE IDENT

CIRCUIT

51S

Standard Steering Signal

18L-D

Comfort Steering Fused Power

51CS

Comfort Steering Switch

Not Used

Not Used

Not Used

51B-A

Comfort Steering Solenoid Pwr

Not Used

Not Used

Not Used

0-B9

Back Light Ground

0-B21

Back Light Ground

49-U

Back Light Power

49-L

Back Light Power

Not Used

Not Used

10

Not Used

10

Not Used

CONNECTOR SDC - DECLUTCH SWITCH


CONNECTOR SC - SEAT COMPRESSOR MOTOR

245482C1

CAV

WIRE IDENT

CIRCUIT

19N

Seat Compressor Fused Pwr

0-DK

Seat Compressor Motor Ground

382391A1

CAV

WIRE IDENT

25G-B

Brake Declutch Switch Control

19A-R

Declutch Switch Fused Power

Not Used

Not Used

Not Used

Bur 5-2750

CIRCUIT

Not Used

0-B18

Back Light Ground

49-R

Back Light Power

Not Used

10

Not Used

Issued 8-06

Printed in U.S.A.

4002-163
CONNECTOR SDR - DRIVING LIGHTS SWITCH

CONNECTOR SFC - FAN CONTROL SWITCH

382391A1

382391A1

CAV

WIRE IDENT

CAV

CIRCUIT
Not Used

WIRE IDENT

CIRCUIT
Not Used

19Z-A

Driving lights Switch Fused Pwr

52J

Fan Control Switch Jumper

41T

Position Lights Switch Power

52-AU

Fan Reverse Auto

Not Used

52J

Fan Control Switch Jumper

19P-C

Fan Reverse Switch Fused Pwr

19Z-B

Driving Lights Switch Fused


Power

52M

Fan Reverse Manual

41J

Driving Lights Power

0-B7

Back Light Ground

0-B19

Back Light Ground

49-Q

Back Light Power

49-P

Back Light Power

Not Used

Not Used

10

Not Used

10

Not Used

CONNECTOR SFL - RETURN-TO-TRAVEL


SWITCH

CONNECTOR SETHR - ETHER SWITCH

382391A1

382391A1

CAV

WIRE IDENT

CIRCUIT

CAV

WIRE IDENT

CIRCUIT

Not Used

55A-B

RTT/Float Switch Power

28J

Ether AIC OK Signal

53P-B

Pilot Control Relay Out

28H

Ether Switch Signal

55A-C

RTT/Float Switch Power

Not Used

0-29

RTT/Float Ground

Not Used

55B

RTT Float Switch Control

Not Used

54B-C

HC-RTT Control Signal

0-B30

Back Light Ground

0-B2

Back Light Ground

49U

Back Light Power

49-K

Back Light Power

Not Used

Not Used

10

Not Used

10

Not Used

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-164
CONNECTOR SFNR - FNR SWITCH

CONNECTOR SHC - HEIGHT CONTROL SWITCH

382391A1

CAV

WIRE IDENT

CIRCUIT

382391A1

CAV

WIRE IDENT

CIRCUIT

26R-A

FNR Reverse Signal

26J

FNR Switch Jumper

26N-A

FNR Neutral Signal

Not Used

26J

FNR Switch Jumper

Not Used

19A-V

FNR Switch Fused Power

Not Used

26F-A

FNR Forward Signal

54A

HC Control Switch Power

32J-A

Trans Enable Indication

0-B3

Back Light Ground

19A-G

FNR Switch Fused Power

49-M

Back Light Power

Not Used

Not Used

10

Not Used

10

Not Used

CONNECTOR SFWW - REAR WIPER AND


WASHER SWITCH

Not Used
53P-D

Pilot Control Relay Out

CONNECTOR SHZ - HAZARD SWITCH

382391A1

87345132

CAV

WIRE IDENT

CIRCUIT

CAV

WIRE IDENT

CIRCUIT

Not Used

0-DT

Front Wiper/Washer Sw Gnd

1-KA

Hazard Switch Power

63LC

Front Wiper LS Relay Control

45H

Hazard Switch Power

Not Used

Not Used

INT Wiper/Washer Sw Fused


Pwr

Not Used

Not Used

4
5

19J-B

Not Used

63W

Front Washer Pump

49-T

Back Light Power

63HC

Front Wiper HS Relay Control

10

Bur 5-2750

Not Used

0-b24

Back Light Ground

49-D

Back Light Power

Not Used

10

Not Used

Not Used

Issued 8-06

Printed in U.S.A.

4002-165
CONNECTOR SPB - PARKING BRAKE SWITCH

CONNECTOR SPE - PIN ENGAGE SWITCH

382391A1

CAV

WIRE IDENT

CIRCUIT
Not Used

382391A1

CAV

WIRE IDENT

CIRCUIT

57-B

19A-L

Park Brk Switch Fused Power

19P-A

33U

Park Brake Switch

Not Used

Not Used

Not Used

Not Used

Not Used

Not Used

Not Used

Not Used

Not Used

0-B29

RTT/Float Ground

49-v

Back Light Power

Not Used

10

Not Used

Pin Engage Solenoid Power


Pin Engage Sw Fused Power

0-B5

Back Light Ground

10

49-F

Back Light Power

CONNECTOR SPC - PILOT CONTROL SWITCH

CONNECTOR SPK - SPEAKER

382391A1

CAV

WIRE IDENT

CIRCUIT

292494A1

Not Used

CAV

WIRE IDENT

CIRCUIT

19A-j

Pilot Control Switch Fused Pwr

65R

Right Speaker

31L

0-PB

Right Speaker Ground

Pilot Control Switch High

Not Used

Not Used

Not Used

Not Used

Not Used

Not Used
Not Used

0-B1

Back Light Ground

49-N

Back Light Power

65L

Left Speaker

Not Used

0-PA

Left Speaker Ground

10

Not Used

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-166
CONNECTOR SPL-BCK-LGT - SPLICE BACK
LIGHT POWER

CAV

WIRE IDENT

49-M

Back Light Power

49-K

Back Light Power

49-F

Back Light Power

49-Q

Back Light Power

49-T

Back Light Power

J
K

Not Used
49-G

L
M

87324393

CAV
A

WIRE IDENT
49

CIRCUIT

Back Light Power


Not Used

49-S

Back Light Power

CONNECTOR SPL-BCK-LT-GD - SPLICE BACK


LIGHT GROUND

CIRCUIT
Back Light Power
Not Used

49-C

Back Light Power

49-H

Back Light Power

49-L

Back Light Power

49A

Back Light Power

49-P

Back Light Power

49-R

Back Light Power

49S

Back Light Power

49-E

Back Light Power

49-B

Back Light Power

49-A

Back Light Power

87324393

CAV

CONNECTOR SPL-BCK-LGT2 - SPLICE BACK


LIGHT POWER

WIRE IDENT

CIRCUIT

0-B13

Back Light Ground

0-B14

Back Light Ground

0-B15

Back Light Ground

0-B17

Back Light Ground

0-B18

Back Light Ground

0-B19

Back Light Ground

0-B8

Front Wiper Motor Ground

0-B21

Back Light Ground

0-DAP

Back Light Ground

0-B23

Back Light Ground

Not Used

Not Used

87324393

CAV
A

WIRE IDENT
49-E

B
C

CIRCUIT
Back Light Power
Not Used

49-J

Bur 5-2750

Back Light Power


Issued 8-06

Printed in U.S.A.

4002-167
CONNECTOR SPL-BCK-LT-GD2 - SPLICE BACK
LIGHT GROUND

CAV

WIRE IDENT

CIRCUIT

0-BS

Fan Control Ground

0-B

Front Washer Ground

0-BL

Rear Washer Ground

CONNECTOR SPL-HOOD-GND - HOOD GROUND


6 PACK

87324393

CAV

WIRE IDENT

CIRCUIT
Not Used

0-B2

Back Light Ground

0-B3

Back Light Ground

0-B4

Back Light Ground

0-B5

Back Light Ground

87324391

CAV

0-B6

CAB2 Ground

0-B26

Buzzer Switch Pad Ground

H
J

Not Used
0-B20

Back Light Ground

0-29

RTT/Float Ground

0-B11

Back Light Ground

0-B7

Back Light Ground

WIRE IDENT

CIRCUIT

0-B12

Hood Down Relay Ground

0-B16

Hood Down Control Ground

0-B22

Hood Up Relay Ground

0-B25

Hood Up Control Ground

0-B10

Hood Ground

Not Used

CONNECTOR SPL-ENG-GND - GROUND SPLICE


6 PACK

87324391

CAV

WIRE IDENT

CIRCUIT

0-BM

Engine Splice Grounds

0-BY

Air Filter Restriction Switch Gnd

Bur 5-2750

Not Used

Issued 8-06

Printed in U.S.A.

4002-168
CONNECTOR SPL-PED-BL - SPL BACK LIGHT
POWER 6 PACK

CONNECTOR SPL-PIN - SPL BACK LIGHT


POWER 6 PACK

87324391

CAV

WIRE IDENT

CIRCUIT

87324391

CAV

WIRE IDENT

CIRCUIT

49-U

Back Light Power

19P-A

Pin Engage Switch Fused Pwr

49-N

Back Light Power

19P

Pin Engage/Fan Fused Power

19P-C

Ran Reverse Switch Fused Pwr

49-D

Back Light Power

49U

Back Light Power

49-V

Back Light Power

19P-D

Fan Reverse Relay Fused Pwr

49-S

Back Light Power

19P-E

Fan Reverse Relay Fused Pwr

Not Used

CONNECTOR SPL-PED-BL-GD - SPL BACK


LIGHT POWER 6 PACK

87324391

CAV

WIRE IDENT

CIRCUIT

0-B9

Back Light Ground

0-B1

Back Light Ground

0-B24

Back Light Ground

0-B30

Back Light Ground

0-B29

RTT/Float Ground

0-B11

Back Light Ground

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-169
CONNECTOR SPL-PK1 - SPLICE 3 - 4 WAY

CONNECTOR SPL-PK2 - SPLICE 3 - 4 WAY

87324462

CAV

WIRE IDENT

CIRCUIT

87324462

CAV

WIRE IDENT

CIRCUIT

42C-A

Front Work Lights Fused Pwr

41T-B

Position Lights LH Switch Pwr

42C-E

Front Work Lights Fused Pwr

41T-E

Position Lights Switch Pwr

42C-D

Front Work Lights Fused Pwr

41T

Position Lights Switch Pwr

42C-C

Front Work Lights Fused Pwr

41T-A

Position Lights RH Switch Pwr

13K

Ignition Switch Power

19Z-A

Driving Light Switch Fused Pwr

13K-B

Ignition Switch Power

19Z-B

Driving Light Switch Fused Pwr

13K-A

Ignition Switch Power

19Z

Driving Light Switch Fused Pwr

13K-C

Ignition Switch Power

19Z-C

High Beam Flash Fused Pwr

35A-D

Backup Alarm Relay Out

41H-C

High Beam RH Power

35A-B

Backup Alarm Disable Switch

41H-B

High Beam LH Power

35A-A

Backup Alarm Relay Out

41H-A

High Beam Power

35A-C

Backup Alarm Relay Out

41H-D

High Beam Power

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-170
CONNECTOR SPL-PK3 - SPLICE 3 - 4 WAY

CAV

WIRE IDENT

CIRCUIT

0-MF

RH Rear Work Light Ground

0-MA

Rear Wiper Motor Ground

Not Used

Not Used

0-MJ

RH Front Work Light Ground


Not Used

0-MN

Roof Grounds

0-MK

Roof Grounds

CONNECTOR SPL-SEC-STR - SEC STR 6PK


87324462

CAV

WIRE IDENT

CIRCUIT

45L-E

Left Turn Signal

45L-D

Left Turn Signal

45L-C

Left Turn Signal

45L-B

Left Turn Signal

45R-C

Right Turn Signal

45R-E

Right Turn Signal

45R-D

Right Turn Signal

45R-B

Right Turn Signal

19J-B

Front Wiper/Washer Sw Fused


Pwr

19J

Front Wiper Fused Power

CAV

19J-C

Front Wiper Relay Fused Power

19J-A

Front Wiper Motor Fused Power

CONNECTOR SPL-ROOF - SPLICE ROOF


GROUND

87324391

WIRE IDENT

CIRCUIT

0-CB

Sec. Steering Signal Ground

0-CA

Sec. Steering Signal Ground

0-CC

Sec. Steering Press Switch Gnd

0-CF

Sec. Steering Solenoid Ground

E
F

Not Used
0-CD

Sec. Steering Splice Ground

87324393

CAV

WIRE IDENT

CIRCUIT

0-MC

Beacon Light Ground

0-MB

Dome Light Ground

0-MU

LH Front Work Light Ground

0-ME

LH Rear Work Light Ground

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-171
CONNECTOR SPL-TRN-GRD - SPLICE
TRANSMISSION GROUND

CAV

WIRE IDENT

CIRCUIT

19A-M

Output Speed Sensor Fused


Pwr

19A-S

Trans Fused Pwr

19A-H

Trans Shifter Fused Pwr

CONNECTOR SRC - RIDE CONTROL SWITCH

87324391

CAV
A

WIRE IDENT
0-HC

CIRCUIT
Transmission Splice Grounds
Not Used
382391A1

0-HW

HOT Ground

0-HV

Coolant Level Sender Ground

0-HL

Redundant Brake Switch Grd

0-HM

Redundant Brake Switch Grd

CONNECTOR SPL-TRNS-PWR - TRANSMISSION


POWER

CAV

WIRE IDENT

CIRCUIT
Not Used

19C-D

Ride Ctrl Switch Fused Pwr

58C

Ride Ctrl Switch Jumper

58T

Ride Ctrl Relay Switch Pwr

58C

Ride Ctrl Switch Jumper

58-F

Ride Ctrl Solenoid Pwr

0-B20

Back Light Ground

49-G

Back Light Power

Not Used

10

Not Used

CONNECTOR SRC-1 - STARTER RELAY

87324393

CAV

WIRE IDENT

CIRCUIT

19A-N

Trans Fused Power

19A-F

Trans Enable Switch Fused Pwr

19A-Q

Trans/Auto Switch Fused Pwr

225316C1

19A-T

Brake Declutch Sw Fused Pwr

CAV

19A-W

Diagnostic Conn. Fused Pwr

21D

Starter Relay Signal

19A-C

FNR Switch Fused Pwr

0-GB

Starter Relay Control Ground

19A-P

Backup Alarm Rly Ctrl Fused


Pwr

19A-R

Declutch Switch Fused Pwr

19A-K

TECM Fused Pwr

Bur 5-2750

WIRE IDENT

CIRCUIT

Issued 8-06

Printed in U.S.A.

4002-172
CONNECTOR SRHSTLK - RH STALK SWITCH

CONNECTOR SRWP - REAR WIPER SWITCH

382391A1

CAV

WIRE IDENT

CIRCUIT

68C

Rear Wiper Park Control

68L

Rear Wiper Switch Power

19K-A

Rear Wiper Switch Fused Power

87318288

CAV

WIRE IDENT

CIRCUIT

31b

64C

Horn Relay Control

49a

19B

Turn Signal Fused Power

56a

41H-A

High Beam Power

56b

41L-A

Low Beam Power

56d

19Z-C

High Beam Flash Fused Power

31

0-EP

Horn Switch Ground

56

41J

Drive Lights Power

45A-A

Left Turn Switch Power

45B-A

Right Turn Switch Power

Not Used

19K-B

Rear Wiper Switch Fused Power

68W

Rear Washer Pump

0-B23

Back Light Ground

49-C

Back Light Power

Not Used

10

Not Used

CONNECTOR SS-TR - SS-MOD-TRANS


CONNECTOR SRTD - DETENT SWITCH

245489C1

CAV

382391A1

CAV

WIRE IDENT

CIRCUIT
Not Used

53P-E

Pilot Control Relay Out

53A

RTD Switched Power

Not Used

Not Used

Not Used

0-B4

Back Light Ground

49-J

Back Light Power

Not Used

10

Not Used

Bur 5-2750

WIRE IDENT

CIRCUIT

19M-C

Sec. Str Accessory Fused Pwr

19R-C

Sec. Str Ignition Fused Pwr

35X-C

Sec. Str Low Press Signal

0-CD

Sec. Str Splice Ground

19S1-X

Sec. Str Fused Power

Not Used

Issued 8-06

Printed in U.S.A.

4002-173
CONNECTOR SSM - SECONDARY STEERING
MODULE

CAV

WIRE IDENT

CIRCUIT

0-B17

Back Light Ground

49S

Back Light Power

Not Used

10

Not Used

CONNECTOR STE - TRANSMISSION ENABLE


SWITCH

225389C1

CAV

WIRE IDENT

CIRCUIT

19R-C

Sec. Steering Ignition Fused


Pwr

51-A

Secondary Steer Control

19S1-X

Secondary Steer Fused Power

0-CE

Secondary Steer Chassis Grnd

Not Used

382391A1

Not Used

CAV

Secondary Steer ACC Fused


Pwr

19M-C

35X-D

Secondary Steer Low Press Sig

51P-A

Secondary Steer High Press

10

Not Used

11

0-CA

Secondary Steer Signal Grnd

12

0-CB

Secondary Steer Signal Grnd

CONNECTOR STA - TRANSMISSION AUTO


SWITCH

WIRE IDENT

CIRCUIT
Not Used

19A-D

Trans Enable Sw Fused Power

26E

Trans Enable Signal

Not Used

Not Used

Not Used

0-DAP

Back Light Ground

49-H

Back Light Power

32J-C

Trans Enable Indiction

10

19A-E

Trans Enable Sw Fused Pwr

382391A1

CAV

WIRE IDENT

CIRCUIT
Not Used

19A-Q

Trans Auto Sw Fused Power

25H

Trans Auto Signal

Not Used

Not Used

Not Used

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-174
CONNECTOR SWL - WORK LIGHTS SWITCH

CAV

WIRE IDENT

CIRCUIT

CAN-LF

CAN Low

17P-A

Switch Pad Pwr From AIC Pwr

10

0-B28

Switch Pad Ground

CONNECTOR TCOT - TORQUE CONVERTER


OUTPUT SENDER

382391A1

CAV

WIRE IDENT

CIRCUIT
Not Used

42-A

Work Lights Fused Power

42FS

Front Work Lights Switch Power

Not Used

42-B

Work Lights Fused Power

42RS

Rear Work Lights Switch Power

0-B14

Back Light Ground

49-A

Back Light Power

Not Used

10

Not Used

291718A1

CAV

WIRE IDENT

CIRCUIT

36G

TCO Temperature Signal

36R-D

TCO Temperature Return

CONNECTOR TDM - TIME DELAY MODULE

CONNECTOR SW-PD - SWITCH PAD

225351C1

CAV

87552623

CAV

WIRE IDENT

CIRCUIT

WIRE IDENT

CIRCUIT

13D

Time Delay Relay Ctrl Power

1DN

Time Delay Fused Power

0-DC

Time Delay Module Ground

41H-D

High Beam Power

43S-D

Time Delay Mod Door Sw Reset

41T-D

Position Lights Switch Pwr

13K-A

Ignition Switch Power

42C-E

Front Work Light Fused Pwr

31H-A

Hydraulic Filter Rest Sw Signal

31F-A

Air Filter Rest Switch Signal

6
7

Not Used

Not Used
CAN-HF

Bur 5-2750

CAN High

Issued 8-06

Printed in U.S.A.

4002-175
CONNECTOR TECM - TRANSMISSION
ELECTRONIC CONTROL MODULE

411398A1

CAV

WIRE IDENT

CIRCUIT

0-DP

Diag TECM Ground

0-DQ

Diag TECM Ground

0-DM

Speed Sensors Ground

0-DN

Out Speed Sensor Ground

32J-D

Trans Enable Indicator Lamp

35C

Backup Alarm Relay Control

58H-A

Ride Control Sw Power VPS2

25P-A

Trans Sol Valve Y5

10

25L-A

Trans Sol Valve Y2

12

25S-B

Output Sw Power VPS1

13

25S-C

Output Sw Power VPS1

15

37D-A

Diagnostic Signal

17

32F-A

Trans Filter Maint Switch

18

37E

Diagnostic Signal Switched

19

25A-A

Engine Speed Signal

20

26F-B

FNR Forward Signal

Bur 5-2750

CAV

WIRE IDENT

CIRCUIT

21

52P-C

Park Brake Relay Out

22

25Y-A

Trans Kick Down Signal

23

19T-A

Time Delay Fused Power

25

CAN-HD

CAN High

26

CAN-LK

CAN Low

27

CAN-LJ

CAN Low

29

25H

Trans Auto Signal

30

26R-B

FNR Reverse Signal

31

26E

Trans Enable Signal

32

25M-A

Trans Sol Valve Y3

39

36T-A

Valve Body Temp Signal

41

25C-A

Turb Speed Signal

42

25B-A

Int Speed Signal

43

25F

Forward Signal

44

26N-B

FNR Neutral Signal

45

19A-K

TECM Fused Power

46

36R-E

Trans Temp/Filter Return

49

36G-A

Torque Conv Out Temp Signal

51

25J-A

Trans Sol Valve Y6

55

25N-A

Trans Sol Valve Y4

56

25K-A

Trans Sol Valve Y1

57

58L

Ride Control Relay LSD

62

25D-A

Output Speed Signal

63

25Z

1st and 4th Gear Signal

64

25R-

Reverse Signal

65

25W

3rd and 4th Gear Signal

66

25G-C

Brake Declutch Switch Control

67

25T-C

Neutral Signal

Issued 8-06

Printed in U.S.A.

4002-176
CONNECTOR TR-SS - SEC-STR-MOD-OPT

CONNECTOR TRANS - CAB TO TRANSMISSION

380838A1

CAV

245488C1

CAV

WIRE IDENT

CIRCUIT

19M-A

Sec. Steering ACC Fused Pwr

19R-A

Sec. Steering Ignition Fused


Pwr

35X-B

Sec. Steering Low Press Signal

0-HP

Sec. Steering Splice Ground

19S1-E

Sec. Steering Fused Power

Not Used

CONNECTOR TRAN-E - TRANS TO ENG

239451A1

CAV

WIRE IDENT

CIRCUIT

WIRE IDENT

CIRCUIT

33R-A

Redundant Brake Switch Signal

31D-B

Coolant Level Sender Eng


Trans

31D

Coolant Level Signal

19M-A

Sec. Steering ACC Fused Pwr

19R-A

Sec. Steering Ignition Fused


Pwr

36T

Valve Body Temp Signal

35X-B

Sec. Steering Low Press Signal

25A

Engine Speed Signal

25C

Turb Speed Signal

25B

Intermediate Speed Signal

10

25D

Output Speed Signal

11

0-HD

Speed Sensor Ground

12

36R-A

Trans Temp/Filter Return

13

36G

Torque Conv Output Temp Sig

14

Not Used

15

Not Used

16

25K

Trans Solenoid Valve Y1

16

25K-9

Trans Solenoid Valve Y2

17

25L-9

Trans Solenoid Valve Y1

17

25L

Trans Solenoid Valve Y2

18

25M

Trans Solenoid Valve Y3

19

25N

Trans Solenoid Valve Y4

0-HP

Sec. Steering Splice Ground

20

25P

Trans Solenoid Valve Y5

0-HC

Trans Splice Grounds

21

25J

Trans Solenoid Valve Y6

31D-B

Coolant Level Sender Eng


Trans

22

25S

Output Sw Power VPS1

23

31H

Hyd Filter Restriction Sw Signal

Not Used

24

Not Used

25

Not Used

26

19S1-E

27

Bur 5-2750

Sec. Steering Fused Power


Not Used

28

0-HE

Output Speed Sensor Ground

29

19A

Output Speed Sensor Fused


Pwr

30

36H

Hydraulic Oil Temperature Sign

31

32F

Trans Filter Maint Switch

Issued 8-06

Printed in U.S.A.

4002-177
CONNECTOR TRC - TRANSMISSION CONTROL

CONNECTOR TS1 - TRANSMISSION SHIFTER

245486C1
371566A1

CAV

WIRE IDENT

CIRCUIT

CAV

WIRE IDENT

CIRCUIT

19A-H

Trans Shifter Fused Power

25K

Trans Solenoid Valve Y1

25F

Forward Signal

25L-9

Trans Solenoid Valve Y1

25R

Reverse Signal

25K-9

Trans Solenoid Valve Y2

25T-B

Neutral Signal

25L

Trans Solenoid Valve Y2

25M

Trans Solenoid Valve Y3

25N

Trans Solenoid Valve Y4

25P

Trans Solenoid Valve Y5

25J

Trans Solenoid Valve Y6

25S

Output Sw Power VPS1

36T

Valve Body Temp Signal

36R-C

Valve Body Temp Return

10

Not Used

11

Not Used

12

Not Used

13

Not Used

14

Not Used

15

Not Used

16

Not Used

Bur 5-2750

CONNECTOR TS2 - TRANSMISSION SHIFTER

245487C1

CAV

WIRE IDENT

CIRCUIT
Not Used

25W

3rd and 4th Gear Signal

25Z

1st and 4th Gear Signal

25Y

Transmission Kick Down Signal

Issued 8-06

Printed in U.S.A.

4002-178
CONNECTOR TSS - TURBINE SPEED SENSOR

CONNECTOR YCS - COMFOR STEERING


SOLENOID

245482C1
291718A1

CAV

WIRE IDENT

CIRCUIT

25C

Turbine Speed Signal

0-HH

Turbine Speed Ground

CAV

WIRE IDENT

CIRCUIT

51B-D

Comfort Steering Solenoid Pwr

0-AQ

Comfort Steering Solenoid Gnd

CONNECTOR YFN - FNA PWM SOLENOID


CONNECTOR WF - WATER IN FUEL SENSOR

8602416

CAV

WIRE IDENT

CIRCUIT

256340A1

35W

Water Indicator

CAV

0-BP

Sensor Ground

56-A

Fan Control PWM

18J-H

Sensor Fused Power

0-BQ

Fan Speed PWM Solenoid Gnd

CONNECTOR WSH - WATER SEPARATOR


HEATER

WIRE IDENT

CIRCUIT

CONNECTOR YFR - FAN REVERSING SOLENOID

225316C1

CAV
182069A1

CAV

WIRE IDENT

CIRCUIT

0-BW

Water Separator Heater Ground

1-GC

Water Separator Heater Power

Bur 5-2750

WIRE IDENT

CIRCUIT

52A-B

Fan Reversing Relay Out

0-BB

Fan Reversing Solenoid Ground

Issued 8-06

Printed in U.S.A.

4002-179
CONNECTOR YPB - PARKING BRAKE SOLENOID

CONNECTOR YRC - RIDE CONTROL OPT

291718A1

CAV

WIRE IDENT

CIRCUIT

291718A1

CAV

WIRE IDENT

CIRCUIT

52P

Parking Brake Relay Out

58

Ride Control Solenoid Power

0-AN

Park Brake Solenoid Ground

58S-E

Ride Control Sol To Front Cab

0-AD

Ride Control Ground

CONNECTOR YPE - PIN ENGAGE OPT


CONNECTOR YSS - SECONDARY STEERING
SOLENOID

245482C1

CAV

WIRE IDENT

CIRCUIT

57

Pin Engage Solenoid Power

0-AE

Pin Engage Ground

225316C1

CAV

CONNECTOR YPP - PILOT PRESSURE


SOLENOID

WIRE IDENT

CIRCUIT

51-C

Sec. Steering Solenoid Control

0-CF

Sec. Steering Solenoid Ground

245482C1

CAV

WIRE IDENT

CIRCUIT

5P-A

Pilot Control Relay Out

0-DU

Pilot Pressure Solenoid Gnd

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-180

NOTES

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4002-181

Symbols
12 Volt Radio .......................................................112

A
A/C High/Low Pressure Switch ............................115
Air Filter Restriction Switch ....................................67
Air Seat Compressor and Switch .........................114
Alarm
Back-up (Europe Only) ......................................96
Back-up (North America Only) ..........................96
Back-up, Disable Switch ...................................76
Back-up, Relay ..................................................76
Alternator ...............................................................40

B
Back-up Alarm (Europe Only) ................................96
Back-up Alarm (North America Only) ....................96
Back-up Alarm Disable Switch ..............................76
Back-up Alarm Relay .............................................76
Batteries ................................................................41
Beacon Switch .......................................................79
Beacon, Rotating (Option) .....................................78
Brake Lamp Pressure Switch ................................83
Brake Lamps Relay ...............................................83
Brake Warning Pressure Switch ............................68
Buzzer ...................................................................66

C
CAN Communication Diagnostics Connector ......109
Cigar Lighter ........................................................114
Circuit Breaker Cab B+ ..........................................47
Climate Control, Automatic
24 to 12 Volt Converter ...................................118
Blower Motor Resistor .....................................117
Blower Motors .................................................117
Compressor Relay ..........................................118
Electronic Panel ..............................................117
Electronic Water Valve ....................................118
External Air Temperature Sensor ....................117
Internal Air Temperature Sensor .....................117
Mixed Air Sensor .............................................117
Recycling Motor ..............................................118
Sun Sensor .....................................................117
Thermocouple Sensor .....................................117
Climate Control, Standard
Air Conditioning Switch ...................................121
Air Recirculation Motor ....................................120
Air Recirculation Switch ..................................122
Blower Motor ...................................................120
Blower Motor Speed Resistors with Thermal Fuse
120
Blower Switch ..................................................121
Control Panel Lights ........................................121
Driver ...............................................................120
Electronic Water Valve ....................................120
Thermostat ......................................................121
Water Valve Potentiometer .............................121
Bur 5-2750

Cluster, Instrument Connector 1 ...........................65


Cluster, Instrument Connector 2 ...........................71
Compressor Clutch ..............................................115
Compressor Clutch Relay ...................................114
Compressor, Seat ...............................................114
Connector 108F ...................................................126
Connector 140M ..................................................126
Connector 197F ...................................................126
Connector 197M ..................................................126
Connector 202M ..................................................127
Connector 209F ...................................................127
Connector 209M ..................................................127
Connector 20M ....................................................127
Connector 215F ...................................................127
Connector 216F ...................................................127
Connector 64F .....................................................128
Connector 64M ....................................................128
Connector 69 .......................................................161
Connector ACT ....................................................128
Connector AIC1 ...................................................128
Connector AIC2 ...................................................129
Connector CAB_E ...............................................130
Connector CAB_F ...............................................131
Connector CAB_RF .............................................131
Connector CAB_T ...............................................132
Connector CAN ...................................................132
Connector CAN2 .................................................132
Connector CL ......................................................133
Connector CLS ....................................................133
Connector CNV ...................................................133
Connector D_OR .................................................133
Connector DIA .....................................................133
Connector DISC ..................................................133
Connector DM .....................................................134
Connector DNS-AC-SWITCH ..............................134
Connector DNS-ACTUATOR ..............................134
Connector DNS-BLUE .........................................134
Connector DNS-COMPRESSOR-RELAY ...........134
Connector DNS-CTRL-PANEL-LIGHT ................137
Connector DNS-DRIVER ....................................137
Connector DNS-ELECTRIC-FAN ........................137
Connector DNS-ELECT-WATER-VALVE ...........136
Connector DNS-ELECT-WATER-VALVE-S ........137
Connector DNS-EXTERNAL-AIR-TEMP-SNS ....134
Connector DNS-HVAC1 ......................................135
Connector DNS-HVAC1-S ..................................138
Connector DNS-HVAC2 ......................................135
Connector DNS-HVAC2-S ..................................138
Connector DNS-HVAC-CAN1 .............................134
Connector DNS-INTERNAL-AIR-TEMP-SNS .....135
Connector DNS-MISED-SIR-SENSOR ...............136
Connector DNS-NOT-USED ...............................135
Connector DNS-PWM-BLOWER ........................136
Connector DNS-PWM-BLOWER-PIN2 ...............136
Connector DNS-PWM-BLOWER-PIN4 ...............136
Connector DNS-RECIRCULATING-SWITCH .....137
Connector DNS-RECYCLING-MOTOR ..............136
Issued 8-06

Printed in U.S.A.

4002-182
Connector DNS-RESISTOR ................................137
Connector DNS-SPEED-SELECTOR .................136
Connector DNS-THERMOCOUPLE-SENSO ......136
Connector DNS-THERMOSTAT-1 ......................137
Connector DNS-THERMOSTAT-2 ......................137
Connector DNS-VOLTAGE-CONVERTER .........136
Connector DNS-WATER-VALVE-POT ................137
Connector DNS-YELLOW ...................................135
Connector DS ......................................................138
Connector E_HD .................................................138
Connector ECA ....................................................139
Connector ECB ....................................................140
Connector ECC ...................................................141
Connector ECD ...................................................142
Connector EDC7 .................................................143
Connector EM ......................................................143
Connector ENG ...................................................144
Connector ENG_D ...............................................144
Connector ENG_H ...............................................145
Connector ENG_T ...............................................145
Connector ESS ....................................................145
Connector FFH ....................................................145
Connector FLSHR ...............................................146
Connector FM ......................................................146
Connector FRONT ...............................................146
Connector FWM ..................................................147
Connector FWMG ................................................147
Connector FWW ..................................................147
Connector GHC ...................................................147
Connector GND_CAB_SPL .................................148
Connector GND_CAB_SPL2 ...............................148
Connector HD ......................................................148
Connector HD_E .................................................148
Connector HD_N .................................................149
Connector HDM ...................................................149
Connector HOT ...................................................149
Connector HVAC_CAN1 .....................................150
Connector HVAC1 ...............................................149
Connector HVAC2 ...............................................149
Connector ISS .....................................................150
Connector K_WCO ..............................................150
Connector LBEE ..................................................150
Connector LLF .....................................................151
Connector LLFW .................................................151
Connector LLR_E ................................................151
Connector LLR_N ................................................151
Connector LLRW .................................................152
Connector LPL .....................................................152
Connector LRF ....................................................152
Connector LRFW .................................................152
Connector LRR_E ...............................................153
Connector LRR_N ...............................................153
Connector LRRW ................................................153
Connector LSPK ..................................................153
Connector OSS ...................................................153
Connector PAF ....................................................154
Connector PBD ....................................................154
Bur 5-2750

Connector PBL ....................................................154


Connector PBW ...................................................154
Connector PO1 ....................................................155
Connector PO2 ....................................................155
Connector PR ......................................................155
Connector PRB1 .................................................155
Connector PRB2 .................................................155
Connector PRBF .................................................156
Connector PRM_A1 ............................................156
Connector PRM_B1 ............................................156
Connector PRM_B2 ............................................156
Connector PRM_C1 ............................................156
Connector PRM_C2 ............................................157
Connector PRM_D1 ............................................157
Connector PRM_E1 ............................................157
Connector PRM_E2 ............................................157
Connector PSS ....................................................157
Connector PXF ....................................................158
Connector PXH ...................................................158
Connector PXM ...................................................158
Connector PXT ....................................................158
Connector RAD ...................................................158
Connector RAD_J1 .............................................159
Connector RAD_J2 .............................................159
Connector RAD_J3 .............................................159
Connector RECT .................................................159
Connector ROOF ................................................160
Connector RSPK .................................................160
Connector RTHP .................................................160
Connector RWM ..................................................160
Connector RWMG ...............................................161
Connector RWW .................................................161
Connector S_KEY ...............................................161
Connector SBE ....................................................161
Connector SBU ...................................................162
Connector SC ......................................................162
Connector SCS ...................................................162
Connector SDC ...................................................162
Connector SDR ...................................................163
Connector SETHR ...............................................163
Connector SFC ....................................................163
Connector SFL ....................................................163
Connector SFNR .................................................164
Connector SFWW ...............................................164
Connector SHC ...................................................164
Connector SHZ ....................................................164
Connector SPB ....................................................165
Connector SPC ...................................................165
Connector SPE ....................................................165
Connector SPK ....................................................165
Connector SPL_BCK_LGT ..................................166
Connector SPL_BCK_LGT2 ................................166
Connector SPL_BCK_LT_GD .............................166
Connector SPL_BCK_LT_GD2 ...........................167
Connector SPL_ENG_GND ................................167
Connector SPL_HOOD_GND .............................167
Connector SPL_PED_BL ....................................168
Issued 8-06

Printed in U.S.A.

4002-183
Connector SPL_PED_BL_GD .............................168
Connector SPL_PIN ............................................168
Connector SPL_PK1 ...........................................169
Connector SPL_PK2 ...........................................169
Connector SPL_PK3 ...........................................170
Connector SPL_ROOF ........................................170
Connector SPL_SEC_STR ..................................170
Connector SPL_TRN_GRD .................................171
Connector SPL_TRNS_PWR ..............................171
Connector SRC ...................................................171
Connector SRC_1 ...............................................171
Connector SRHSTLK ..........................................172
Connector SRTD .................................................172
Connector SRWP ................................................172
Connector SS_TR ...............................................172
Connector SSM ...................................................173
Connector STA ....................................................173
Connector STE ....................................................173
Connector SW_PD ..............................................174
Connector SWL ...................................................174
Connector TCOT .................................................174
Connector TDM ...................................................174
Connector TECM .................................................175
Connector TR_SS ...............................................176
Connector TRAN_E .............................................176
Connector TRANS ...............................................176
Connector TRC ....................................................177
Connector TS1 ....................................................177
Connector TS2 ....................................................177
Connector TSS ....................................................178
Connector WF .....................................................178
Connector WSH ...................................................178
Connector YCS ....................................................178
Connector YFN ....................................................178
Connector YFR ....................................................178
Connector YPB ....................................................179
Connector YPE ....................................................179
Connector YPP ....................................................179
Connector YRC ...................................................179
Connector YSS ....................................................179
Connector, Diagnostic ...........................................63
Coolant Level Sender ............................................74
Crank Control Relay ..............................................41
Crank Request Relay ............................................41

D
Declutch Brake Switch ...........................................63
Declutch Switch .....................................................63
Diagnostic Connector ............................................63
Diodes
Lights .................................................................81
Secondary Steering .........................................105
Wipers .............................................................103
Dome Lamp ...........................................................79
Door Switch ...........................................................78
Driving Lamp Switch ..............................................86

Bur 5-2750

E
Electrical Wire Identification ....................................8
Electromagnetic Detents .......................................54
Electronic Diesel Control .......................................51
Engine Speed Sensor ...........................................63

F
Fan PWM Solenoid ...............................................61
Fan Reverse Relay ................................................59
Fan Reversing Solenoid ........................................61
Fan Reversing Switch ...........................................59
Filter Maintenance Switch .....................................63
Flasher Module ......................................................84
FNR Switch for Joystick Controls ..........................63
FNR Switch for Single Axis Controls .....................63
Front
Left Hand Work Lamp .......................................79
Right Hand Work Lamp .....................................80
Front Left Hand Combination Lamp ......................88
Front Right Hand Combination Lamp ....................89
Front Washer Pump Motor ..................................102
Front Wiper and Washer Switch ..........................100
Front Wiper Cut Out Relay ....................................98
Front Wiper High Speed Relay ..............................98
Front Wiper Low Speed Relay ..............................99
Front Wiper Motor ...............................................101
Fuel Filter Heater ...................................................48
Fuel Filter Heater Relay ........................................46
Fuel Level Sender .................................................67

G
Grid Heater ............................................................47
Grid Heater Relay ..................................................47

H
Hazard Switch .......................................................85
Heater
Fuel Filter ..........................................................48
Grid ...................................................................47
Water Separator ................................................47
Height Control Switch ............................................53
Height Control/Return-To-Travel Proximity Switch 55
High-Low Beam Switch .........................................85
Hood
Down Relay .....................................................124
Motor ...............................................................125
Switch .............................................................124
Up Relay .........................................................124
Horn .......................................................................90
Horn Relay ............................................................90
Horn Switch ...........................................................85
Hydraulic Filter Restriction Switch .........................72
Hydraulic Oil Temperature Sender ........................72

I
Ignition Switch .......................................................43
Instrument Cluster Connector 1 ............................65
Issued 8-06

Printed in U.S.A.

4002-184
Instrument Cluster Connector 2 .............................71
Intermediate Speed Sensor ...................................63

L
Lamp
Dome .................................................................79
High Beam ..................................................88, 89
Left Hand Front Combination ............................88
Left Hand Front Work ........................................79
Left Hand Rear Combination (Europe Only) .....95
Left Hand Rear Combination (North America Only)
............................................................94
Left Hand Rear Work ........................................80
License Plate (Europe Only) .............................96
License Plate (North America Only) ..................95
Low Beam ...................................................88, 89
Position .......................................................88, 89
Right Hand Front Combination ..........................89
Right Hand Front Work .....................................80
Right Hand Rear Combination (Europe Only) ...93
Right Hand Rear Combination (North America
Only) ...................................................92
Right Hand Rear Work ......................................80
Switch, Driving ..................................................86
Turn .............................................................88, 89
Left Hand Front Combination Lamp ......................88
Left Hand Front Work Lamp ..................................79
Left Hand Rear Combination Lamp (Europe Only) 95
Left Hand Rear Combination Lamp (North America
Only) .........................................................94
Left Hand Rear Work Lamp ...................................80
Left Speaker ........................................................112
License Plate Lamp .........................................95, 96
License Plate Lamp (Europe Only) ........................96
License Plate Lamp (North America Only) ............95
Lights Diodes .........................................................81
Locating Components on the Schematic Posters ..38

M
Magnetic Detents ...................................................54
Master Disconnect Switch .....................................42
Module
Flasher ..............................................................84
Secondary Steering .........................................106
Time Delay ........................................................42
Transmission Electronic Control .......................63
Motor
Hood ................................................................125
Starter ...............................................................43

N
Neutral Start Relay ................................................44

O
Outlet, Power .......................................................111
Output Speed Sensor ............................................63
Bur 5-2750

P
Parking Brake Relay .............................................. 66
Parking Brake Solenoid ......................................... 67
Parking Brake Switch ............................................ 73
Pilot Control Relay ................................................. 55
Pilot Control Switch ............................................... 60
Pilot Pressure Solenoid ......................................... 56
Pin Engage Solenoid ............................................. 56
Pin Engage Switch ................................................ 56
Potentiometer
Throttle .............................................................. 50
Power Converter (24 volts to 12 volts) ................111
Power Outlet ........................................................111
Power Relay Module
A Ignition Power ................................................ 46
B Ignition Power ................................................ 46
C Fuel Filter Heater ........................................... 46
D Accessory Power ........................................... 48
E Power Converter 24V to 12V .......................111
Proximity Switch
Height Control/Return-To-Travel .......................55
Return-To-Dig ................................................... 54

R
Radiator Coolant Temperature Sender ................. 68
Radio
12 Volt .............................................................112
Rear
Left Hand Combination Lamp (Europe Only) .... 95
Left Hand Combination Lamp (North America
Only) .................................................. 94
Left Hand Work Lamp ....................................... 80
Right Hand Combination Lamp (Europe Only) . 93
Right Hand Combination Lamp (North America
Only) .................................................. 92
Right Hand Work Lamp ..................................... 80
Rear Washer Pump Motor ...................................102
Rear Wiper and Washer Switch ............................ 99
Rear Wiper Motor ................................................102
Redundant Brake Pressure Switch 1 .................... 73
Redundant Brake Pressure Switch 2 .................... 73
Relay
Backup Alarm ....................................................76
Brake Lamps ..................................................... 83
Compressor Clutch .........................................114
Crank Control ....................................................41
Crank Request .................................................. 41
Fan Reverse ..................................................... 59
Front Wiper Cut Out .......................................... 98
Front Wiper High Speed ................................... 98
Front Wiper Low Speed .................................... 99
Fuel Filter Heater .............................................. 46
Grid Heater ....................................................... 47
Hood Down .....................................................124
Hood Up ..........................................................124
Horn .................................................................. 90
Neutral Start ...................................................... 44
Issued 8-06

Printed in U.S.A.

4002-185
Parking Brake ....................................................66
Pilot Control .......................................................55
Power Relay Module A Ignition Power ..............46
Power Relay Module B Ignition Power ..............46
Power Relay Module C Water Separator Htr ....46
Power Relay Module D Accessory Power .........48
Power Relay Module E Power Converter ........111
Ride Control ......................................................58
Starting ..............................................................40
Voltmeter ...........................................................44
Resistor
Alternator ...........................................................40
Return to Dig Switch Switch ..................................55
Return-To-Dig Proximity Switch ............................54
Return-To-Travel/Float Switch ...............................53
Ride Control Relay ................................................58
Ride Control Solenoid ............................................60
Ride Control Switch ...............................................58
Right Hand Front Combination Lamp ....................89
Right Hand Front Work Lamp ................................80
Right Hand Rear Combination Lamp (Europe Only) .
93
Right Hand Rear Combination Lamp (North America
Only) .........................................................92
Right Hand Rear Work Lamp ................................80
Right Speaker ......................................................112
Rollback Jumper ....................................................61
Rollback Pressure Switch ......................................60
Rotating Beacon (Option) ......................................78

S
Seat Compressor and Switch ..............................114
Secondary Steering
Module ............................................................106
Motor ...............................................................107
Pressure Switch ..............................................107
Solenoid ..........................................................105
Secondary Steering Diodes .................................105
Sender
Coolant Level ....................................................74
Fuel Level ..........................................................67
Hydraulic Oil Temperature ................................72
Radiator Coolant Temperature ..........................68
Torque Converter Output Temperature .............63
Sensor
Engine Speed ....................................................63
Intermediate Speed ...........................................63
Output Speed ....................................................63
Transmission Solenoid Valve and Temperature ...
63
Turbine Speed ...................................................63
Water In Fuel .....................................................50
Shifter, Transmission .............................................63
Solenoid
Fan PWM ..........................................................61
Fan Reversing ...................................................61
Parking Brake ....................................................67
Bur 5-2750

Pilot Pressure ....................................................56


Pin Engage .......................................................56
Ride Control ......................................................60
Secondary Steering .........................................105
Speaker
Left ..................................................................112
Right ................................................................112
Specifications ..........................................................7
Speed Resistors
Blower Motor ...................................................120
Starter Motor .........................................................43
Starting Relay ........................................................40
Steering
Secondary, Module .........................................106
Secondary, Motor ............................................107
Secondary, Pressure Switch ...........................107
Secondary, Solenoid .......................................105
Switch
A/C High/Low Pressure ...................................115
Air Filter Restriction ...........................................67
Back-up Alarm Disable ......................................76
Beacon ..............................................................79
Blower .............................................................121
Brake Lamp Pressure .......................................83
Brake Warning Pressure ...................................68
Declutch ............................................................63
Declutch Brake ..................................................63
Door ..................................................................78
Driving Lamp .....................................................86
Fan Reversing ...................................................59
Filter Maintenance .............................................63
FNR for Joystick Controls .................................63
FNR for Single Axis Controls ............................63
Front Wiper and Washer .................................100
Hazard ..............................................................85
Height Control ...................................................53
High-Low Beam .................................................85
Hood ...............................................................124
Horn ..................................................................85
Hydraulic Filter Restriction ................................72
Ignition ..............................................................43
Master Disconnect ............................................42
Pad ....................................................................70
Parking Brake ....................................................73
Pilot Control Switch ...........................................60
Pin Engage .......................................................56
Proximity, Height Control/Return-To-Travel ......55
Proximity, Return-To-Dig ...................................54
Rear Wiper and Washer ....................................99
Redundant Brake Pressure 1 ............................73
Redundant Brake Pressure 2 ............................73
Return to Dig .....................................................55
Return-To-Travel/Float ......................................53
Ride Control ......................................................58
Rollback Pressure .............................................60
Seat Compressor ............................................114
Secondary Steering Pressure .........................107
Issued 8-06

Printed in U.S.A.

4002-186
Transmission Auto ............................................63
Transmission Enable .........................................63
Transmission Kick-down ...................................63
Turn Signal ........................................................85
Work Lamps ......................................................78
Switch Pad .............................................................70

T
Thermal Fuse
Blower Motor ...................................................120
Throttle Potentiometer ...........................................50
Time Delay Module ................................................42
Torque Converter Output Temperature Sender ....63
Transmission Auto Switch .....................................63
Transmission Electronic Control Module ...............63
Transmission Enable Switch .................................63
Transmission Kick-down Switch ............................63
Transmission Shifter ..............................................63
Transmission Solenoid Valve and Temperature Sensors ...........................................................63
Turbine Speed Sensor ...........................................63
Turn Signal Switch .................................................85

U
Understanding the Troubleshooting Tables ...........38

V
Voltmeter Relay .....................................................44

W
Warning Buzzer .....................................................66
Water In Fuel Sensor .............................................50
Water Separator
Heater ...............................................................47
Heater Relay .....................................................46
Wiper
Front Cut Out Relay ..........................................98
Front Motor ......................................................101
Front Switch ....................................................100
Front Washer Pump Motor ..............................102
Front Washer Switch .......................................100
Front Wiper High Speed Relay .........................98
Front Wiper Low Speed Relay ..........................99
Rear Motor ......................................................102
Rear Switch .......................................................99
Rear Washer Pump Motor ..............................102
Rear Washer Switch .........................................99
Wiper Diodes .......................................................103
Wire Identification ....................................................8
Work Lamp Switch .................................................78

Bur 5-2750

Issued 8-06

Printed in U.S.A.

4003

Section
4003
BATTERIES

CNH America LLC.


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

Bur 6-42330

Copyright 2003 CNH Ameica LLC.


All rights reserved.
Printed in U.S.A.
Issued April, 2003

4003-2

TABLE OF CONTENTS
SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrolyte Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspecting and Cleaning a Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BATTERY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Visual Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specific Gravity Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capacity (Load) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHARGING A BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charging Guide For Maintenance Free Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charging Guide For Batteries Other Than Maintenance Free Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PREPARING A DRY CHARGED BATTERY FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 6-42330

Issued 4-03

3
3
4
4
4
5
5
5
6
7
7
8
8

Printed in U.S.A.

4003-3

SAFETY RULES
WARNING: Never try to charge the battery if
the electrolyte in the battery is frozen.
47-83A

WARNING: Never cause sparks to occur or


smoke near batteries that are charging or
have been recently charged.
13-8A

WARNING: Disconnect the ground cable


first when the battery cables are
disconnected from the battery.
Connect the ground cable last when the
battery cables are connected to the battery.
47-55A

WARNING: Some
batteries
have
a
ventilation tube. If there is battery acid in the
ventilation tube, this battery acid can be
released when the battery is turned upside
down. If you turn the battery upside down,
make sure that the end of the ventilation tube
is away from you and away from any other
people in the area. Battery acid can cause
severe burns.

WARNING: Battery acid causes severe


burns. Batteries contain sulfuric acid. Avoid
contact with skin, eyes, or clothing. Antidote:
EXTERNAL-Flush
with
water.
INTERNAL-Drink large quantities of water or
milk. Follow with milk of magnesia, beaten
egg, or vegetable oil. Call physician
immediately. Eyes: Flush with water for 15
minutes and get prompt medical attention.
Batteries produce explosive gases. Keep
sparks, flame, and cigarettes away. Ventilate
when charging or using in enclosed area.
Always shield eyes when working near
batteries.
Keep out of reach of children.
D-47-53A

48-57B

SPECIAL TOOLS

B795328

The CAS10147 tester is used to do the Capacity


(Load) Test. This tool is first used on Page 6.

Bur 6-42330

Issued 4-03

Printed in U.S.A.

4003-4

MAINTENANCE
Electrolyte Level

Inspecting and Cleaning a Battery

If the battery is a maintenance free battery, check the


level of the electrolyte every 1000 hours of operation
or six months, whichever occurs first. For all other
batteries, check the level of the electrolyte every 250
hours of operation.

If damage causes an electrolyte leak, replace the


battery.

NOTE: A maintenance free battery will have the


words Maintenance Free on the decal on the top of
the battery. If the center part of the decal has been
removed for access to the battery caps, it is possible
that the words Maintenance Free have been removed
from the decal.
Check the level of the electrolyte more often during
hot weather. The use of a large amount of water by
the batter y can be caused by high batter y
temperature or a voltage regulator setting that is too
high. Keep the electrolyte level above the top of the
plates in the battery at all times to prevent damage to
the battery.
NOTE: On maintenance free batteries it is
necessary to remove the center part of the decal for
access to the battery caps. Do not discard the center
part of the decal. Install the center part of the decal
after the battery caps have been installed.

Inspect the battery at regular intervals for dir t,


corrosion, and damage. Electrolyte and dirt on the
top of the battery can cause the battery to discharge
by making a passage for the current to flow.
If the battery must be cleaned, remove the battery
from the battery carrier and clean the battery, cable
terminals, and the battery carrier. When available,
use Case Battery Saver and Cleaner according to
the instructions on the container. Case Battery Saver
and Cleaner also helps prevent corrosion. If Case
Battery Saver and Cleaner is not available, use
baking soda and water as a cleaner. DO NOT permit
any type of cleaner to enter the cells of the battery.
Install the battery in the machine and make sure the
fasteners are tight. Apply Case Battery Saver and
Cleaner or Urethane Seal Coat to the cable terminals
to prevent corrosion. See the Parts Counter Catalog.
DO NOT apply grease.

If the level of the electrolyte is low, add distilled water


or other clean water until the electrolyte is just below
the cell opening. Do not add more water than is
n e e d e d . To o m u c h w a t e r c a n c a u s e b a d
performance, a short service life, and corrosion
around the battery.
NOTE: Add water only. DO NOT add electrolyte.

Bur 6-42330

Issued 4-03

Printed in U.S.A.

4003-5

BATTERY TEST
NOTE: To correctly test a battery, do each part of the
battery test until you know the condition of the
battery.

Visual Checks
1. Make sure the cable connections are clean and
tight. Clean foreign material from the top of the
battery.
2. Inspect the battery case, battery posts, and
cables for damage.
3. Check the electrolyte level. See Page 4.
4. If you added water to the battery, the battery
must be charged for 15 minutes at 15 to 25
amperes to mix the water with the electrolyte.

Specific Gravity Check


A hydrometer is used to check the specific gravity
(weight) of the electrolyte. The specific gravity is an
indication of the level of charge for each cell.
Hydrometers are made to show the correct specific
gravity when the temperature of the electrolyte is
26.7C (80F).
When you check the specific gravity, you must know
the temperature of the electrolyte. If your hydrometer
does not have a thermometer, get a thermometer to
check the temperature of the electrolyte. The
thermometer must indicate a high temperature of at
least 52C (120F).
1. Remove enough electrolyte from a cell so that
the float is free in the tube.
NOTE: If the specific gravity cannot be checked
without first adding water to the cell, the battery must
be charged for 15 minutes at 15 to 25 amperes to mix
the water with the electrolyte. Then check the specific
gravity.
2. Read the float.
3. Read the thermometer. If the reading is above
26.7C (80F) add specific gravity points to the
reading for specific gravity. If the reading is below
26.5C (80F) subtract specific gravity points
from the reading for specific gravity. See the
following illustration and add or subtract specific
gravity points as needed.

B790863

1. TEMPERATURE IN F

2. TEMPERATURE IN C

SPECIFIC GRAVITY CHART

4. Make a record of the corrected specific gravity


reading for each cell.
5. If the difference between the high reading and
the low reading is 0.050 or more, charge the
battery and check the specific gravity again. If
after charging, the difference is still 0.050 or
more, install a new battery.
6. The corrected specific gravity reading shows the
level of charge for the cell. The level of charge
must be at least 75% in each of the cells. ln
maintenance free batteries the level of charge is
at least 75% if the corrected specific gravity
reading is 1.240 or higher. In all other batteries
the level of charge is at least 75% if the corrected
specific gravity reading is 1.230 or higher.
7. If the difference between the high reading and
the low reading is less than 0.050, and the level
of charge is at least 75% in all of the cells, do the
Capacity (Load) Test.
8. If the difference between the high reading and
the low reading is less than 0.050, but the level of
charge is less than 75% in any of the cells,
charge the battery and check the specific gravity
again. If after charging:
A. The level of charge is less than 75% in any of
the cells, discard the battery.
B. The level of charge is at least 75% in all of the
cells, do the Capacity (Load) Test.

Bur 6-42330

Issued 4-03

Printed in U.S.A.

4003-6

Capacity (Load) Test


This test can be done using a variable load tester
s u c h a s t h e S u n E l e c t r i c VAT- 3 3 . O t h e r t e s t
equipment can be used. Connect the test equipment
according to the instructions of the manufacturer of
the equipment.
1. The level of charge of the battery must be at
least 75%. Do the Specific Gravity Check in this
section.
2. Prepare the tester (Sun Electric VAT-33 shown)
for the test.
A. Select the voltmeter range that will measure 1
to 18 volts.
B. Make sure the load control knob is in the OFF
position.
C. Select the ammeter range that will measure 0
to 1000 amperes.
D. Move the volt lead switch to the NT. position.
3. Connect the tester to the battery as shown.

NOTE: Never apply a load for longer than 15


seconds. After each 15 seconds, turn the load control
knob to OFF for at least one minute.
4. Apply a 15 ampere load to the battery for 15
seconds. Wait at least three minutes before
applying the load again.
5. Check and make a record of the temperature of
the electrolyte.
6. Find the correct load for this test in Specifications
in Section 4001.
NOTE: The correct load is half of the cold cranking
amperes at -17C (0F).
7. Turn the load control knob until the ammeter
indicates the specified load. Keep the load for 15
seconds and read the voltmeter. Turn the load
control knob to OFF.
8. Compare the test reading and the temperature of
the electrolyte to the chart below.
Temperature of . . . . . . . . . . . . . . . Minimum Voltage
electrolyte
21C (70F) and above . . . . . . . . . . . . . . . . . . . . 9.6
16C (60F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
10C (50F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
4C (40F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
-1C (30F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
-7C (20F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9
-12C (10F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7
-18C (0F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
A. If the test result is equal to or more than the
vo l t a g e s h o w n , t h e b a t t e r y i s i n g o o d
condition.
B. If the test result is less than the voltage
shown, discard the battery.

B790499

1. LOAD CONTROL KNOB

Bur 6-42330

2. AMMETER CLAMP (TIP OF


ARROW AWAY FROM
BATTERY)

Issued 4-03

Printed in U.S.A.

4003-7

CHARGING A BATTERY
The charging rate must be decreased if:
WARNING: Never try to charge the battery if
the electrolyte in the battery is frozen.
47-83

1. Too much gas causes the electrolyte to flow from


the cells.

Before you charge the battery, check the level of the


electrolyte.

2. The temperature of the electrolyte rises above


52C (125F).

It is difficult to give an exact charging rate because of


the following variable conditions: (1) temperature of
the electrolyte, (2) level of charge, and (3) condition
of the battery. Use the charging guide for the correct
charging rate and time.

NOTE: For the best charge, use the slow charging


rates.
The battery is fully charged when, over a three hour
period at a low charging rate, no cell is giving too
much gas, and the specific gravity does not change.

See Specifications in Section 4001 for the reserve


capacity of the battery in this machine.

Charging Guide For Maintenance Free Batteries


Recommended Rate* and Time for Fully Discharged Battery
Battery Capacity - See
Reserve Capacity under
Specifications

Slow Charge

Fast Charge

10 Hours at 5 Amperes
5 Hours at 10 Amperes

2.5 Hours at 20 Amperes


1.5 Hours at 30 Amperes

Above 80 to 125 Minutes

15 Hours at 5 Amperes
7.5 Hours at 10 Amperes

3.75 Hours at 20 Amperes


1 .5 Hours at 50 Amperes

Above 125 to 170 Minutes

20 Hours at 5 Amperes
10 Hours at 10 Amperes

5 Hours at 20 Amperes
2 Hours at 50 Amperes

Above 170 to 250 Minutes

30 Hours at 5 Amperes
15 Hours at 10 Amperes

7.5 Hours at 20 Amperes


3 Hours at 50 Amperes

80 Minutes or Less

*lnitial rate for standard taper charger.

NOTE: A maintenance free battery will have the words Maintenance Free on the decal on the top of the battery. If
the center part of the decal has been removed to get access to the battery caps, it is possible the words
Maintenance Free will have been removed from the decal.
Continued on next page

Bur 6-42330

Issued 4-03

Printed in U.S.A.

4003-8

Charging Guide For Batteries Other Than Maintenance Free


Batteries
Recommended Rate* and Time for Fully Discharged Battery

Battery Capacity - See


Reserve Capacity under
Specifications

Slow Charge

Fast Charge

10 Hours at 5 Amperes
5 Hours at 10 Amperes

2.5 Hours at 20 Amperes


1.5 Hours at 30 Amperes

Above 80 to 125 Minutes

15 Hours at 5 Amperes
7.5 Hours at 10 Amperes

3.75 Hours at 20 Amperes


1 .5 Hours at 50 Amperes

Above 125 to 170 Minutes

20 Hours at 5 Amperes
10 Hours at 10 Amperes

5 Hours at 20 Amperes
2 Hours at 50 Amperes

Above 170 to 250 Minutes

30 Hours at 5 Amperes
15 Hours at 10 Amperes

7.5 Hours at 20 Amperes


3 Hours at 50 Amperes

Above 250 Minutes

24 Hours at 10 Amperes

6 Hours at 40 Amperes
4 Hours at 60 Amperes

80 Minutes or Less

*lnitial rate for standard taper charger.

PREPARING A DRY CHARGED BATTERY FOR USE


1. Remove the caps from the battery.
2. Fill each cell to the top of the separators with
electrolyte. This will per mit the volume of
electrolyte to increase when heated by charging
the battery.
3. Install the caps on the battery.

5. Charge the battery at 30 amperes until the


spe cific gravity is 1 .25 0 or m ore a nd the
temperature of the electrolyte is at least 15.5C
(60F).
6. If necessary, fill each cell with electrolyte until the
electrolyte is just below split ring at the bottom of
the cell opening.

4. Connect a battery charger to the battery.

Bur 6-42330

Issued 4-03

Printed in U.S.A.

Section
4005

4005

INSTRUMENT CLUSTER

CNH America LLC.


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

Bur 5-2760

Copyright 2006 CNH Ameica LLC.


All rights reserved.
Printed in U.S.A.
Issued August, 2006

4005-2

TABLE OF CONTENTS
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Self-Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LCD Multi-function Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Navigating Through The LCD Multi-function Display Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Entering The Service Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Select Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hardware Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Software Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting Power Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Language Screen, Measurement Units, and Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Options Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Display Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MPH/KPH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RETRIEVING FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Fault Code Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault Code Grouping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VEHICLE FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUMENT CLUSTER FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 5-2760

Issued 8-06

3
4
4
5
6
9
10
10
10
10
11
13
13
13
13
13
14
14
14
15
17
27
32

Printed in U.S.A.

4005-3

INSTRUMENT CLUSTER

10

11

15
14

12

13

BD06H039

1.
2.
3.
4.
5.
6.
7.
8.

LOW BRAKE PRESSURE INDICATOR


HIGH BEAM INDICATOR
TRANSMISSION OIL TEMPERATURE GAUGE
CAUTION MASTER INDICATOR
MULTI FUNCTION LCD DISPLAY
STOP MASTER INDICATOR
HYDRAULIC OIL TEMPERATURE GAUGE
WAIT TO START ENGINE PREHEAT

9.
10.
11.
12.
13.
14.
15.

LACK OF AUX STEER PRESSURE (OPTIONAL)


PARKING BRAKE INDICATOR
RIGHT TURN INDICATOR
FUEL LEVEL GAUGE
FUEL LEVEL AT MINIMUM
ENGINE COOLANT TEMPERATURE GAUGE
LEFT TURN INDICATOR

The instrument cluster monitors a number of functions and can be tailored to fit the operators preferences The
instrument cluster not only monitors machine functions, it warns the operator when caution is needed due to a
possible malfunction and when immediate action is needed due to a possible critical malfunction. When the
machine is started, the instrument cluster will perform the following self-test:

Bur 5-2760

Issued 8-06

Printed in U.S.A.

4005-4

Self-Test
1. Turn the ignition (key) switch to the ON position.
2. The instrument cluster will automatically check
each monitored system.
3. All LEDs (Light Emitting Diodes) will illuminate
for 2 - 3 seconds.
4. Four gauges will energize for 2 - 3 seconds.
5. The warning alarm will sound for 2 - 3 seconds.

Power Circuit Test


A. Check fuse ECA-F3. If the fuse is bad, replace
the fuse and repeat Self-Test. If the fuse is
good, go to next step.
B. Check
wire
19EA
for
continuity.
Repair/r eplace the wire as required. If
continuity is found go to next step.
C. Check power relay module A for proper
operation, see Section 4002. If the power
relay module checks good, go to next step.

6. If there is an open circuit between a sensor and


the instrument cluster, the LED will flash and the
warning alarm will sound for 5 seconds.

D. Check the ignition switch for proper operation,


see Section 4002. If the ignition switch checks
good, go to next step.

7. If there were no faults detected during the check,


all monitored systems will return to normal
operation.

E. Check fuse ECC-F5. If the fuse is bad, replace


the fuse.

8. If only some of the LEDs illuminate, replace the


instrument cluster.
9. If the LEDs illuminate, but the warning alarm
does not sound, see section 4002 and test the
alarm circuit.
10. If the warning alarm sounds but the LEDs do not
illuminate, if no power is present at buzzer,
replace the instrument cluster, if power is present
at the buzzer, replace the buzzer.
11. If the warning alarm does not sound and the
LEDs do not illuminate on the instrument cluster,
do the following steps to test the power circuit:

Bur 5-2760

Issued 8-06

Printed in U.S.A.

4005-5

LCD Multi-function Display

2. This example, shows that the Transmission


Control Lever is in Neutral. The display will show
Forward, Neutral, or Reverse, depending on
where the Directional Control Lever is
positioned.
NOTE: Forward and Reverse will blink if the
transmission clutches are disconnected.
3. This example shows the maximum gear allowed
when in Automatic mode. If display is blank the
Manual mode has been selected.
4. This example shows the current transmission
mode that has been selected.
A. If the Transmission is operating normally it will
display either
BD06J132

The LCD Multi-Function Display is located at the


center of the modular dashboard. On start up the
cluster will flash the instructional lamps and the LCD
Multi-Display will display, CASE, with the machine
model and current hour reading.

1
3

A - Automatic

M - Manual operation.

B. If the Transmission is not operating normally


the display will show

C - Substitute Clutch.

L - Limp Home.

S - Transmission Shutdown.

U - TCU Shutdown.

5. This example (not displayed) will show the


transmission clutches disengaged, if the Park
Brake is OFF.
6. This example shows the Power Boost Status.

7
BD06F185

MAX - Maximum Power.

STD - Normal/Standard mode of Operation.

AUTO - Switches automatically


Maximum and Standard Power.

ECO - Limited Power for fuel efficiency.

between

7. This example will show the Time in either 12


hour or 24 hour.

LCD MULTI-FUNCTION DISPLAY

Information will be displayed in different zones on the


LCD, as directed by the operator or machine. In
most situations the operator or technician will be
given specific information to follow if conditions are
not correct.
1. In the example, above, the machine hours are
d i s p laye d . M a c h i n e h o u r s w i l l a l way s b e
displayed briefly, on start up. After, the machine
is started, the display will show engine rpms.
After, beginning travel, the machine will display
travel speed, if default settings were not changed
by the operator.

Bur 5-2760

Issued 8-06

Printed in U.S.A.

4005-6

Navigating Through The LCD


Multi-function Display Screens

Using The Arrow Keys


At any time, during operation or with the key switch
on, the operator may scroll through three information
screens and two trip screens by using the arrow
keys. These five screens are in a circular loop and
may be reached by pressing the up or down key. The
following sequence is using the down key only.

NOTE: Pressing the escape key will return the LCD


back to the normal driving screen.

D
BD06F186

Located on the steering column, just to the left of the


Park Switch, is the key pad. Use this key pad to
move from one screen to another, choose various
selections, monitor the machine functions, and
retrieve information. All functions can be accessed in
the same basic manner.
A. Escape key: Use this key to exit and return to
the driving screen. Use this key anytime you
would like to start over and begin again, plus
use to check active, acknowledge errors.

BD06F188

From the driving screen push the down arrow, as


shown.

B. Enter key: Use this key to confirm, yes, this is


the desired function.
C. Up arrow key: Use this key to scroll up to
selections.
D. Down arrow key: Use this key to scroll down
to selections.
NOTE: Arrows on the screen will indicate if
selections are up or down from the current selection.
NOTE: Display units can be changed by the
operator.
BD06F183

Info 1 is the first information screen using the down


arrow from the driving screen. It displays engine
RPMs, speed, fuel level, and the voltage level.

Bur 5-2760

Issued 8-06

Printed in U.S.A.

4005-7

BD06F169

BD06F027

Info 2 will be displayed next. The Info 2 screen will


display coolant temperature, turbocharger air
temperature, engine oil temperature in either
Fahrenheit or Celsius, as well as oil pressure PSI.

Press the down button again and the Trip 1 screen


will display. The LCD provides two trip computers.
These will display since last reset the total time in
h o u r s , t h e t o t a l f u e l , a n d t h e a ve r a g e f u e l
consumption per hour.

BD06F170
BD06F184

Push the down button again and the Info 3 screen.


This screen displays the temperature in Fahrenheit
or Celsius of the transmission oil, hydraulic oil, sump
oil, and radiator coolant temperature.

Bur 5-2760

By continuing to scroll down, the fifth screen will


display the Trip 2 screen. Trip 1 and Trip 2 screens
can be reset independently. The previous screen can
be accessed by using the up arrow key.

Issued 8-06

Printed in U.S.A.

4005-8

Reset The Trip Information

BD06F172
BD06F170

Highlight the trip screen you wish to set.

The trip screen will indicate a reset message. At this


screen, press confirm to clear the numbers and reset
the trip information. The current date and time will
display automatically. The hours, fuel consumption,
and fuel used per hour will reset and revert to zero.

BD06F187

Press the confirm button to reset the trip selection to


zero.

Bur 5-2760

Issued 8-06

Printed in U.S.A.

4005-9

Entering The Service Screens


After the machine has been started or the key switch has been turned to on the operator or service technican may
use this service menu to adjust machine configurations to working conditions, test components, view faults that
may have occurred, or select preferences.
NOTE: When all the selections have been made they will be stored in memory. If there is an abrupt battery
disconnect you may loose all of your selections and need to reprogram the LCD Multi-function display.

BD06H038 / BD06F188

Press and hold the confirmation button for two seconds to arrive at the above service screen. Use down arrow to
scroll through the menus.
Items and selections in this menu are:
1. Power Mode Menu

Month

Year

Max - Maximum power possible

Standard - Standard operation

Part Number

Auto - Will cycle between Max and Standard

Serial Number

Eco - Limited power for economy

ID

Version

2. Preferences Menu

6. Cluster H/W

Language - English, Italian, French, Spanish,


Portuguese, German

Part Number

Units - Metric, English or Imperial

Loader Version

Clock - 24 or 12 hour

ID

Version

3. Options Menu

7. Cluster S/W

Fan Auto - manual or automatic

Idle Auto - manual or automatic

Change Model *

Show RPM

Select Tires (Select tire sizes)

Show MPH/KPH

Clutch Calibration (calibrate gear box)*

4. Display Menu

8. Config Menu

Gear Limits (choose maximum gear)

Day Display

Park Brake (Park brake test)

Day LED

Cold Start (choose cold start system)

Night Display

FAN Test (sound level)

Night LED

Special

5. Clock Menu

Hour

Minute

Day

Bur 5-2760

- Reset Error
- Factory Set

Issued 8-06

Printed in U.S.A.

4005-10
* The tests in the configuration menu should be
performed only by a qualified operator or technician,
as some tests require the engine to be running at
high RPMs.

Software Screen

Select Screen
The select screen will allow you to make time
s e t t i n g s a s w e l l a s g i ve a c c e s s t o m a c h i n e
information. Navigate this screen also by highlighting
your selection and pressing confirm. This will allow
you to change clock settings or view the hardware
and software screens. No operator changes can be
made to the hardware or software screens.
BD06H028

The cluster software selection will display the CNH


part number, serial number, ID number and software
version of the Instrument cluster. This display is a
convenient source of information when ordering parts
or accessories. Press escape to exit from this field
and return to the selection menu or use the up or
down arrow key to toggle to the software information
screen.

Selecting Power Modes


BS06F177

Hardware Screen
Scroll to the hardware selection and press confirm to
display machine information.

The power mode allows the operator to choose the


most effective machine power for the current job
conditions. Most commonly auto is chosen, as the
power will automatically increase or decrease
between maximum power and standard power while
the machine is working. This allows for maximum
power if necessary, but will switch to standard mode
for economy. Maximum power can be chosen for
more severe work conditions. Economy can be
chosen for limited power and fuel efficiency.
Press and hold the confirmation button for two
seconds to arrive at the service screen.

BD106F193

The cluster hardware selection will display the CNH


part number, serial number, ID number and version
of the Instrument cluster. This display is a convenient
source of infor mation when ordering par ts or
accessories. Press escape to exit from this field and
return to the selection menu or use the up or down
arrow key to toggle to the software information
screen.

Bur 5-2760

BD06H038

At the screen shown above, highlight the power


mode and press the confirmation button to move to
the Power Mode Selection Menu.

Issued 8-06

Printed in U.S.A.

4005-11

Preferences

BD06F178

At the Power Mode Menu press the confirmation


bu t t o n a g a i n t o a c t i va t e t h e s e l e c t i o n s. T h e
highlighted section will flash to indicate a new
selection can be made.
Press the up or down button to select the Power
Mode, and then press the confirmation button again.
This changes the mode and locks it into memory.
The selected mode will display in zone 3 (bottom) of
the Multi-Function Display when power mode is
correctly selected.
NOTE: Selecting options and navigating through the
screen menus are the same for all functions. The
display will tell the operator if errors have occurred.

BD06F179

Language Screen, Measurement Units,


and Clock
The LCD screen can be set with language, units, and
clock preferences. Use the arrow keys to scroll to the
preferences menu. Press confirm.
Choose the preferences desired, language in
(English, Italian, Spanish, Portuguese, German,
French, measurement units in English, Metric, or
Imperial and clock units in either 12 or 24 hour).
Highlight the preference you wish to change and
press the confirm key. The preference will flash and
allow you to scroll through the choices. When the
correct preference is chosen, use the confirm key to
lock in the preference for the display. The escape
key will allow you to leave this application.

BD06F176

S h o u l d a n e r r o r m e s s a g e d i s p l ay, p r e s s t h e
confirmation button to acknowledge and begin again.

Bur 5-2760

Issued 8-06

Printed in U.S.A.

4005-12

Clutch Calibration
After warming the oil temperature:
1. Park the machine on a firm level surface.
2. Place the
NEUTRAL.

Transmission

Control

Lever

in

3. Set the Park Brake.


4. With the engine running, at idle, enter the
Service Screen Menu and scroll to Config.

BD06F196

If, conditions are not correct, an error message will


appear and guide the operator or technican.
There are six, if conditions not met, screens:

BD06F202

Use the confirm and arrow button to scroll to the


screen shown above. At this screen push the confirm
button again.

Not in neutral

Park Brake OFF

Machine moving

Oil temp too low

Oil temp too high

Engine RPM low

Engine RPM high

If conditions are correct the operator or technican will


see six calibration screens pass. They will display in
this order:

Adjust K1

Adjust K2

Adjust K3

Adjust K4

Adjust KV

Adjust KR

Once the process is completed this screen will direct


the operator or technican to shut the engine OFF and
then re-start.
BD06F195

This screen will prompt the operator or technican to


confirm or escape.

Bur 5-2760

If the process is not completed the operator or


technican will be prompted to escape.

Issued 8-06

Printed in U.S.A.

4005-13

Auto Idle
Idling can be changed from automatic to a fixed rate.
The fixed idle rate is defined as Standard Idle at 900
RPM. Highlight the auto idle selection by using the
arrow keys, then press confirm. When you have
chosen the selection, lock the selection into memory
by pressing the confirm key.

Display Menu

BD06F174

Options Menu
Use the arrow keys to choose the options menu.
Press the confirm key, and the options sub-menu will
appear. The options menu will allow the operator to
choose options for the fan, idle.

Fan Auto
The fan can be set to run at automatic or the fan will
run at maximum speed. Automatic is the more
common or preferred setting. It will switch between
high speed, low speed, or reverse as conditions
require depending on actual temperature of the
coolant, turbocharger air, transmission oil, and
hydraulic oil.

The display menu can be used to change the


background and brightness of the screen. Use the
arrow keys to make your selection from the display
menu and press the confirm key to lock the selection
into memory. The screen display can be changed to
suit working conditions for day and night separately.

RPM
Engine speed in RPM will show on the display if the
engine speed is running up to 550 RPMs, and will
disappear if the engine speed is lower than 300
RPM.

MPH/KPH
Vehicle speed will show on the display if it is up to 1.0
MPH / 1.5 KPH and will disappear if the vehicle
speed is less than 0.6 MPH / 1.0 KPH.

The operator can choose fan speed or reversing


capabilities. Highlight the fan auto selection by using
the arrow keys, then press confirm. When you have
chosen the selection, lock the selection into memory
by pressing the confirm key.

Bur 5-2760

Issued 8-06

Printed in U.S.A.

4005-14

RETRIEVING FAULT CODES


General Fault Code Identification
1. Press and hold the escape key and up arrow key
for more than 2 seconds to access the fault
codes.

Fault Code Grouping


1. 1000 to 1999 vehicle errors.
2. 2000 to 2999 not used.
3. 3000 to 3999 engine errors.
4. 4000 to 4999 transmission errors.

5. 5000 to 5999 eltro-hydraulic system errors.

6. 6000 to 6999 reserved.


7. 7000 to 7999 reserved.
8. 8000 to 8999 optional equipment IE: GPS.
9. 9000 to 9999 internal AIC errors.

D
BD06F186

A. Escape key
B. enter key
C. up key
D. down key
2. Yellow Faults, buzzer will beep once every 2
seconds:
A. Operator can acknowledge it by pressing the
enter key.
B. The message will disappear.
C. Buzzer will not beep anymore.
D. Yellow lamp will stay ON.
E. Fault will remain in Yellow list until it is closed.
3. Red Faults, buzzer
alternating sounds:

will

be

continuous,

A. Operator can acknowledge it by pressing the


enter key.
B. Buzzer will change to a less stressing sound,
but will remain.
C. Message will remain on display with indication
of URGENT STOP.

Bur 5-2760

Issued 8-06

Printed in U.S.A.

4005-15

VEHICLE FAULT CODES


CODE

DEFINITION

POSSIBLE STEPS FOR REPAIR

1310

Hydraulic filter blocked

Change filter

1311

Engine air filter blocked

Change filter

1312

Hydraulic oil temperature above normal

1313

Hydraulic oil temperature to high

1314

Transmission oil temperature above normal

1315

Transmission oil temperature to high

1.
2.
3.
4.

Stop machine operations


Run engine at 1500 rpm
Check fan operation
Check cooling core for clogs

Brake pressure too low

1.
2.
3.
4.

Stop machine operations


Run engine at 1500 rpm
Check brake system pressure
Check brake system for leaks

1317

Steering pressure too low

1.
2.
3.
4.

Stop machine operations


Run engine at 1500 rpm
Check steering system for operation
Check steering system for leaks

1318

Engine coolant temperature above normal

1319

Engine coolant temperature high - critical

1.
2.
3.
4.

Stop machine operations


Run engine at 1500 rpm
Check fan operation
Check radiator core for clogs

1320

Engine oil pressure too low

1321

Engine oil pressure below normal

1. Stop machine operations


2. Check engine oil level
3. Check pressure sender unit

1322

Engine oil pressure above normal

1. Check engine oil for proper type


2. Check pressure sender unit

1323

Battery voltage low

1324

Battery voltage high

1325

Oil temperature too high

1326

Coolant level low

Fill radiator level

1327

Moved during accelerated idle

No information available at time of print.

1328

Moving when shifting to low idle

No information available at time of print.

1331

Electrical charging system voltage low critical level

1332

Water detected in fuel

Drain fuel filter

1333

Engine overspeed

Check engine speeds

1334

Intake manifold temperature high - critical

Check for defective or clogged after cooler

1316

1335

Bur 5-2760

Check charging system

Brake pressure too low

1. Stop machine operations


2. Run engine at 1500 rpm
3. Check sending unit

1. Stop machine operations


2. Check charging system

1.
2.
3.
4.

Stop machine operations


Run engine at 1500 rpm
Check brake system pressure
Check brake system for leaks

Issued 8-06

Printed in U.S.A.

4005-16
CODE
1336

DEFINITION
Transmission oil filter blocked

POSSIBLE STEPS FOR REPAIR


Replace filter

NOTE: The following fault codes are for optional climate controlled heating and air conditioning system.
CODE
1909

1910

1919

1920

1921

Bur 5-2760

DEFINITION
Open circuit evaporator temperature sensor

DESCRIPTION AND POSSIBLE


STEPS FOR REPAIR
AC relay compressor is disabled.

Short circuit evaporator temperature sensor

1. Check sensor for short circuit to ground or


open circuit.
2. Check harness between control module and
relay.

Water valve motor output failure, does not


work correctly

1. Verify if the system controls are functioning


properly when requesting heat or AC.
2. The motor is working in a degraded mode,
replace valve.

Recirculation actuator DC motor output failure,


does not work correctly

1. Turn system on with fan speed on low, verify


position of flap.
2. Place the fan speed on high, check position of
flap.
3. Check harness between controller and flap
motor.

AC relay output failure, does not work.

1. Check for proper connection of relay.


2. Replace relay with known good relay and retest
system.
3. Verify system activation when AC button is
pressed.
4. Check charge level of AC system.

Issued 8-06

Printed in U.S.A.

4005-17

ENGINE FAULT CODES


CODE

DEFINITION

DESCRIPTION AND POSSIBLE


STEPS FOR REPAIR

3001

Foot throttle sensor signal not plausible

Idle switch defect or wiring of idle switch broken


or accelerator pedal defect.
Check wiring, replace idle switch or replace
accelerator pedal.

3002

Foot throttle sensor signal above range max.

Short circuit in wiring or in accelerator pedal.


Check wiring or replace accelerator pedal.

3003

Foot throttle sensor signal below range min.

Short circuit in wiring or in accelerator pedal.


Check wiring or replace accelerator pedal.

3004

Foot throttle sensor - no signal

Check wiring or replace accelerator pedal

3006

Coolant temperature sensor signal not


plausible

See OTS (Oil Temperature Sensor) plausibility


check (Fault 3033)

3007

Coolant temperature sensor signal above


range max.

Sensor defective or short circuit to external


source.
Check wiring or replace sensor.

3008

Coolant temperature sensor signal below


range min.

Sensor defective or short circuit to ground.


Check wiring or replace sensor.

3009

Coolant temperature sensor null (via CAN)

No CAN plausibility check performed, restart


system, if problem reoccurs.
Check wiring or replace sensor.

3015

Fuel temperature signal above range max.

Sensor defective or short circuit to external


source.
Check wiring or replace sensor.

3016

Fuel temperature signal below range min.

Sensor defective or short circuit to ground.


Check wiring or replace sensor.

3019

Boost pressure sensor signal above range


max.

Sensor defective or short circuit to external


source.
Check wiring or replace sensor.

3021

Boost pressure sensor null (via CAN)

No CAN plausibility check performed, restart


system, if problem reoccurs.
Check wiring or replace sensor.

3022

Boost pressure sensor signal not plausible

Difference of ambient and boost pressure is out


of range.
Check wiring or replace sensor.

3023

Atmospheric pressure sensor signal not


plausible

3024

Atmospheric pressure sensor signal above


range max.

3025

Atmospheric pressure sensor signal below


range min.

Bur 5-2760

Ambient pressure sensor inside ECU is defect.


Replace ECU (not necessary if never running in
high altitude and if turbocharger is without VGT)

Issued 8-06

Printed in U.S.A.

4005-18
CODE

DEFINITION

DESCRIPTION AND POSSIBLE


STEPS FOR REPAIR

3028

Oil pressure sensor pressure too low

Inaccurate oil pressure sensor or defect (e.g. too


low oil level, leakage...) in the oil system.
Check oil pressure sensor for accuracy and
check oil system.

3029

Oil pressure sensor short-circuit to battery

Sensor defective or short circuit to external


source.
Check wiring or replace sensor.

3030

Oil pressure sensor short-circuit to ground

Sensor defective or short circuit to ground.


Check wiring or replace sensor.

3031

Oil pressure sensor ADC conversion error

No information available at time of print.

Oil pressure sensor pressure too high

Inaccurate oil pressure sensor or defect (e.g.


blocked piping) in the oil system.
Check oil pressure sensor for accuracy and
check oil system.

3033

Oil temperature sensor signal not plausible

Inaccurate oil or coolant temperature sensors or


insufficient oil or coolant recirculation (low
coolant level etc.).
Check oil and coolant temperature sensor for
accuracy and check oil and coolant system for
proper functioning.

3034

Oil temperature sensor signal above range


max.

Sensor defective or short circuit to external


source.
Check wiring or replace sensor.

3035

Oil temperature sensor signal below range


min.

Sensor defective or short circuit to ground.


Check wiring or replace sensor.

3036

Oil temperature sensor signal CAN


transmission disturbed

No CAN plausibility check performed, restart


system, if problem reoccurs.
Check wiring or replace sensor.

3037

Boost pressure sensor signal low

Sensor defective or short circuit to ground.


Check wiring or replace sensor.

3043

Vehicle speed sensing hardware conversion


error

No information available at time of print.

3046

Vehicle speed sensing signal not plausible

No information available at time of print.

3051

Battery voltage to ECM too high

Alternator voltage governor defect.


Replace alternator governor device or alternator.

Battery voltage to ECM too low

Battery defect, alternator defect, wiring problems


(too high resistance) or ECU defect. Occurrence
possible during cold start.
Replace battery or alternator. Check ECU and
wiring.

Cylinder 1 unclassified error in injector

Depending on the pattern, various reasons can


cause the defect, internal ECU problems also
possible.
Check the wiring and the injection signals,
replace ECU

3032

3052

3060

Bur 5-2760

Issued 8-06

Printed in U.S.A.

4005-19
DESCRIPTION AND POSSIBLE
STEPS FOR REPAIR

CODE

DEFINITION

3061

Cylinder 1 injector cable short-circuit low side


to battery

Short circuit in wiring with external source.


Check the wiring or replace injector

3062

Cylinder 1 signal low

Check the wiring and the injection signals,


replace ECU

3063

Cylinder 1 short-circuit high side to ground

Defective coil of injector.


Check the wiring and replace injector

3064

Cylinder 5 unclassified error in injector

Depending on the pattern, various reasons can


cause the defect, internal ECU problems also
possible.
Check the wiring and the injection signals,
replace ECU

3065

Cylinder 5 injector cable short-circuit low side


to battery

Short circuit in wiring with external source.


Check the wiring or replace injector

3066

Cylinder 5 signal low

Check the wiring and the injection signals,


replace ECU.

3067

Cylinder 5 short-circuit high side to ground

Defective coil of injector.


Check the wiring and replace injector

3068

Cylinder 3 unclassified error in injector

Depending on the pattern, various reasons can


cause the defect, internal ECU problems also
possible.
Check the wiring and the injection signals,
replace ECU

3069

Cylinder 3 injector cable short-circuit low side


to battery

Short circuit in wiring with external source.


Check the wiring or replace injector

3070

Cylinder 3 signal low

Check the wiring and the injection signals,


replace ECU.

3071

Cylinder 3 short-circuit high side to ground

Defective coil of injector.


Check the wiring and replace injector

3072

Cylinder 6 unclassified error in injector

Depending on the pattern, various reasons can


cause the defect, internal ECU problems also
possible.
Check the wiring and the injection signals,
replace ECU

3073

Cylinder 6 injector cable short-circuit low side


to battery

Short circuit in wiring with external source.


Check the wiring or replace injector

3074

Cylinder 6 signal low

Check the wiring and the injection signals,


replace ECU.

3075

Cylinder 6 short-circuit high side to ground

Defective coil of injector.


Check the wiring and replace injector

Cylinder 2 unclassified error in injector

Depending on the pattern, various reasons can


cause the defect, internal ECU problems also
possible.
Check the wiring and the injection signals,
replace ECU

3076

Bur 5-2760

Issued 8-06

Printed in U.S.A.

4005-20
DESCRIPTION AND POSSIBLE
STEPS FOR REPAIR

CODE

DEFINITION

3077

Cylinder 2 injector cable short-circuit low side


to battery

Short circuit in wiring with external source.


Check the wiring or replace injector

3078

Cylinder 2 signal low

Check the wiring and the injection signals,


replace ECU.

3079

Cylinder 2 short-circuit high side to ground

Defective coil of injector.


Check the wiring and replace injector

3080

Cylinder 4 unclassified error in injector

Depending on the pattern, various reasons can


cause the defect, internal ECU problems also
possible.
Check the wiring and the injection signals,
replace ECU

3081

Cylinder 4 injector cable short-circuit low side


to battery

Short circuit in wiring with external source.


Check the wiring or replace injector

3082

Cylinder 4 signal low

Check the wiring and the injection signals,


replace ECU.

3083

Cylinder 4 short-circuit high side to ground

Defective coil of injector.


Check the wiring and replace injector

3088

Crankshaft sensor lost synchronization

Signal interrupted do to wiring problem, defective


or incorrectly installed crankshaft speed sensor.
Check wiring, sensor installation and proper
functioning of crankshaft sensor (evaluate raw
signals)

3089

Crankshaft sensor defective

Check wiring, sensor installation and proper


functioning of crankshaft sensor (evaluate raw
signals).

3090

Camshaft sensor lost phase

Signal interrupted do to wiring problem, defective


or incorrectly installed camshaft phase sensor.
Check wiring, sensor installation and proper
functioning of camshaft phase sensor (evaluate
raw signals)

3091

Camshaft sensor phase synchronization


failure

Check wiring, sensor installation and proper


functioning of camshaft phase sensor (evaluate
raw signals).

3093

Offset between camshaft and crankshaft


outside boundaries

Signal interrupted do to wiring problem, defective


or incorrectly installed camshaft or crankshaft
sensor.
Check wiring, sensor installations and proper
functioning of camshaft and crankshaft sensors
(evaluate raw signals)

3095

Operating with camshaft sensor only

Check wiring, sensor installation and proper


functioning of crankshaft sensor (evaluated raw
signals).

3102

Rail pressure sensor CP3 signal below range


min.

Short circuit of wiring to ground or defective


pressure sensor.
Check wiring and proper functioning of rail
pressure sensor

Bur 5-2760

Issued 8-06

Printed in U.S.A.

4005-21
CODE

DEFINITION

DESCRIPTION AND POSSIBLE


STEPS FOR REPAIR

Rail pressure relief valve open

Defective rail pressure sensor, defect in other


injection relevant component.
Check rail pressure sensor for plausible values,
ensure proper functioning of the injection
components

3105

Rail pressure relief valve pressure shock


requested

PRV does not open once the pressure limit is


reached: Mechanical defect or wrong application
parameter.
Check application value of maximum rail
pressure, check functioning of the PRV

3106

Rail pressure relief valve did not open after


pressure shock

PRV does not open even after pressure shock:


Stuck PRV or wrong application parameter.
Check application value of maximum rail
pressure, check functioning of the PRV

3107

Metering unit output short-circuit to battery on


low side

Short circuit of wiring to external source or inside


relay.
Check wiring or replace relay

3110

Rail pressure sensor offset monitoring signal


above range max.

3111

Rail pressure sensor offset monitoring signal


below range min.

3104

Rail pressure sensor inaccurate.


Ensure correct wiring and proper functioning of
rail pressure sensor, replace sensor

3112

Rail pressure sensor CP3 signal above range


max.

Short circuit of wiring to external source or


defective pressure sensor, rail pressure
overshoot.
Check wiring and proper functioning of rail
pressure sensor

3113

Grid heater battery switch relay short-circuit to


battery

Short circuit of main relay to external source or


defective main relay.
Check the wiring connecting the battery to the
EDC or replace main relay

3114

Grid heater battery switch relay short-circuit to


ground

Short circuit to ground of main relay or defective


main relay.
Check the wiring connecting the battery to the
EDC or replace main relay

3118

ECM 12V sensor supply voltage high

3119

ECM 12V sensor supply voltage low

3131

Grid heater always switched on

Short circuit to ground of grid heater.


Check grid heater switch and replace it

3137

Metering unit open load

Broken or disconnected wiring or defective relay.


Check of wiring or replace relay

Metering unit signal not plausible

Defective wiring, ECU, power stage or metering


unit.
Check wiring, ECU, power stage and metering
unit

3138

Bur 5-2760

Ambient pressure sensor inside ECU is defective.


Replace ECU (not necessary if never running in
high altitude and if turbocharger without VGT)

Issued 8-06

Printed in U.S.A.

4005-22
CODE

DEFINITION

DESCRIPTION AND POSSIBLE


STEPS FOR REPAIR

3141

Set point of fuel volume flow through metering


unit is lower than calculated limit

High pressure system: Rail pressure sensor


inaccurate, high pressure pump defective.
Low pressure system: Metering unit reflux too
low.
Check for defects according to failure list.

3147

Oil temperature sensor signal above normal


range

Check oil temperature sensor for accuracy and


check oil system.

3154

Grid heater relay short-circuit to battery

Short circuit of wiring to external source or inside


relay.
Check wiring or replace relay

3155

Grid heater relay short-circuit to ground

Short circuit of wiring to ground or inside relay.


Check wiring or replace relay

3156

Grid heater relay no load

Broken or disconnected wiring or defective relay.


Check wiring or replace relay

3161

Fan actuator signal low

No information available at time of print.

Fuel rail/system pressure - too low

High pressure side: Leakage in high pressure


section, injection nozzle stuck in open position,
worn high pressure pump, worn injector, leaking
pressure relieve valve
Low pressure side: Pressure before gear pump
too low, gear pump output too low (fuel filter
clogged, leakage in low pressure side).

3172

Fuel rail/system pressure - too high

Metering unit stuck in open position,


zero-delivery throttle clogged, metering unit
without power due to electrical error.
Low pressure side: Pressure before gear pump
too high (e.g. by pressure relieve valve), pressure
after zero-delivery throttle too high.

3173

Fuel rail/system pressure - too low

See fault 3171

3174

Fuel rail/system pressure - too high

See fault 3172

Fuel system leak detected large leak

Leakage in the high pressure section, injection


nozzle stuck in open position, worn high pressure
pump, worn injector, leaking pressure relieve
valve, injector reflux too high.

Fuel delivery exceeded threshold for pressure


in overrun mode

High pressure system: Leakage in the high


pressure section, injection nozzle stuck in open
position, worn or defective high pressure pump,
worn injector, leaking pressure relieve valve.
Low pressure system: 'Zero delivery' is not active
in metering unit (excessive leakage in metering
unit).
Check for defects according to failure list.

3171

3175

3176

Bur 5-2760

Issued 8-06

Printed in U.S.A.

4005-23
CODE

DEFINITION

3178

Time-out of CAN message BC2EDC1

3179

Time-out of CAN message BC2EDC2

DESCRIPTION AND POSSIBLE


STEPS FOR REPAIR
Defective CAN controller of Body Computer,
undervoltage of BC, missing BC, CAN cable
connecting the BC is disconnected or broken.
Short circuit in wiring. Check presence and
correct connection of the BC to the network,
Check correct functioning of the BC CAN
controller and its voltage supply. Check wiring.
Defective CAN controller of Vehicle Control
Module, undervoltage of VCM, missing VCM,
CAN cable connecting the VCM is disconnected
or broken. Short circuit in wiring. Check presence
and correct connection of the VCM to the
network, Check correct functioning of the VCM
CAN controller and its voltage supply. Check
wiring.

3180

Time-out of CAN message VCM2EDC

3188

Cylinder 1 open load

3192

Cylinder 2 open load

3196

Cylinder 3 open load

3200

Cylinder 4 open load

3204

Cylinder 5 open load

3208

Cylinder 6 open load

3210

Bank 1 general short-circuit on injection cable

Short circuit of high-side to battery or ground.


Check the wiring or replace injector.

3211

Bank 1 injection cable short-circuit low side to


ground

Short circuit of low-side to ground in injector


cable.
Check the wiring or replace injector.

3212

Bank 1 no signal

No information available at time of print.

3213

Bank 1 unclassified error

Depending on the pattern, various reasons can


cause the defect, internal ECU problem.
Check the wiring and the injection signals,
replace ECU

3218

Bank 2 general short-circuit on injection cable

Short circuit of high-side to battery or ground.


Check the wiring or replace injector.

3219

Bank 2 injection cable short-circuit low side to


ground

Short circuit of low-side to ground in injector


cable.
Check the wiring or replace injector.

3220

Bank 2 no signal

No information available at time of print.

Bank 2 unclassified error

Depending on the pattern, various reasons can


cause the defect, internal ECU problem.
Check the wiring and the injection signals,
replace ECU

3221

Bur 5-2760

Broken wire or disconnection of wiring or inside


injector.
Check the wiring or replace injector.

Issued 8-06

Printed in U.S.A.

4005-24
CODE

DEFINITION

DESCRIPTION AND POSSIBLE


STEPS FOR REPAIR

3227

Injection processor error - stop engine

Clock error or interruption of the power supply


voltage.
Check the power supply or replace ECU if
problem reoccurs.

3228

Injection processor error - stop engine

Defective ECU, reset ECU.


If no recovery, replace ECU.

Injection processor error - stop engine

Internal failure of ECU or 'TESTMODE' takes too


long.
Check 'TESTMODE' parameters or replace ECU
if problem reoccurs

3230

Injection processor error - stop engine

Defective SPI-bus participant, timing problem


due to software bug.
Replace ECU if problem reoccurs (Send in ECU
for investigation)

3231

Injection processor error - stop engine

3232

Injection processor error - stop engine

3233

Injection processor error - stop engine

3234

Injection processor error - stop engine

3238

Communication error of CJ940 processor

3242

Recovery which is locked

3243

Recovery which is suppressed

3244

Recovery which is visible

3229

Defective ECU.
Replace ECU if problem reoccurs

Electric disturbances, internal defect of the ECU


leading to a SPI bus communication error.
Replace ECU if failure remains present
Electronic disturbances, various hardware
defects (ECU internal) or configuration problems.
Analyze what error triggered the recovery (Read
out label HWEMon_numRecovery and compare
the value with the according table). If error occurs
repeatedly, reprogram EDC. If error remains,
replace EDC.

3245

Communication supervision watchdog control


flag

Defective monitoring module or CPU (e.g.


impaired functioning of the CPU clock) of the
EDC. Disturbed SPI-Bus.
If error exists only temporary (i.e. injection
reoccurs) error can be ignored and error deleted
in the fault memory. In case of a permanent error
the injection remains blocked and the ECU has to
be replaced

3246

Redundant shutoff paths during initial

Watch dog switch off path defect.


If failure remains after ECU initialization: replace
ECU

3247

Redundant shutoff paths during initial

3248

Redundant shutoff paths during initial

Bur 5-2760

Electronic disturbances, internal ECU problem.


If failure remains after ECU initialization: replace
ECU

Issued 8-06

Printed in U.S.A.

4005-25
CODE

DEFINITION

DESCRIPTION AND POSSIBLE


STEPS FOR REPAIR

3253

Error status ADC monitoring

3254

Error status ADC monitoring

3255

Error status ADC monitoring

3256

Error status ADC monitoring

3258

Short-circuit to battery at high side power


stage

Short circuit of wiring to external source or inside


relay.
Check wiring or replace relay

3259

Short-circuit to ground at high side power


stage

Short circuit of wiring to ground or inside relay.


Check of wiring or replace relay

3260

Open load at low side power stage

Broken or disconnected wiring or defective relay.


Check wiring or replace relay

3261

Short-circuit to battery or excessive


temperature at low side power stage

Short circuit of wiring to external source or inside


relay.
Check wiring or replace relay

3262

Short-circuit to ground at low side power stage

Short circuit of wiring to ground or inside relay.


Check wiring or replace relay

3265

Energizing time exceeds limit of over run


monitoring

Electronic disturbances, requested torque


increase via tester, wrong application of injection
relevant parameters, defective ECU.
Check injection relevant application, if failure
persists replace ECU

3266

Plausibility error in engine speed check

Electronic disturbances, internal ECU problem.


If failure persists after reinstallation replace ECU

Supply voltage CJ940 upper limit

Excessive voltage supply of a CJ940 component:


High battery voltage, defective wiring, internal
defect of the EDC.
Check the battery for correct voltage supply,
check wiring. If defect remains replace EDC
(internal defect)

Supply voltage CJ940 lower limit

Insufficient voltage supply of a CJ940


component: Low battery voltage, defective wiring,
internal defect of the EDC.
Check the battery for sufficient voltage supply,
check wiring. If defect remains replace EDC
(internal defect)

Sensor supply voltage 1 high

Excessive battery voltage, defect in wiring


harness, electrical failure in connected sensors
or in the EDC.
Check battery voltage, check wiring for correct
voltage supply of the sensor and the EDC,
replace EDC

3278

3279

3280

Bur 5-2760

Buffer overrun
No additional information available at time of print

Issued 8-06

Printed in U.S.A.

4005-26
CODE

DEFINITION

DESCRIPTION AND POSSIBLE


STEPS FOR REPAIR

Sensor supply voltage 1 low

Insufficient battery voltage, defect in wiring


harness, electrical failure connected sensors or
in the EDC.
Check battery voltage, check wiring for correct
voltage supply of the sensor and the EDC,
replace EDC

Sensor supply voltage 2 high

Excessive battery voltage, defect in wiring


harness, electrical failure in connected sensors
or in the EDC.
Check battery voltage, check wiring for correct
voltage supply of the sensor and the EDC,
replace EDC

Sensor supply voltage 2 low

Insufficient battery voltage, defect in wiring


harness, electrical failure connected sensors or
in the EDC.
Check battery voltage, check wiring for correct
voltage supply of the sensor and the EDC,
replace EDC

Sensor supply voltage 3 high

Excessive battery voltage, defect in wiring


harness, electrical failure in connected sensors
or in the EDC.
Check battery voltage, check wiring for correct
voltage supply of the sensor and the EDC,
replace EDC

3286

Sensor supply voltage 3 low

Insufficient battery voltage, defect in wiring


harness, electrical failure connected sensors or
in the EDC.
Check battery voltage, check wiring for correct
voltage supply of the sensor and the EDC,
replace EDC

3290

Turbo compound monitoring signal not


plausible

No information available at time of print.

3281

3283

3284

3285

Bur 5-2760

Issued 8-06

Printed in U.S.A.

4005-27

TRANSMISSION FAULT CODES


CODE

DEFINITION

POSSIBLE STEPS FOR REPAIR

Logical error at FNR switch

1. Check the cables from the TCU to the FNR


switch.
2. Check the connectors from the TCU to the FNR
switch.
3. Check the FNR switch.

4114

Logical error at direction select signal

1. Check the cables from the TCU to the FNR


switch.
2. Check the connectors from the TCU to the FNR
switch.
3. Check the FNR switch signal combinations.

4116

Logic error at park brake status

1. Check the cables from the TCU to the


instrument cluster connector 2 pin 6.
2. Check park brake switch.

4117

Logic error at direction select signal 2

1. Check the cables from the TCU to the FNR


switch.
2. Check the connectors from the TCU to the FNR
switch.
3. Check the FNR switch signal combinations.

4119

Short circuit to ground at ride control

4120

Short circuit to battery voltage at ride control

4121

Open circuit at ride control

1. Check the cables from the TCU to the ride


control relay.
2. Check the connectors from the TCU to the ride
control relay.
3. Check the ride control relay.

4133

Short circuit to battery voltage or open circuit


at temperature sensor

1. Check the connectors.


2. Check the temperature sensor.

4134

Short circuit to ground at temperature sensor

4135

Short circuit to battery voltage or open circuit


at converter output temperature sensor

4136

Short circuit to ground at converter output


temperature sensor

4137

Short circuit to battery voltage or open circuit


at parking brake sensor input

4145

Short circuit to battery voltage or open circuit


at engine speed sensor

4146

Short circuit to ground at engine speed sensor

4113

1. Check the cables from TCU to the sensor.


2. Check the connectors.
3. Check the temperature sensor.

1. Check the cables from TCU to the sensor.


2. Check the connectors.
3. Check the parking brake sensor.
1. Check the parking brake fuse.
2. Check the parking brake relay.
3. Check the parking brake solenoid.
1. Check the cables from TCU to the sensor.
2. Check the connectors.
3. Check the speed sensor.

4147

Bur 5-2760

Logical error at engine speed sensor input

NOTE: This fault code is reset after power up of the


TCU. It is also reset if the signal is above zero
speed threshold.

Issued 8-06

Printed in U.S.A.

4005-28
CODE

DEFINITION

4148

Short circuit to battery voltage or open circuit


at turbine speed sensor input

4149

Short circuit to ground at turbine speed sensor


input

4150

Logical error at turbine speed sensor input

POSSIBLE STEPS FOR REPAIR

1. Check the cables from TCU to the sensor.


2. Check the connectors.
3. Check the speed sensor.
1. Check the cables from TCU to the sensor.
2. Check the connectors.
3. Check the speed sensor.
NOTE: This fault code is reset after power up of the
TCU.

4151

Short circuit to battery voltage or open circuit


at intermediate speed sensor input

4152

Short circuit to ground at intermediate speed


input

4153

Logical error at intermediate speed sensor


input

4154

Short circuit to battery voltage or open circuit


at output speed sensor

4155

Short circuit to ground at output speed sensor

4156

Logical error at output speed sensor

1. Check the cables from TCU to the sensor.


2. Check the connectors.
3. Check the speed sensor.
1. Check the cables from TCU to the sensor.
2. Check the connectors.
3. Check the speed sensor.
NOTE: This fault code is reset after power up of the
TCU.
1. Check the cables from TCU to the sensor.
2. Check the connectors.
3. Check the speed sensor.
1. Check the cables from TCU to the sensor.
2. Check the connectors.
3. Check the speed sensor.
NOTE: This fault code is reset after power up of the
TCU.

4158

Output speed zero, does not match other


speeds.

1. Check the sensor signal of the output speed


sensor.
2. Check the connector connected to the output
speed.
3. Check the cable from the TCU to the sensor.
NOTE: This fault code is reset after power up of the
TCU.

4160

Invalid gear range restriction (CAN)

4180

Vehicle controller time-out (CAN)

4185

Invalid test mode signal (CAN)

4186

Invalid park brake status (CAN)

Bur 5-2760

1. Check the cluster controller.


2. Check wire of CAN-Bus.
3. Check the cable to the cluster controller.
1. Check the cluster controller.
2. Check wire of CAN-Bus.
3. Check the cable to the cluster controller.

Issued 8-06

Printed in U.S.A.

4005-29
CODE

DEFINITION

4209

Short circuit to battery voltage at clutch K1

4210

Short circuit to ground at clutch K1

4211

Open circuit at clutch K1

4212

Short circuit to battery voltage at clutch K2

4213

Short circuit to ground at clutch K2

4214

Open circuit at clutch K2

4215

Short circuit to battery voltage at clutch K3

4216

Short circuit to ground at clutch K3

4217

Open circuit at clutch K3

4225

Short circuit to battery voltage at clutch K4

4226

Short circuit to ground at clutch K4

4227

Open circuit at clutch K4

4228

Short circuit to battery voltage at clutch KV

4229

Short circuit to ground at clutch KV

4230

Open circuit at clutch KV

4231

Short circuit to battery voltage at clutch KR

4232

Short circuit to ground at clutch KR

4233

Open circuit at clutch KR

4241

Short circuit to ground at backup alarm relay

4242

Short circuit to battery voltage at backup alarm


relay

4243

Open circuit at backup alarm relay

4273

4274

4275

Bur 5-2760

POSSIBLE STEPS FOR REPAIR

1. Check the cable from the TCU to the


transmission control valve.
2. Check the connectors from the TCU to the
transmission control valve.
3. Check the regulator resistance.
4. Check internal wire harness of the transmission
control valve.

1. Check the cable from the TCU to the backup.


alarm relay.
2. Check the connectors from the backup alarm
relay to TCU.
3. Check the resistance of backup alarm relay
circuit.

Slippage at clutch K1

1.
2.
3.
4.
5.

Check pressure at clutch K1.


Check main pressure in the system.
Check signal at internal speed sensor.
Check signal at output speed sensor.
Replace clutch.

Slippage at clutch K2

1.
2.
3.
4.
5.

Check pressure at clutch K2.


Check main pressure in the system.
Check signal at internal speed sensor.
Check signal at output speed sensor.
Replace clutch.

Slippage at clutch K3

1.
2.
3.
4.
5.

Check pressure at clutch K3.


Check main pressure in the system.
Check signal at internal speed sensor.
Check signal at output speed sensor.
Replace clutch.

Issued 8-06

Printed in U.S.A.

4005-30
CODE

DEFINITION

POSSIBLE STEPS FOR REPAIR

Slippage at clutch K4

1.
2.
3.
4.
5.

Check pressure at clutch K4.


Check main pressure in the system.
Check signal at internal speed sensor.
Check signal at output speed sensor.
Replace clutch.

Slippage at clutch KV

1.
2.
3.
4.
5.

Check pressure at clutch KV.


Check main pressure in the system.
Check signal at internal speed sensor.
Check signal at output speed sensor.
Replace clutch.

Slippage at clutch KR

1.
2.
3.
4.
5.

Check pressure at clutch KR.


Check main pressure in the system.
Check signal at internal speed sensor.
Check signal at output speed sensor.
Replace clutch.

4279

Oil temperature at valve body is above limit

1. A critical stop function warning has occurred.


2. Red stop indicator comes on and continuous
buzzer sounds.
3. Stop machine and perform required service on
the critical area.
4. Cool down machine.
5. Check oil level.
6. Check temperature sensor.

4281

Engine speed is measured above 5,000 rpm


for 0.2 seconds

4276

4277

4278

Check engine speed sensor


1. Check oil filter.
2. Check wiring from TCU to filter maintenance
switch.
3. Check filter maintenance switch (measure
resistance).

4282

TCU sensed a voltage at oil filter maintenance


switch out of the allowed range (dirty filter)

4284

Overspeed output

No information available at time of print.

4288

Engine torque or engine power overload

No information available at time of print.

4289

Transmission output torque overload

No information available at time of print.

4290

Transmission input torque overload

No information available at time of print.

4291

4292

Bur 5-2760

Oil temperature at converter output is above


limit

1. A critical stop function warning has occurred.


2. Red stop indicator comes on and continuous
buzzer sounds.
3. Stop machine and perform required service on
the critical area.
4. Cool down machine.
5. Check oil level.
6. Check temperature sensor.

Joystick status indicator short-circuit to ground

1. Check the cables from the TCU to the joystick.


2. Check the connectors from the TCU to the
joystick.
3. Check the resistance of the joystick.

Issued 8-06

Printed in U.S.A.

4005-31
CODE

DEFINITION

POSSIBLE STEPS FOR REPAIR

Joystick status indicator short-circuit to battery


voltage

1. Check the cables from the TCU to the joystick.


2. Check the connectors from the TCU to the
joystick.
3. Check the resistance of the joystick.

4294

Joystick status indicator over current

1. Check the cables from the TCU to the joystick.


2. Check the connectors from the TCU to the
joystick.
3. Check the resistance of the joystick.

4305

Power supply for sensors short-circuit to


battery voltage

1. Check the cables from the sensors TCU.


2. Check the connectors from the sensors to the
TCU.

4306

Power supply for sensors short-circuit to


ground

4307

Low voltage at battery

4308

High voltage at battery

4309

Error at VPS 1 for solenoid power supply

4310

Error at VPS 2 for solenoid power supply

4325

Vehicle ID #1 time out

No information available at time of print.

4326

Undefined VIN request via CAN.

No information available at time of print.

4337

General EEPROM fault

Replace the TCU.

4338

Configuration error

Reprogram the correct configuration for the


vehicle.

4339

Application error (ZF internal)

Replace the TCU.

4341

Clutch calibration fault

4342

Clutch adjustment data lost

4293

Bur 5-2760

1. Check batteries.
2. Check B+ wires from batteries to TCU.
3. Check voltage at TCU connector pin 45.
1.
2.
3.
4.

Check fuse A2.


Check cable from control valve to TCU.
Check connectors from control valve to TCU.
Replace TCU.

Do the transmission clutch calibration procedure.

Issued 8-06

Printed in U.S.A.

4005-32

INSTRUMENT CLUSTER FAULT CODES


CODE

DEFINITION

9128

CAN timed out during operation

9129

CAN timed out during operation

9130

CAN timed out during operation

Bur 5-2760

DESCRIPTION AND POSSIBLE


STEPS FOR REPAIR
If error is permanent or repeats often, check CAN
wiring harness and connections on the CAN bus
circuits.

Issued 8-06

Printed in U.S.A.

5001
Section
5001
REMOVAL AND INSTALLATION OF STEERING
COMPONENTS

CNH America LLC.


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

Bur 5-2780

Copyright 2006 CNH Ameica LLC.


All rights reserved.
Printed in U.S.A.
Issued August, 2006

5001-2

TABLE OF CONTENTS
STEERING CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUXILIARY STEERING PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUXILIARY STEERING PUMP AND MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING BACK PRESSURE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 5-2780

Issued 8-06

3
3
5
8
8
8
10
10
10
12
12
12
14
14
14
16
16
16

Printed in U.S.A.

5001-3

STEERING CONTROL VALVE


Removal

STEP 7

STEP 1
Remove the cab skirts from the cab or canopy.

STEP 2
Remove all dirt and grease from steering control
valve.

STEP 3
Remove hydraulic reservoir fill cap, attach a vacuum
pump to the reservoir, start the pump.
BD06G245

STEP 4
Tag hoses connected to steering control valve.

Remove the mounting nut and washers from the


steering shaft.

STEP 5

STEP 8

BD06G262

Disconnect hoses from steering control valve, cap or


plug the fittings and hoses, turn off the vacuum
pump.

BD06G246

Remove the steering wheel from the shaft.

STEP 9

STEP 6

BD06G247
BD06G244

Remove the center cap from the steering wheel.

Bur 5-2780

Remove the six mounting screws from the instrument


cover.

Issued 8-06

Printed in U.S.A.

5001-4

STEP 10

STEP 13

BD06G248

BD06G258

Remove the five mounting screws for the left and


right hand trim.

Remove the two mounting screws from the lower


trim.

STEP 11

STEP 14

BD06G249

BD06G259

Disconnect the ignition switch, remove the right and


left hand trim pieces from the column.

Pull floor mat away from the column and remove the
lower trim from the column.

STEP 12

STEP 15

BD06G257

Remove the screw from the brace.

Bur 5-2780

BD06G260

Remove the two lower mounting screws from the


front vent.

Issued 8-06

Printed in U.S.A.

5001-5

Installation

STEP 16

STEP 18

BD06G261

Remove the three vents from the front trim, remove


the three mounting bolts inside of the vent holes,
remove the vent.

STEP 17

BD06G264

Put the rubber bushing on the spacer with the


tapered end towards the steering valve.

STEP 19
Have an assistant push the valve into place while
turning the steering shaft, this will engage the
splines.

STEP 20

BD06G263

Remove the four mounting bolts for the steering


control valve.
IMPORTANT: Have an assistant support and
remove the valve while removing the mounting bolts.
BD06G263

Install and tighten the four mounting bolts for the


steering control valve.

Bur 5-2780

Issued 8-06

Printed in U.S.A.

5001-6

STEP 21

STEP 24

BD06G261

Install the front trim, install and tighten the three


mounting bolts inside of the vent holes, install three
vents into the front trim.

BD06G257

Install the screw into the brace.

STEP 25

STEP 22

BD06G249

BD06G260

Install the two lower mounting screws that mount the


front vent to the cab.

Connect the ignition switch, install the right and left


hand trim pieces onto the column.

STEP 26

STEP 23

BD06G248

BD06G258

Install and tighten the five mounting screws for the


left and right hand trim.

Install the lower trim onto the column, instal and


tighten the two mounting screws mounting the lower
trim, place the floor mat into position.

Bur 5-2780

Issued 8-06

Printed in U.S.A.

5001-7

STEP 27

STEP 30

BD06G247

BD06G262

Install and tighten the six mounting screws for the


instrument cover.

Start the vacuum pump, remove the caps and plugs


the fittings and hoses. Connect hoses to steering
control valve according to the tags installed during
removal, remove and discard the tags.

STEP 28

STEP 31
Remove the vacuum pump from the reservoir, install
and tighten the reservoir fill cap.

STEP 32
Start and run the machine at low idle, turn the wheel
to full left and then to full right, stop the machine and
check for leaks.

STEP 33
BD06G245

Install the skirts onto the cab or canopy.

Install the steering wheel, install and tighten the


mounting nut and washers.

STEP 34

STEP 29

Check fluid level in hydraulic reservoir. Add oil as


required. See Section 1002 for specifications.

BD06G244

Install the center cap on the steering wheel.

Bur 5-2780

Issued 8-06

Printed in U.S.A.

5001-8

AUXILIARY STEERING PRIORITY VALVE


Removal

Installation

1. Park loader on level ground and lower bucket to


ground. Put transmission in NEUTRAL, apply
parking brake, and shut down engine,

1. Connect and hand tighten fitting (5) to the elbow


in the steering priority valve.

2. Put master disconnect switch in OFF position.

3. Tighten pressure tube fitting (5).

3. Remove all dirt and grease from auxiliary


steering priority valve and adjacent area. See
illustration on page 9.

4. Tighten the nuts (6).

4. Remove hydraulic reservoir fill cap.

2. Install cap screws, washers and nuts (6).

5. Connect and tighten pressure hose (7).


6. Connect and tighten steering pressure hose (9).

5. Connect a vacuum pump to hydraulic reservoir.

7. Connect and tighten steering load sensing hose


(1).

6. Start vacuum pump.

8. Connect and tighten load sensing hose (2).

7. Tag and disconnect suction hose from the


suction port (4) from auxiliary steering pump and
motor. Install a cap on the fitting and a plug in the
hose.

9. Connect electrical connector to the pressure


switch (3).

8. Tag and disconnect tank return tube (10) from


the priority valve. Install a cap on the elbow and
a plug in the tube.
9. Stop the vacuum pump.
10. Tag and disconnect the wiring from the steering
solenoid (8).
11. Tag and disconnect the wiring from the pressure
switch (3).

10. Connect electrical connector to the steering


solenoid (8).
11. Start vacuum pump.
12. Connect and tighten tank return tube (10).
13. Connect and tighten hose to auxiliary steering
pump port (4).
14. Stop vacuum pump. Disconnect vacuum pump
from hydraulic reservoir.
15. Install fill cap on hydraulic reservoir.

12. Tag and disconnect load sensing hose (2) from


auxiliary steering priority valve. Install a cap on
the elbow and a plug in the hose.

16. Put battery disconnect switch in ON position.


Start engine and run at low idle for 30 seconds.
Stop engine and check for leaks.

13. Tag and disconnect load sensing hose (1) from


the priority valve. Install a cap on the elbow and
a plug in the hose.

17. Check to make sure priority valve operates


correctly. See Section 5002.

14. Tag and disconnect steering pressure hose (9)


from priority valve. Install a cap on the fitting and
a plug in the hose.

18. Check fluid level in hydraulic reservoir. Add oil as


required. See Section 1002 for specifications.

15. Tag and disconnect pressure hose (7) from


priority valve. Install a cap on the fitting and a
plug in the hose.
16. Loosen fitting (5) connected to elbow installed in
steering priority valve.
17. Support auxiliary steering priority valve. Remove
four nuts (6), cap screws, and washers.
18. Remove auxiliary steering priority valve.

Bur 5-2780

Issued 8-06

Printed in U.S.A.

5001-9

1
2
3
6

10
4

9
8

BC05M084

1.
2.
3.
4.
5.

STEERING LOAD SENSING HOSE TO PRIORITY VALVE


STEERING LOAD SENSING HOSE TO STEERING VALVE
PRESSURE SWITCH
SUCTION PORT
PUMP OUT PRESSURE TUBE FITTING

6.
7.
8.
9.
10.

CAP SCREWS AND NUTS


PRESSURE HOSE
STEERING SOLENOID
STEERING PRESSURE HOSE
TANK RETURN TUBE

AUXILIARY STEERING PRIORITY VALVE ILLUSTRATION

Bur 5-2780

Issued 8-06

Printed in U.S.A.

5001-10

STEERING PRIORITY VALVE


Removal
1. Park loader on level ground and lower bucket to
ground. Put transmission in NEUTRAL, apply
parking brake, and shut down engine,
2. Put master disconnect switch in OFF position.
3. Remove all dirt and grease from steering priority
valve (7) and adjacent area. See illustration on
page 11.
4. Remove hydraulic reservoir fill cap.
5. Connect a vacuum pump to hydraulic reservoir.

Installation
1. Install bolts with washers (8) through priority
valve. Install new O-ring on top of priority valve
(not shown). Install priority valve (7) onto low
pressure pump, tighten bolts to37 to 48 Nm
(27 to 35.5 pound feet).
2. Install new O-rings (6) onto high pressure pump
discharge tube (5).
3. Place tube into position and intsall four split
flanges (3) and eight bolts (4) with washers,
tighten bolts.

6. Start vacuum pump.

4. Connect all hoses as tagged to the steering


priority valve (7).

7. Tag and disconnect all hoses connected to the


steering priority valve (7).

5. Stop vacuum pump.

8. Loosen and remove eight bolts (4) and four spit


flanges (3).
9. Remove the high pressure pump discharge tube
(5), discard O-rings (6).
10. Support the steering priority valve (7), remove
mounting bolts (8).
11. Remove steering priority valve (7).

6. Disconnect
reservoir.

vacuum

pump

from

hydraulic

7. Install fill cap on hydraulic reservoir.


8. Put battery disconnect switch in ON position.
Start engine and run at low idle for 30 seconds.
Stop engine and check for leaks.
9. Check to make sure steering priority valve
operates correctly. See Section 5002.
10. Check fluid level in hydraulic reservoir. Add oil as
required. See Section 1002 for specifications.

Bur 5-2780

Issued 8-06

Printed in U.S.A.

5001-11

3
6

BC05M087

1.
2.
3.
4.

LOW PRESSURE PUMP (LOADER PUMP)


HIGH PRESSURE PUMP (STEERING PUMP)
SPLIT FLANGE
BOLT

5.
6.
7.
8.

STEERING PUMP OUTPUT LINE


O-RINGS
STEERING PRIORITY VALVE
BOLT

STEERING PRIORITY VALVE ILLUSTRATION

Bur 5-2780

Issued 8-06

Printed in U.S.A.

5001-12

AUXILIARY STEERING PUMP AND MOTOR


Removal
1. Park loader on level ground and lower bucket to
ground. Put transmission in NEUTRAL, apply
parking brake, and shut down engine,

7. Connect ground cable (1) to ground stud of


auxiliary steering pump and motor (7) following
tag installed during removal.

2. Put master disconnect switch in OFF position.

8. Connect positive cable (2) to B+ stud of auxiliary


steering pump and motor (7) following tag
installed during removal.

3. Tag and disconnect two wiring harness (8) from


auxiliary steering pump and motor (7) solenoid.
See illustration on page 13.

9. Connect wiring harness wires (8) to auxiliary


steering pump and motor (7) following tags
installed during removal.

4. Tag and disconnect positive cable (2) from B+


stud of auxiliary steering pump and motor (7).
5. Tag and disconnect ground cable (1) from
ground stud of auxiliary steering pump and motor
(7).
6. Remove hydraulic reservoir fill cap.
7. Connect a vacuum pump to hydraulic reservoir.
8. Start vacuum pump.
9. Disconnect suction hose (4) from auxiliary
steering pump and motor (7). Install a plug in
suction hose and cap on fitting.
10. Stop vacuum pump.
11. Loosen fittings on pressure tube (5).
12. Support auxiliary steering pump and motor (7).
Remove nuts (3), cap screws, and washers
securing auxiliary steering pump and motor (7).
13. Remove pressure tube (5) and auxiliary steering
pump and motor (7).

Installation
1. Position auxiliary steering pump and motor (7) on
its mounting plate while connecting and hand
tightening pressure tube (5) to auxiliary steering
priority valve (6). See illustration on page 13.

10. Put master disconnect switch in ON position.


11. Start and run engine at low idle and raise bucket
500 mm (20 inches) above ground. Check that
auxiliary steering light on information center is
OFF.
IMPORTANT: In following Step, do not run auxiliary
steering pump and motor continuously for more than
20 seconds at a time without a two minute cool down.
12. With engine at low idle and machine steering
straight ahead, turn key switch to OFF position to
stop engine and then immediately back to ON
position (not START position). Auxiliary steering
pump and motor should star t operating
immediately. Check that auxiliary steering light
on infor mation center is ON and auxiliar y
steering pump and motor is operating.
13. Turn steering wheel all the way to left and right to
make sure that auxiliary steering pump and
motor operates correctly.
14. Restart engine. Check that auxiliary steering light
on information center stays ON and auxiliary
steering pump and motor is operating. After
about three seconds motor should stop operating
and auxiliary steering light should go out.
15. Let engine run and allow batteries to recharge for
a minimum of 10 minutes.

2. While supporting auxiliary steering pump and


motor (7) have an assistant install cap screws,
washers, and nuts (3) to secure auxiliary steering
pump and motor (7), tighten the nuts.
3. Tighten pressure tube (5) fittings securely.
4. Start vacuum pump.
5. Remove plug from suction hose (4) and cap from
elbow. Connect suction hose to elbow installed in
auxiliary steering pump and motor (7).
6. Stop and disconnect vacuum pump. Install fill
cap in hydraulic reservoir.
Bur 5-2780

Issued 8-06

Printed in U.S.A.

5001-13

2
1

3
8
7

4
5

BC05M085

1. GROUND CABLE
2. POSITIVE CABLE
3. NUT (4)

4. SUCTION HOSE
7. AUXILIARY STEERING PUMP AND MOTOR
5. PRESSURE TUBE
8. WIRING HARNESS
6. AUXILIARY STEERING PRIORITY VALVE
AUXILIARY STEERING PUMP AND MOTOR ILLUSTRATION

Bur 5-2780

Issued 8-06

Printed in U.S.A.

5001-14

STEERING CYLINDER
Removal
1. Loosen the fill cap for the hydraulic reservoir to
release pressure in the reservoir, then tighten the
fill cap.
2. Disconnect grease hoses (1 and 16) from
steering cylinders (11). See illustration on page
15.
3. Disconnect hydraulic hoses (2, 3, 9, and 10) from
steering cylinders (11).
4. Install a plug in each hose (2, 3, 9, and 10) to
prevent entry of foreign matter.
5. Remove locknut (15).
6. Remove cap screw (13).
7. Remove pin (12).
8. Remove washers (14).
9. Remove cap screw (8), washer (7), and spacer
(6) securing pivot pin (5) at rear of steering
cylinders (11).
10. Use a suitable driver and drive pivot pin (5) out of
steering cylinder (11).
11. Remove washer(s) (4) from between steering
cylinders (11) and rear frame of machine.
12. Remove steering cylinders (11).

Installation
1. Put steering cylinders (11) in position in machine.
Make sure that washers (4) are installed
between steering cylinder (11) and rear frame.
See illustration on page 15.
NOTE: Install a washer (4) on top and bottom of
steering cylinders (11) if possible. If only one washer
(4) can be installed, place washer (4) at bottom of
steering cylinders (11).
2. Make sure washers (14) are installed between
steer ing cylinders (11) and front frame of
machine.
3. Install the pivot pin (5) to secure rear of steering
cylinders (11) to machine frame. Install spacer
(6), washer (7), and cap screw (8) to secure pivot
pin (5).
4. Tighten cap screw (8).
5. Install pin (12) in front of steering cylinders (11).
Make sure that washers (14) are installed in
correct position.
6. Install cap screw (13) and new locknut (15) in
steering cylinders (11) rod end and pin (12).
Tighten locknut (15).
NOTE: Cap screw (13) should turn freely in hole
after tightening.
7. Connect hose assemblies (2, 3, 9, and 10) to
steering cylinders (11).
8. Connect grease hoses (1 and 16) to steering
cylinders (11).
9. Tighten hydraulic reservoir fill cap.
10. Start engine.
11. Turn steering wheel all the way to right and then
to the left several times.
12. Stop the engine. Check fluid level in hydraulic
reservoir. Add oil as required. See Section 1002
for specifications.

Bur 5-2780

Issued 8-06

Printed in U.S.A.

5001-15

10

8
7
6
5
4
3

11

2
12

13
14
15

11

16
BS03B141

1.
2.
3.
4.

GREASE HOSE
HOSE ASSEMBLY
HOSE ASSEMBLY
WASHER

5.
6.
7.
8.

PIVOT PIN
SPACER
WASHER
CAP SCREW

9.
10.
11.
12.

HOSE ASSEMBLY
HOSE ASSEMBLY
STEERING CYLINDER
PIN

13.
14.
15.
16.

CAP SCREW
WASHER
LOCKNUT
GREASE HOSE

STEERING CYLINDER ILLUSTRATION

Bur 5-2780

Issued 8-06

Printed in U.S.A.

5001-16

STEERING BACK PRESSURE VALVE


Removal
1. Remove the fill cap for the hydraulic reservoir to
release pressure in the reser voir, attach a
vacuum pump to the reservoir, start the pump.
2. Disconnect hoses 2 and 6 from the pressure
valve.
3. Remove the nuts, bolts and spacers from the
pressure vale, remove the valve from the
machine.

Installation
1. Install the valve, bolts, spacers and nuts onto the
machine, tighten the bolts.
2. Install new O-rings onto the fittings of the hoses,
install and tighten the hoses.
3. Stop the vacuum pump, install and tighten the
reservoir filler cap.
4. Start and run the machine at low idle, turn the
steering wheel from full left lock to full right lock
holding the steering over relief.
5. Stop the machine and check for leaks.
6. Check fluid level in hydraulic reservoir. Add oil as
required. See Section 1002 for specifications.

Bur 5-2780

Issued 8-06

Printed in U.S.A.

5001-17

BS06G529

1.
2.
3.
4.

STEERING CONTROL VALVE


RETURN HOSE
PRESSURE HOSE
CONNECTOR M27 ORB

5. RELIEF VALVE
6. RETURN HOSE TO FILTERS
7. RETURN MANIFOLD

STEERING BACK PRESSURE VALVE ILLUSTRATION

Bur 5-2780

Issued 8-06

Printed in U.S.A.

5001-18

NOTES

Bur 5-2780

Issued 8-06

Printed in U.S.A.

5002

Section
5002
STEERING SPECIFICATIONS, PRESSURE CHECKS,
AND TROUBLESHOOTING

CNH America LLC.


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

Bur 5-2790

Copyright 2006 CNH Ameica LLC.


All rights reserved.
Printed in U.S.A.
Issued August, 2006

5002-2

TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING THE STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUXILIARY STEERING SYSTEM PUMP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUXILIARY STEERING SYSTEM MOTOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Understanding The Results Of The Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Setting Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Setting Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING CYLINDER LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING BACK PRESSURE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 5-2790

Issued 8-06

3
3
4
4
4
5
5
5
5
6
6
7
8
9
10

Printed in U.S.A.

5002-3

SPECIAL TOOLS

B785789

OEM-1239 (CAS-10280) FLOWMETER

B009638

CAS-1804 PRESSURE TEST FITTING KIT

B797157

CAS-1808 FLOWMETER FITTING KIT

TROUBLESHOOTING THE STEERING SYSTEM


NOTE: The steering hydraulic schematic is included
in the hydraulic schematic. Refer to the rear pocket of
this manual.

4. Do the main hydraulic pump test. See Section


8002. If the main pump is bad, repair or replace
the main hydraulic pump.

1. Make sure the oil level in the hydraulic reservoir


is correct. Visually inspect the steering system
for leakage and damage.

5. Test the steering cylinders for leakage, refer to


instructions on page 8. If a steering cylinder is
leaking, repair or replace the steering cylinder.

2. The loader/steering pump differential pressure


must be properly adjusted. Refer to Section 8002
Testing and Adjusting the Loader/Steering Pump
differential Pressure.

6. If the steering system is noisy test the back


pressure relief valve, refer to instructions on
page 9.

3. Do the steering limit valve pressure test. Refer to


page 6. If the pressure is above or below
specifications, adjust the steering limit valve.

Bur 5-2790

Issued 8-06

Printed in U.S.A.

5002-4

AUXILIARY STEERING SYSTEM PUMP TEST


Equipment Required

6. Connect the ammeter clamp (1) to the cable as


in illustration.

1. CAS- 10280 Flowmeter


2. CAS-1808 Flowmeter fitting kit

Test Procedure
1. Install articulation lock.

BB830300

1. AMMETER CLAMP

7. Make sure that the parking brake is applied and


the bucket is on the floor.

1
BD03A040

1. ARTICULATION LOCK

NOTE: When performing this pressure check,


always be sure the articulation lock is in place,
especially when working in the articulation joint
areas.
2. Loosen and remove the outlet hose to the
Auxiliary Steering Pump from the Auxiliar y
Steering Priority Valve.
3. Install a plug into the Auxiliary Steering Priority
Valve.
4. Connect the inlet of the flowmeter to the outlet
line of the Auxiliary Steering Pump.
5. Install the outlet hose of the flowmeter in the
hydraulic reservoir and hold in place with wire.

8. Make sure that


temperature.

the

oil

is

at

operating

9. Make sure that the load valve for the flowmeter is


open (zero pressure).
10. Start and run the engine.
11. Stop the engine and turn the key back to the On
position.
12. Turn the steering wheel, this will activate the
auxiliary steering pump.
13. Turn the load valve on the flowmeter towards
CLOSED until the pressure is 104 bar (1500 psi).
14. Read the flowmeter and ammeter gauges and
record the readings.
15. The flowmeter reading must not be less than
24.6 L/min, (6.5 U.S. gpm). The ammeter reading
must be 315 amps.
16. Turn the key switch to the OFF position. If the
flow was less than the specification, or if the
amperage was more than 315 amperes, remove
the auxiliary steering motor and pump. Test the
auxiliary steering motor. If the motor is good,
make repairs to the pump.

Bur 5-2790

Issued 8-06

Printed in U.S.A.

5002-5

AUXILIARY STEERING SYSTEM MOTOR TEST


Test Equipment

5. Push the button on the remote starter switch (1)


and look at the voltmeter in the tester.

1. A 24 volt battery that is fully charged.


NOTE: A 24 volt battery system (two 12 volt
batteries in a series) is used for this test. A 12 volt
battery system will cause damage to the auxiliary
steering motor.

6. Turn the load control (8) until the voltmeter (7)


indicates 24 volts. Look at the ammeter (6) in the
tester. Make a record of the ammeter indication.

2. A remote starter switch.

3. A tachometer to check the armature speed.


4. A Sun Electric VAT-33 Starting and Charging
System Tester.

Test Procedure
1. Remove the connector that is between the
ter minals on the magnetic switch and the
auxiliary steering motor.
2. Remove the auxiliary steering motor from the
auxiliary steering pump.
3. Remove the drive coupling from the auxiliary
steering motor (3).
4. Connect the auxiliary steering motor (3), remote
starter switch (1) and tester (2) to the 24 volt
battery system (5) as illustrated.

B795328

6. AMMETER
7. VOLTMETER
8. LOAD CONTROL

7. Hold the tachometer against the armature shaft.


Look at the tachometer. Make a record of the
indication.
8. Release the button on the remote starter
switch (1).

Understanding The Results Of The


Test
1. If the ammeter indication in step 6 was 30
amperes or less and the tachometer indication in
step 7 was 6950 r/min (r pm) or more, the
auxiliary steering motor is good.

2. If the armature speed was less than 6950 r/min


(rpm) and the ammeter indication was higher
than 30 amperes, replace the motor.

B790852

1.
2.
3.
4.
5.

Bur 5-2790

REMOTE STARTER SWITCH


TESTER
AUXILIARY STEERING MOTOR
AMMETER CLAMP
24 VOLT BATTERY SYSTEM

Issued 8-06

Printed in U.S.A.

5002-6

STEERING PRIORITY VALVE


NOTE: The loader/steering pump differential pressure must be properly adjusted before doing this test. Refer to
Section 8002 Testing and Adjusting the Loader/Steering Pump Differential Pressure.

Pressure Setting Test

4. Make sure that the temperature of the hydraulic


oil is at least 54 C (129 F).

1. Install articulation lock (1).

5. To measure the temperature of the oil using the


instrument panel:
A. Press the up or down arrow key.
B. Stop at the info screen with the temperatures
that need to be monitored.
6. Apply the parking brake.
7. Start and run the engine at full throttle.
8. Lower the lift arms and hold the control lever in
the FLOAT position.
9. Hold the bucket control lever in the rollback
position.

1
BD03A040

1. ARTICULATION LOCK

IMPORTANT: When performing the following


pressure check and adjustment, the articulation lock
must be installed. Use caution when working in or
near the articulation area.
2. Remove the dust cap from the test port (1).

10. Continue holding until the specified temperature


of the oil is reached.
11. Stop the engine.
12. Start the engine and operate the machine at full
throttle.
13. With the articulation lock still in place, turn and
hold the steering wheel for a hard right turn.
14. Continue holding the steering wheel, and read
the pressure gauge.
15. The pressure gauge must indicate 239 to 243
bar (3465 to 3525 psi). If the pressure is not
correct, adjust the steering relief valve.

2
1
BD06F148

1. G1 TEST PORT
2. G2 TEST PORT

3. Connect a 345 bar (5000 psi) pressure gauge to


the test port (2).
NOTE: Make sure when you connect the pressure
gauge that you do so in a manner that you can read
the pressure gauge while sitting in the operators
seat.

Bur 5-2790

Issued 8-06

Printed in U.S.A.

5002-7

Pressure Setting Adjustment


1. Turn the adjusting screw clockwise to increase
the pressure setting. Turn the adjusting screw
counterclockwise to decrease the pressure
setting.

2. Repeat pressure test procedure.


3. If necessary, adjust the limit valve again until
within the specified range.

4. Stop the engine before removing the pressure


gauge.
BD06F147

1. STEERING PRIORITY VALVE


2. LIMIT VALVE

Bur 5-2790

Issued 8-06

Printed in U.S.A.

5002-8

STEERING CYLINDER LEAK TEST


NOTE: Make sure all persons are clear of the area
of the center pivot. Make sure the center pivot is free
of any obstructions.
1. Park the machine on a level surface.
2. Turn the machine all the way to the right.
3. Stop the engine and apply the parking brake.
4. Find the tube that is connected to the rod end of
the left-hand steering cylinder. Disconnect the
tube from the left-hand cylinder.
5. Install a plug in the tube.
6. Start and run the engine at full throttle.
7. Turn the steering wheel to the right. Hold the
steering wheel for a full right turn. Have another
person check for leakage from the opening of the
rod end of the left-hand steering cylinder.
8. If there is constant leakage from the rod end, the
piston packing in the left-hand steering cylinder
is damaged. Repairs must be made. See Section
5005.

Bur 5-2790

9. Connect the tube to the rod end of the left-hand


steering cylinder.
10. Turn the machine all the way to the left.
11. Stop the engine.
12. Find the tube that is connected to the rod end of
the right-hand steering cylinder. Disconnect the
tube from the right-hand steering cylinder.
13. Install a plug in the tube.
14. Start and run the engine at full throttle.
15. Turn the steering wheel to the left. Hold the
steering wheel for a full left turn. Have another
person check for leakage at the opening of the
rod end of the right-hand steering cylinder.
16. If there is constant leakage from the rod end, the
piston packing in the right-hand steering cylinder
is damaged. Repairs must be made. See Section
5005.
17. Connect the tube to the rod end of the right-hand
steering cylinder.

Issued 8-06

Printed in U.S.A.

5002-9

STEERING BACK PRESSURE VALVE


1

BS06G529

1.
2.
3.
4.

Bur 5-2790

STEERING CONTROL VALVE


RETURN HOSE
PRESSURE HOSE
CONNECTOR M27 ORB

5. RELIEF VALVE
6. RETURN HOSE TO FILTERS
7. RETURN MANIFOLD

Issued 8-06

Printed in U.S.A.

5002-10

Pressure Test
1. Disconnect the return hose (2) from the
connector (4).
2. Install a T fitting and connect a pressure gauge
capable of reading 35 bar (500 psi).
3. Start and run the machine at high idle.

4. Turn the steering wheel and observe the


pressure.
5. The pressure should be 8 to 10 bar (115 to 145
psi).
6. If pressure is not as specified, replace the relief
valve.
NOTE: The relief valve is not adjustable.

Bur 5-2790

Issued 8-06

Printed in U.S.A.

Section
5005

5005

STEERING CYLINDERS

CNH America LLC.


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

Bur 5-3160

Copyright 2006 CNH Ameica LLC.


All rights reserved.
Printed in U.S.A.
Issued August, 2006

5005-2

TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 5-3160

Issued 8-06

3
3
3
3
5

Printed in U.S.A.

5005-3

SPECIFICATIONS
Torque for piston cap screw........................................................................ 810 to 925 Nm (597.5 to 682 pound feet)
Torque for gland............................................................................................. 339 to 475 Nm (250 to 350 pound feet)

STEERING CYLINDER
Disassembly
1. Fasten tube (18) in a vise. Be careful not to
damage the tube. See illustration on page 4.
2. Remove gland (1) from tube (18).
3. Pull piston rod (14) and piston (9) straight out of
tube (18).
4. Fasten piston rod (14) yoke in vise and put a
support below piston rod near piston (9). Put a
shop cloth between support and piston rod to
prevent damage to piston rod.
5. Loosen and remove bolt and washer (8) that hold
piston (9).
6. Remove piston (9) from piston rod (14).

Inspection
1. Clean all parts in cleaning solvent.
2. Check to be sure that piston rod (14) is straight. If
piston rod is bent, install a new piston rod.
3. Inspect inside of tube (18) for deep grooves and
other damage. If there is any damage to tube, a
new tube must be used.
4. Remove small scratches on piston rod (14) or
inside tube (18) with emery cloth of medium grit.
Use emery cloth with a rotary motion.
5. Inspect bushing (17). If bushing requires
replacement, remove grease fitting (15) and
retaining rings (16) then press bushing from tube
end.

7. Remove and discard seal (13), loader ring (12),


wear ring (11), and cast iron ring (10) from piston
(9).
8. Remove gland (1) from piston rod (14).
9. Remove and discard O-ring (7), backup ring (6),
rod wiper (2), rod seal (3), buffer seal (4), and
bearing (5) from gland (1).

Bur 5-3160

Issued 8-06

Printed in U.S.A.

5005-4

15

16

17
16

18
8
9

19
13
12
11
10

14

BC05M089

1.
2.
3.
4.
5.

GLAND
ROD WIPER
ROD SEAL
BUFFER SEAL
BEARING

6.
7.
8.
9.
10.

BACKUP RING
O-RING
BOLT AND WASHER
PISTON
RING CAST IRON

11.
12.
13.
14.

WEAR RING
RING LOADER
SEAL
PISTON ROD

15.
16.
17.
18.

GREASE FITTING
RETAINING RING
BUSHING
TUBE

STEERING CYLINDER ILLUSTRATION

Bur 5-3160

Issued 8-06

Printed in U.S.A.

5005-5

Assembly
1. Install bearing (5) in gland (1).
2. Install buffer seal (4) in gland (1) so that lips of
seal are toward small end of gland.
3. Install rod seal (3) in gland (1). Rod seal must be
installed so that lips of seal are toward small end
of gland. Seal can be difficult to install. Use tools
that will not damage seal. See illustration on
page 4.
4. Install rod wiper (2) in gland (1) with wiper lips
toward large end of gland.
5.
6. Install O-ring (7) on gland (1).
7. Install backup ring (6) on gland (1). The backup
ring must be toward large end of gland. If backup
ring is not flat on both sides, the side that is not
flat must be toward O-ring (7).
8. Fasten piston rod (14) yoke in vise.

17. Install bolt and hardened washer (8) in piston (9).


18. Install piston (9) on piston rod (14) and start bolt
(8) into piston rod.
19. Tighten bolt (8) to a torque of 810 to 925 Nm
(597.5 to 682 pound feet).
20. Fasten tube (18) in vise. Be careful not to
damage tube.
21. Apply petroleum jelly to O-rings (7) and backup
ring (6) on gland (1) and to sealing surface in
tube (18).
22. Lubricate piston (9) and inside of tube (18) with
clean hydraulic oil.
23. Push the piston (9) straight into tube (18). Be
careful not to damage cast iron ring (10), wear
ring (11), and seal (13) on piston (9).
24. When piston (9) is in smooth part of tube (18),
start gland (1) into tube (18).
25. If the original parts are being assembled:

9. Lubricate piston rod (15) and bore in gland (1)


with clean hydraulic oil.

A. Tighten gland to a torque of 339 to 475 Nm


(250 to 350 pound-feet).

NOTE: If a new gland (1) is being installed, write


part number of cylinder on gland.

B. Install and tighten self-tapping screw (19) to a


torque of 2.3 Nm (20 inch-pounds).

10. Push gland (1) onto piston rod (14) large end
first. If necessary, use a soft hammer to drive the
gland onto piston rod.

C. If, after tightening gland, the self-tapping


screw (19) holes are not aligned, a new hole
for self-tapping screw must be drilled. See
Step 26.

11. Put a support below and near the end of piston


rod (14). Put a cloth between support and piston
rod to prevent damaging piston rod.

26. If a new gland (1) or a new tube (18) are being


assembled:

12. Install new cast iron ring (10) on piston (9).


13. Install new wear ring (11) on piston (9).
14. Install a new loader ring (12) on piston (9).
15. Install a new seal (13) over loader ring (12).
16. Clean the threads on the end of piston rod (14)
and threads of bolt (8) using Loctite cleaning
solvent. Allow to dry. Apply Loctite 243 to piston
rod threads 6.4 mm (1/4 inch) from open end of
piston rod so that there is 12.7 mm (1/2 inch) of
Loctite 243 on piston rod threads. DO NOT apply
Loctite to first 6.4 mm (1/4/inch) of piston rod
threads.

Bur 5-3160

A. Tighten gland (1) to a torque of 339 to 475 Nm


(250 to 350 pound-feet).
B. Use a No. 27 drill bit and drill a hole half in
gland (1) and half in tube (18). Drill to a depth
of 11 mm (7/16 inch). Do not drill within 13 mm
(1/2 inch) of a hole for gland wrench.
C. Install and tighten self-tapping screw (19) to a
torque of 2.3 Nm (20 inch-pounds).
27. If hoses were removed with cylinder, install new
O-rings, if equipped, on hose fittings. Lubricate
O-rings with clean oil. Install hoses.

Issued 8-06

Printed in U.S.A.

5005-6

NOTES

Bur 5-3160

Issued 8-06

Printed in U.S.A.

Section
5006

5006

CENTER PIVOT

CNH America LLC.


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

Bur 5-3170

Copyright 2006 CNH Ameica LLC.


All rights reserved.
Printed in U.S.A.
Issued August, 2006

5006-2

TABLE OF CONTENTS
SPECIFICATIONs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CENTER PIVOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTING THE FRONT FRAME TO THE REAR FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 5-3170

Issued 8-06

3
3
4
4
6
9

Printed in U.S.A.

5006-3

SPECIFICATIONS
SPECIAL TORQUES
M16 bolt for upper pivot pin .......................................................................220 to 250 Nm (162 to 184 pound-feet)
M12 bolts for bearing retainers and lower pivot pin...........................................................124 Nm (91 pound-feet)
M12 bolts for lower pin plate .......................................................................128 to 136 Nm (94 to 100 pound-feet)
Ferry head screws for the drive shaft ................................................................61 to 81 Nm (45 to 60 pound-feet)
LUBRICANT
Pivot bearings and seals ............................................................................... Case AKCELA molydisulfide grease
Steering cylinder rod eyes............................................................................. Case AKCELA molydisulfide grease

SPECIAL TOOLS
CAS10219 ....................................................................................................................... Hand pump (hydraulic ram)
CAS10512 ....................................................................................................................................... 10 ton ram (long)
CAS10592 ........................................................................................................... Puller set, includes 24827 leg ends
CAS10600 ................................................................................ Bearing cup and seal puller, includes 24850 adapter
CAS10193 .............................................................................................................................. Vacuum pump (12 volt)
CAS2029 ................................................................................... *Top bearing driver, bottom bearing driver and plate
* (Requires screw, two nuts, and two washers from CAS10592)

BC06A174

CAS2029 DRIVER SET

Bur 5-3170

Issued 8-06

Printed in U.S.A.

5006-4

CENTER PIVOT
Disassembly

19. Disconnect the supply hose.

1. Remove all dirt and grease from the area of the


center pivot. Park the machine on a level surface.

20. Install a cap on the hose and a plug in the fitting.

2. Lower the bucket until the bucket is flat on the


floor.
3. Stop the engine and apply the parking brake.

22. Loosen and remove the self-locking nut and bolt


that hold the pivot pin for the steering cylinder rod
eye.

4. Remove the covers from both sides of the


machine.

23. Remove the pivot pin from the rear frame and the
steering cylinder rod eye.

5. Disconnect the front wiring harness from the cab


floor.

24. Remove the washer from the rear frame. Move


the steering cylinder out of the way.

6. Remove any tie straps that fasten the front wiring


harness to the chassis near the center pivot.

25. Repeat steps 22, 23 and 24 for the other steering


cylinder.

7. Loosen and remove the nut and washer that


fasten the chassis ground wire and cab ground
wire to the studs.

26. Loosen and remove the Ferry head screws and


retainers that fasten the drive shaft to the front
yoke. Move the drive shaft out of the way.

8. Loosen and remove the bolt, lock washer, and


nut that fasten the clamp on the front wiring
harness to the bracket on the rear frame. Move
the front wiring harness out of the way.

27. Place two stands below and in contact with the


front frame.

9. Loosen and remove the fill cap for the hydraulic


reservoir.
10. Connect a vacuum pump to the hydraulic
reservoir. Start the vacuum pump.
11. Disconnect the brake hose from the backside of
front brake line bracket.

21. Stop the vacuum pump.

28. Install blocks between the rear axle and the rear
frame on both sides of the machine to prevent
the rear frame from tipping.
29. Put a jack in contact with both sides of the rear
frame near the center pivot area. Use another
jack at the rear of the machine to prevent the rear
frame from tipping.

12. Install a plug in the tube and a cap on the fitting.

30. Loosen and remove the bolt (1), washer (2), and
spacer (3) that fasten the upper pivot pin (4) to
the rear chassis (5).

13. Disconnect the hoses for the steering cylinder.

31. Use a prybar to remove the upper pivot pin (4).

14. Install caps on the fittings and plugs in the hoses.

32. Loosen and remove the bolts (1) and washers (2)
that fasten the lower pin plate (15) to the lower
pivot pin (10).

15. Loosen and remove the bolts, lock washers, and


self-locking nuts that fasten the mounting bracket
for the hoses to the bracket on the front frame.
16. Loosen and remove the bolts, flat washers, and
self-locking nuts that fasten the bracket for the
hoses to the rear frame.

33. Loosen and remove the bolts (1) and washers (2)
that fasten the lower pin plate (15) to the bottom
of the rear chassis (5).

17. Disconnect the return hose.

34. Use the ram and hand pump to remove the lower
pivot pin (10).

18. Install the cap on the hose and a plug in the


fitting.

35. Install the puller on the bottom spacer (14), see


Special Tools in this section.

Bur 5-3170

Issued 8-06

Printed in U.S.A.

5006-5

2
3

7
5
8

10
6

9
5

12

16

11
6

8
13
6
2

14

1
5

8
15

BS03B152

1.
2.
3.
4.

BOLT
WASHER
SPACER
UPPER PIVOT PIN

5.
6.
7.
8.

REAR CHASSIS
SEAL
BEARING RETAINER
SHIM

9.
10.
11.
12.

UPPER PIVOT BEARING


LOWER PIVOT PIN
LOWER BEARING SPACER
LOWER PIVOT BEARING

13.
14.
15.
16.

BEARING RETAINER
BOTTOM SPACER
LOWER PIN PLATE
FRONT CHASSIS

CENTER PIVOT ASSEMBLY

Bur 5-3170

Issued 8-06

Printed in U.S.A.

5006-6
36. Remove the bottom spacer (14).
37. Release the parking brake.
38. Use prybars to turn the left rear wheel backwards
and the right rear wheel forward to move the front
of the rear frame to the left for access to the
bearings. Install blocks under the wheels to
prevent the rear frame from moving.

Assembly
1. Pack the bearing cones with grease. Be careful
not to mix the bearing cones.
2. Lubricate the bore in the top pivot with grease.
3. Install a bearing cup (20) in the top pivot (22).
4. Install the bearing driver (17) and plate (21).

39. Apply the parking brake.

17 18

40. Hold the bearing retainer (13) in place and


loosen and remove the bolts (1) and washers (2)
that fasten the bearing retainer (13) and shims
(8) to the bottom of the rear pivot.

19

41. Remove the bearing retainer (13) and shims (8).


42. Remove the lower bearing spacer (11) from the
top of the lower pivot.

20

43. Loosen and remove the bolts (1) and washers (2)
that fasten the bearing retainer (7) and shims (8)
to the top of the top pivot.
44. Remove the bearing retainer (7) and shims (8).
45. Use the puller to remove the seal (6) from the top
of the bottom pivot.
46. Use the puller to remove the seal (6) from the
bottom of the top pivot.
47. Use an acceptable driver, the hydraulic ram, and
the hand pump to remove the upper pivot
bearing (9) from the top pivot. See Special Tools
in this section.
NOTE: The spacers are matched to the bearing
sets. Do not mix the spacers. Do not use the old
spacers if new bearing sets are being installed.
48. Use an acceptable driver, the hydraulic ram, and
the hand pump to remove the lower pivot bearing
(12) from the bottom pivot. See Special Tools in
this section.
NOTE: The spacers are matched to the bearing
sets. Do not mix the spacers. Do not use the old
spacers if new bearing sets are being installed.

21

22
BC06A118

17. BEARING DRIVER


18. NUT
19. SREW

20. BEARING CUP


21. PLATE
22. TOP PIVOT

5. Tighten a nut (18) on the screw (19) until the


bearing cup (20) is seated in the bore of the top
pivot (22). Remove the bearing driver (17) and
plate (21) from the top pivot (22).
6. Install a bearing cone (25), spacer (24), the other
bearing cone (23), and the remaining bearing
cup (26) in the top pivot (22).
7. Install the bearing driver (17) and plate (21).
8. Tighten a nut (18) on the screw (19) until the
bearing cup (26) is seated against the spacer
(24). Remove the bearing driver (17) and plate
(21) from the top pivot (22).

17
23

18

19
26

24

49. Use an acceptable driver to press the seal (6) out


of each bearing retainer (7 and 13).

25

21

22
BC06A119

23. BEARING CONE


24. SPCAER

Bur 5-3170

25. BEARING CONE


26. BEARING CUP

Issued 8-06

Printed in U.S.A.

5006-7
9. Put the bearing retainer (7) in place on the upper
pivot bearing assembly (9).
10. Install the bearing driver (17) and plate (21).
11. Tighten a nut (18) on the screw (19) until the
bearing retainer (7) is tight against the upper
pivot bearing assembly (9).

17

18

19

18. Use an acceptable driver to install the seal (6) in


the bottom of the top pivot.
19. The bottom of the seal (6) must be even with the
bottom of the top pivot.

27

BC06A125.

21

22

20. Apply grease to the upper pivot pin (4).


BC06A120

12. Measure the gap (27) between the bearing


retainer (7) and the top pivot (22). Make a record
of the measurement. Subtract 0.0762 to 0.1016
mm (0.003 to 0.004 inch) from the measurement.
Select shims (8) equal to that value.
13. Remove the bearing driver (17), plate (21), and
bearing retainer (7) from the top pivot.
14. Install the shims (8) and the bearing retainer (7).
15. Install the washers (2) and bolts (1). Tighten the
bolts (1) to 124 Nm (91 pound-feet).

21. Install the upper pivot pin (4) in the top pivot.
22. Lubricate the top pivot until grease is forced out
of the seal (6).
23. Rotate the upper pivot pin (4) to check the
bearing assembly. The upper pivot pin (4) must
rotate smoothly, but not easily. Leave the upper
pivot pin (4) in place to keep dirt out of the upper
pivot bearing (9).
24. Lubricate the bore for the bottom pivot with
grease. Install a bearing cup in the bottom pivot.
25. Install the bearing driver (17) and plate (21).

16. Install the seal (6) in the bearing retainer (7). The
top of the seal (6) must be even with the top of
the bearing retainer (7).

19

21

18
28
29
17
BC06A123

BC06A121

17. Fill the other seal (6) for the top pivot with grease.

26. Tighten a nut (18) on the screw (19) until the


bearing cup (28) is seated in the bore in the
bottom pivot (29).
27. Remove the bearing driver (17) and plate (21)
from the bottom pivot (29).
28. Install a bearing cone (25), spacer (24), the other
bearing cone (23), and the remaining bearing
cup (26) in the bottom pivot (29).
29. Install the bearing driver (17) and plate (21).

Bur 5-3170

Issued 8-06

Printed in U.S.A.

5006-8

21

18

25

40. Install the seal (6) in the bearing retainer (13).


The bottom of the seal (6) must be even with the
bearing retainer (13).

19

24
29

23

26
17
BC06A124

30. Tighten a nut (18) on the screw (19) until the


bottom bearing cup (26) is seated against the
spacer (24).
31. Remove the bearing driver (17) and plate (21)
from the bottom pivot (29).

BC06A126

41. Install the other seal (6) in the bottom pivot. The
top of the seal (6) must be even with the top of
the bottom pivot.

32. Put the bearing retainer (13) in place on the


lower pivot bearing (12).
33. Install the bearing driver and plate.

21

18

19
29
30

12

BC06A121

17

42. Install the lower bearing spacer (11) and the


bottom spacer (14).

13
BC06A125

34. Tighten a nut (18) on the screw (19) until the


bearing retainer (13) is tight against the lower
pivot bearing assembly (12).
35. Measure the gap (30) between the bearing
retainer (13) and the bottom pivot (29). Make a
record of the measurement. Subtract 0.0762 to
0.1016 mm (0.003 to 0.004 inch) from the
measurement. Select shims (8) equal to that
value.
36. Remove the bearing driver (17), plate (21) and
bearing retainer (13) from the bottom pivot.

43. Apply grease to the lower pivot pin (10).


44. Install the lower pivot pin (10) in the bottom pivot.
45. Hold the bottom spacer (14) in place and
lubricate the bottom pivot until grease is forced
out of the seal (6).
46. Rotate the lower pivot pin (10) to check the
bearing assembly. The lower pivot pin (10) must
rotate smoothly, but not easily.
47. Remove the lower pivot pin (10) and the upper
pivot pin (4).
48. Remove the bottom spacer (14).

37. Install the shims (8), the bearing retainer (13),


washers (2) and bolts (1).
38. Tighten the bolts (1) to 124 Nm (91 pound-feet).
39. Fill the seal (6) for the bearing retainer (13) with
grease.

Bur 5-3170

Issued 8-06

Printed in U.S.A.

5006-9

CONNECTING THE FRONT FRAME TO THE REAR FRAME


1. Release the parking brake.
2. Move the rear frame into alignment with the front
frame.
3. Move the steering cylinders as required to move
the rear frame into alignment with the front
frame.

26. Align the hole in the pivot pin with the holes in the
steering cylinder rod eye, and install the pivot pin.
27. Install the bolt and self-locking nut that hold the
pivot pin.
28. Repeat steps 25, 26 and 27 for the other steering
cylinder.

4. Apply the parking brake.

29. Start the vacuum pump.

5. Apply grease to the upper pivot pin (4).

30. Connect the return hose.

6. Install the upper pivot pin (4), spacer (3), washer


(2) and bolt (1). Be careful not to damage the
seal (6).

31. Connect the supply hose.

7. Tighten the bolt (1) to 220 to 250 Nm (162 to 184


pound-feet).
8. Apply grease to the lower pivot pin (10).
9. Install the lower pivot pin (10) in the frames. Be
careful not to damage the seal (6).
10. Use the ram and hand pump to install the bottom
spacer (14). See Special Tools in this section.

32. Put the bracket for the hoses in position on the


rear frame. Install the bolts, flat washers, and
self-locking nuts that fasten the bracket to the
rear frame.
33. Put the bracket for the hoses in position on the
front frame.
34. Install the bolts, flat washers, and self-locking
nuts that fasten the bracket to the front frame.
35. Connect the hoses for the steering cylinders.

11. Install the lower pin plate (15), three inner bolts
(1), and washers (2) that fasten the lower pin
plate (15) to the lower pivot pin (10).

36. Connect the brake hose for the front brakes at


the front bracket.

12. Tighten the bolts (1) to 69 Nm (51 pound-feet).

38. Connect the front wiring harness to the rear


wiring harness.

13. Measure the gap between the lower pin plate


(15) and the bottom pivot. Make a record of the
measurement. Subtract 0.0762 to 0.1016 mm
(0.003 to 0.004 inch) from the measurement.
Select shims equal to that value.
14. Loosen the bolts (1) that fasten the lower pin
plate (15) to the lower pivot pin (10).
15. Start the six outer bolts (1) into the lower pin
plate (15) and the bottom pivot.

37. Stop the vacuum pump.

39. Put the clamp on the wiring harness in position


on the bracket. Install the bolt, lock washer, and
nut that fasten the clamp on the wiring harness to
the bracket.
40. Put the ground wire in position on the stud. Install
the washer and nut that fasten the ground wire to
the stud.

16. Install the shims (8).

41. Install a tie strap to fasten the wiring harness to


the tube.

17. Tighten the six outer bolts (1) to 128 to 136 Nm


(94 to 100 pound-feet).

42. Disconnect the vacuum pump from the hydraulic


reservoir.

18. Tighten the three inner bolts (1) to 124 Nm (91


pound-feet).

43. Check the fluid level in the hydraulic reservoir.


Add oil as required.

19. Remove the jacks from the rear frame.

44. Install the fill cap in the hydraulic reservoir.

20. Remove the blocks from the rear axle.

45. Bleed air from the front axle bleed screws. Refer
to Section 7002 for complete brake bleeding
instructions.

21. Remove the stands from the front frame.


22. Put the drive shaft in position on the front yoke.
23. Install new Ferry head screws that fasten the
drive shaft to the front yoke.
24. Tighten the Ferry head screws to 61 to 81 Nm
(45 to 60 pound-feet).

46. Lubricate the pivot pins for the steering cylinder


rod eyes.
47. Install the covers on both sides of the machine.

25. Put the steering cylinder rod eye in position in the


frame. Install the washer between the steering
cylinder rod eye and the rear frame.
Bur 5-3170

Issued 8-06

Printed in U.S.A.

5006-10

NOTES

Bur 5-3170

Issued 8-06

Printed in U.S.A.

Section
5008

5008

AUXILIARY STEERING MOTOR AND PUMP

CNH America LLC.


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

Bur 6-42430

Copyright 2003 CNH Ameica LLC.


All rights reserved.
Printed in U.S.A.
Issued April, 2003

5008-2

TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUXILIARY STEERING MOTOR AND PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 6-42430

Issued 4-03

3
4
4
4
4

Printed in U.S.A.

5008-3

SPECIFICATIONS
Auxiliary steering motor
Maximum amperes...............................................................................................................................30 amperes
Minimum armature speed ............................................................................................................ 6950 r/min (rpm)
Motor ...........................................................................................................................................................24 volts
Auxiliary steering pump
Minimum flow ..............................................................................................24.6 L/min at 104 bar at 315 amperes
(6.5 U.S. gpm at 1500 psi at 315 amperes)

Bur 6-42430

Issued 4-03

Printed in U.S.A.

5008-4

AUXILIARY STEERING MOTOR AND PUMP


Disassembly

Assembly

NOTE: Refer to Section 5001 for removal and


installation of the auxiliary steering motor and pump.

1. Lubricate all parts with clean hydraulic oil before


assembly.

NOTE: The pump is the only component that is


disassembled. The switch (8) and motor (1) are
replaced as units and are not serviced. Refer to the
illustration on page 5.

2. Lubricate and install a new seal (4) and retaining


ring (3) on the plate (17). Refer to the illustration
on page 5.

1. Make an alignment mark on the pump assembly


and motor (1).
2. Loosen and remove the two screws (15) and lock
washers (14) that hold the pump assembly to the
motor (1).
3. Remove and discard the mounting gasket (13),
retaining ring (3) and seal (4) from the pump
assembly.
4. Loosen and remove the four bolts (2) that hold
the pump assembly together.
5. Remove the end plate (21) from the body (18).
6. Remove and discard the seal (6) and backup ring
(5) from the end plate (21).
7. Remove the wear plate (23), drive gear (20) and
driven gear (19) from the body (18).
8. Remove the body (18) from the plate (17).
9. Remove and discard the O-rings (7) from the
body (18).

3. Lubricate and install a new backup ring (5) and a


new seal (6) on the plate (17).
4. Lubricate and install new O-rings (7) on the body
(18).
5. Lubricate and install the pins (22), drive gear
(20), driven gear (19) and wear plates (23) on the
body (18).
6. Lubricate and install a new backup ring (5) and a
new seal (6) on the end plate (21).
7. Align the marks, made during disassembly, on
the end plate (21), body (18) and plate (17) and
install the four bolts (2). Tighten the four bolts (2).
8. Install a new gasket (13) on the pump assembly.
9. Align the marks, made during disassembly, on
the pump assembly and the motor (1).
10. Install the lock washer (14) and screw (15).
Torque the screw (15) to 35 to 39 Nm (312 to 348
pound-inches).

10. Remove the pins (22) and wear plate (23) from
the body (18).
11. Remove and discard the seal (6) and backup ring
(5) from the plate (17).
NOTE: The only serviceable items on the pump
assembly are the seals (6), backup rings (5), O-rings
(7), seal (4), retaining ring (3) and gasket (13). If any
of the other items are damaged, replace the pump
assembly.

Inspection
1. Inspect the wear plates (23) for grooves, scoring
and pitting. If damage is found replace the pump
assembly. Refer to the illustration on page 5.
2. Inspect the drive gear (20) and driven gear (19).
If the shafts are worn or damaged, replace the
pump assembly.
3. Clean all parts in cleaning solvent and air dry.
4. Inspect the plate (17), end plate (21) and body
(18). Replace the pump assembly as necessary.
Bur 6-42430

Issued 4-03

Printed in U.S.A.

5008-5

10

11
16

12

1
13
3

17

14
15

5
6
23

19
7
22
18
22
7
20
23
6
5
21
2
BS01C121

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

MOTOR
BOLT
RETAINING RING
SEAL
BACKUP RING
SEAL

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

O-RING
SWITCH
CABLE
SCREW
LOCK WASHER
WASHER

13.
14.
15.
16.
17.
18.

GASKET
LOCK WASHER
SCREW
WIRE
PLATE
BODY

19.
20.
21.
22.
23.

DRIVEN GEAR
DRIVE GEAR
END PLATE
PINS
WEAR PLATE

AUXILIARY STEERING PUMP AND MOTOR ILLUSTRATION

Bur 6-42430

Issued 4-03

Printed in U.S.A.

5008-6

NOTES

Bur 6-42430

Issued 4-03

Printed in U.S.A.

SECTION INDEX

POWER TRAIN
Section Title

Section Number

Removal and Installation of Power Train Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6001


Transmission Specifications, Pressure Checks, and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6002
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6003
Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6004
Rear Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6004
Drive Shafts, Center Bearing, and Universal Joints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6005
Wheels and Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6006
Transmission Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6007

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

Bur 5-3180

Copyright 2006 CNH Ameica LLC.


All rights reserved.
Printed in U.S.A.
Issued August, 2006

6001
Section
6001
REMOVAL AND INSTALLATION OF POWER TRAIN
COMPONENTS

CNH America LLC.


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

Bur 5-4010

Copyright 2006 CNH America LLC.


All rights reserved.
Printed in U.S.A.
Issued August, 2006

6001-2

TABLE OF CONTENTS
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Axle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Axle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 5-4010

Issued 8-06

3
3
7
8
13
13
15
16
18
18
20
21

Printed in U.S.A.

6001-3

TRANSMISSION
Removal

STEP 7

STEP 1
Park the machine on a level surface and lower the
bucket to the floor. Stop the engine and apply the
parking brake.

STEP 2
Place the master disconnect switch in the OFF
position.

STEP 3
Refer to Section 9007 and remove ROPS cab or
ROPS canopy.

STEP 4
Refer to Section 8001 and remove the hydraulic
pump.

BD01D315

Disconnect transmission wiring harness connector


from control valve connector. Remove socket head
bolt securing wiring harness clamp. Move wiring
harness away from transmission.

STEP 8

STEP 5
Put a 25.5 liter (27 quar ts) container under
transmission drain plug. Remove drain plug and drain
transmission oil. Install drain plug after oil has
drained.

STEP 6

BD01D317

Just above where clamp was installed, tag and


disconnect transmission wiring harness connector
from temperature sensor. Move wiring harness away
from transmission.

STEP 9
BD01D306

Identify, tag, and disconnect brake pump pressure


hose and brake to hydraulic reservoir hose. Position
hoses away from transmission. Remove and discard
O-ring face seals from fittings. Plug hoses and cap
fittings to prevent entr y of foreign matter into
hydraulic system.

BD01D310

Remove two socket head bolts securing transmission


wiring harness clamps.
Bur 5-4010

Issued 8-06

Printed in U.S.A.

6001-4

STEP 10

STEP 13

BD01D312

BD01F281

Identify, tag, and disconnect transmission wiring


harness connectors from engine speed sensor,
intermediate speed sensor, and turbine speed
sensor. Move transmission wiring harness away from
transmission.

Remove two bolts and washers securing hose


retainer to front of rear chassis. Move hose retainer
towards front of machine.

STEP 14

STEP 11

BD03A165

BD01D316

Remove socket head bolt securing wiring harness


clamp. Move wiring harness away from transmission.

STEP 12

Identify, tag, and disconnect parking brake hose from


parking brake. Plug hose and cap fitting to prevent
entry of foreign matter into hydraulic system. Move
hose away from transmission. Remove four bolts and
two straps securing center drive shaft to transmission
output flange. Disconnect center drive shaft from
transmission.

BD01D314

Identify, tag, and disconnect transmission wiring


harness connectors from filter maintenance switch
and output speed sensor. Move transmission wiring
harness away from transmission.

Bur 5-4010

Issued 8-06

Printed in U.S.A.

6001-5

STEP 15

STEP 18

BD03A161

BD01D339

Remove four bolts and two straps securing rear drive


shaft to transmission output flange. Disconnect rear
drive shaft from transmission.

Remove fitting. Remove and discard O-ring from


fitting. Install a plug in transmission port.

STEP 19
STEP 16

BD01D340
BD03A160

Remove two bolts. Remove fill tube, with cap and oil
gauge assembled, two seals, and metal strainer.
Discard seals.

Repeat Steps 17 and 18 and disconnect the other


cooler hose and remove fitting.

STEP 20

STEP 17

BD01D343

BD01D318

Connect lifting equipment to transmission lifting eyes.


Take up all slack in lifting equipment.

Identify, tag, and disconnect cooler hose from fitting


installed in LH side of transmission. Install a plug in
hose. Remove and discard O-ring face seal from
fitting.

Bur 5-4010

Issued 8-06

Printed in U.S.A.

6001-6

STEP 21

STEP 23

BD01D342

BD03A164

In area between the transmission and the engine,


remove four bolts and two straps. Use pry bar to
disconnect engine drive shaft from transmission.
Using 3/4 inch drive socket, extensions, and impact
wrench, remove four bolts and washers securing
transmission to top mounting bracket.

Raise transmission just enough to enable removal of


RH and LH mounting brackets. Remove two bolts
and washers securing RH and LH mounting brackets
to transmission. Remove RH and LH mounting
brackets.

STEP 24
STEP 22

BD01D345
BD03A163

Remove bolts and washers securing RH and LH


mounting brackets to rear chassis.

Slowly and carefully raise transmission from loader


while checking that all hoses, electrical connectors,
and wires have been disconnected and nothing
interferes with transmission removal. Remove
transmission from loader.

STEP 25

BD01D361

If top mounting bracket requires removal, remove bolt


and washer then remove bracket.

Bur 5-4010

Issued 8-06

Printed in U.S.A.

6001-7

Transmission Mounting
4

2
1

C
B
1
3

2
2

5
7

1
5

2
A

BS03B153

1.
2.
3.
4.
5.

Bur 5-4010

ISOLATOR BOLT
WASHER
BOLT
BOLT
BOLT

6.
7.
A.
B.
C.

MOUNTING BRACKET
TOP MOUNTING BRACKET
REAR CHASSIS TRUNNION
BRACKET (6 OR 7)
SMALLER PIECE ON TOP

Issued 8-06

Printed in U.S.A.

6001-8

Installation

STEP 29

STEP 26
Check isolators for deterioration, tears, deformation,
or other damage. Replace as necessary: refer to
Page 7.

STEP 27

BD03A164

Install RH and LH mounting brackets on transmission


using two washers and bolts. Do not tighten bolts.

STEP 30

BD01D361

If top mounting bracket was removed, put bracket on


rear chassis trunnion and secure using washer and
bolt. Do not tighten bolt.

STEP 28

BD03A163

Loosely install washers and bolts to secure RH and


LH mounting brackets to rear chassis. Tighten bolts
securing RH and LH mounting brackets to
transmission to a torque of 481 to 590 Nm (355 to
435 pound feet).

BD01D345

Move transmission into position above loader. Slowly


lower transmission into loader.

Bur 5-4010

Issued 8-06

Printed in U.S.A.

6001-9

STEP 31

STEP 33

NOTE: In this step, new straps and bolts securing


the drive shaft must be installed whenever these
parts are removed. Bolts have a nylon patch to
maintain torque which requires new bolts.

BD01D343

Disconnect lifting equipment from transmission lifting


eyes.
BD01D342

STEP 34

Using 3/4 inch drive socket, extensions, and impact


wrench, install four washers and bolts to secure top
mounting bracket to transmission. Then tighten bolts
to a torque of 251 to 319 Nm (185 to 235 pound feet).
If bracket had been removed, tighten bolt to a torque
of 890 to 1000 Nm (655 to 735 pound feet). Connect
engine drive shaft to transmission. Install two new
straps and four new bolts. Tighten bolts to a torque of
61 to 81 Nm (45 to 60 pound feet).

STEP 32
BD01D340

Install new O-ring on fitting and install fitting in


transmission. Install new O-ring face seal in fitting
then connect cooler hose to fitting following tag
installed during removal. Remove and discard tag.

STEP 35

BD03A163

Tighten bolts securing RH and LH mounting brackets


to a torque of 890 to 1000 Nm (655 to 735 pound
feet).

BD01D318

Install new O-ring on fitting and install fitting in


transmission. Install new O-ring face seal in fitting
then connect cooler hose to fitting following tag
installed during removal. Remove and discard tag.

Bur 5-4010

Issued 8-06

Printed in U.S.A.

6001-10

STEP 36

STEP 39

BD03A160

BD01F281

Position fill tube, two new seals, and metal strainer


on transmission; metal strainer is installed between
seals. Secure using two bolts. Tighten bolts to a
torque of 17 to 33 Nm (12 to 24 pound feet).

Position hose retainer on front of rear chassis and


secure using two washers and bolts.

STEP 40

STEP 37

BD01D314

BD03A161

Connect rear drive shaft to transmission then install


two straps and four bolts. Tighten bolts to a torque of
61 to 81 Nm (45 to 60 pound feet).

Connect transmission wiring harness connectors to


output speed sensor and filter maintenance switch
following tags installed during removal. Remove and
discard tags.

STEP 41
STEP 38

BD01D316
BD03A165

Connect center drive shaft to transmission and install


two straps and four bolts. Tighten bolts to a torque of
61 to 81 Nm (45 to 60 pound feet). Connect parking
brake hose to parking brake following tag installed
during removal. Remove and discard tag.
Bur 5-4010

Install socket head bolt to secure wiring harness


clamp.

Issued 8-06

Printed in U.S.A.

6001-11

STEP 42

STEP 45

BD01D312

BD01D315

Connect transmission wiring harness connectors to


turbine speed sensor, intermediate speed sensor,
and engine speed sensor following tags installed
during removal. Remove and discard tags.

Install socket head bolt to secure wiring harness


clamp. Connect transmission wir ing har ness
connector to control valve connector.

STEP 46
STEP 43

BD01D306
BD01D310

Install two socket head bolts to secure transmission


wiring harness clamps.

At brake valve, install new O-ring face seals in


fittings. Connect brake to hydraulic reservoir hose
and brake pump pressure hose following tags
installed during removal. Remove and discard tags.

STEP 44
STEP 47

BD01D317

Connect transmission wiring harness connector to


temperature sensor following tag installed during
removal. Remove and discard tag.

Bur 5-4010

BD03A177

Check that transmission drain plug is tight.

Issued 8-06

Printed in U.S.A.

6001-12

STEP 48

STEP 50

Fill transmission with 15-40W engine oil until oil level


is up to the arrow in sight glass.

Refer to Section 9007 and install ROPS cab or ROPS


canopy.

STEP 49

STEP 51

Refer to Section 8001 and install the hydraulic pump.

Start and run engine at idle speed with transmission


in neutral. If transmission oil level is at or below
bottom of crosshatch region, put articulation lock in
LOCKED position and add engine oil, 15-40W, until
oil level is up to crosshatch region. Shut down engine
and put articulation lock in OPERATING position.

Bur 5-4010

Issued 8-06

Printed in U.S.A.

6001-13

FRONT AXLE
Removal

STEP 4

STEP 1

BD03A167

BD03A040

Park machine on level surface. Have assistant put


articulation lock in LOCKED position.

Remove four bolts and two straps securing front drive


shaft to front axle.

STEP 5

IMPORTANT: If machine is equipped with


quick-attached components, disconnect them from
machine prior to proceeding.

STEP 2

BD03A166

BD03A092

Raise bucket and have assistant install safety link.


Lowe r loa der ar ms slowly until sa fety link is
supporting loader arms.

Remove clamp securing lubrication hose to machine


and nut securing opposite end of hose. Remove four
bolts and two straps securing center drive shaft to
front drive shaft. Use a pry bar to separate drive
shafts. While supporting center bearing and front
drive shaft, remove four nuts and bolts and eight
washers. Lower center bearing and front drive shaft
from mounting plate and remove from machine.

STEP 3
Stop engine. Actuate brake pedal several times to
discharge brake accumulators. Put key switch in ON
position and move loader control lever back and forth
at least 30 times to release any pressure from
hydraulic circuit. Put key switch in OFF position.

Bur 5-4010

Issued 8-06

Printed in U.S.A.

6001-14

STEP 6

STEP 9

BD03A168

Disconnect brake hose from elbow. Remove and


discard O-ring face seal from elbow.

BD01F297

Use an acceptable jack to hold front axle.

STEP 10
STEP 7

BD01F295
BD01F298

Remove bolts and washers from front wheels.


Remove both wheels from front axle.

STEP 11

BD01D392

Using an acceptable hydraulic jack, raise one tire


from ground and install an acceptable jack stand
under machine.

BD01F296

STEP 8

Remove eight nuts bolts, and washers securing front


axle to machine.

Repeat Step 68 to raise other front axle tire from


ground.

STEP 12
Carefully lower front axle and remove from under
machine.

Bur 5-4010

Issued 8-06

Printed in U.S.A.

6001-15

Front Axle Mounting

3
4

BS03B151

1. BOLT
2. WASHER
3. WASHER

Bur 5-4010

4. NUT
5. FRONT AXLE

Issued 8-06

Printed in U.S.A.

6001-16

Installation

STEP 15

STEP 13
Carefully move front axle under machine and raise
against mounting pads on machine.

STEP 14

BD01F295

BD01F296

Apply one drop of engine oil to threads prior to


assembly. Install eight washers, bolts, washers, and
nuts to secure front axle to machine. Tighten bolts to
a torque of 765 to 865 Nm (565 to 630 pound feet).

BS06G052

Install both wheels on front axle and secure. Tighten


bolts to a preliminary torque of 298 Nm (230 pound
feet) in sequence indicated; then tighten to a torque
of 640 to 720 Nm (475 to 530 pound feet) in same
sequence.

STEP 16

BD01F297

Remove jack from front axle.

Bur 5-4010

Issued 8-06

Printed in U.S.A.

6001-17

STEP 17

STEP 20

BD01F298

BD03A166

Position and support center bearing and front drive


shaft and install eight washers and four bolts and
nuts. Tighten bolts to a torque of 99 to 128 Nm (73 to
94 pound feet). Install two straps and four bolts.
Tighten bolts to a torque of 61 to 81 Nm (45 to 60
pound feet). Secure lubrication hose to machine
using clamp; secure opposite end of hose using nut.

STEP 21

BD01D392

Using an acceptable hydraulic jack, raise axle and


remove jack stand from under machine.

STEP 18
Repeat Step 78 to remove other jack stand from
under machine.

STEP 19
BD03A167

Secure drive shaft to front axle using two straps and


four bolts. Tighten bolts to a torque of 61 to 81 Nm
(45 to 60 pound feet).

STEP 22
If necessary, fill axle with gear lubricant specified in
Section 1002.

STEP 23
Refer to Section 7002 and bleed brakes.
BD03A168

Install a new O-ring face seal in elbow. Connect


brake hose to elbow.

STEP 24
Star t engine and raise bucket. Have assistant
remove safety link. Lower bucket to ground and stop
engine.

STEP 25
Put articulation lock in OPERATING position.
Bur 5-4010

Issued 8-06

Printed in U.S.A.

6001-18

REAR AXLE
Removal

STEP 5

STEP 1
Park machine on a level surface; be sure to allow
adequate space at side of machine for removal of
rear axle. Stop engine. Actuate brake pedal several
times to discharge brake accumulators. Put key
switch in ON position and move loader control lever
back and for th at least 30 times to release any
pressure from hydraulic circuit.

STEP 2
BD03A169

Disconnect brake hose from elbow. Remove and


discard O-ring face seal from elbow.

STEP 6

BD03A040

Put articulation lock in LOCKED position.

STEP 3
Install wood blocks between rear axle and chassis to
prevent rear axle from pivoting.

BD01F299

Using an acceptable hydraulic jack, raise one tire


from ground and install an acceptable jack stand
under machine. Repeat this step for other tire.

STEP 4

STEP 7

BD03A162

Remove four bolts and two straps. Use a pry bar to


disconnect rear drive shaft from rear axle.
BD01F302

Use an acceptable jack to hold rear axle.

Bur 5-4010

Issued 8-06

Printed in U.S.A.

6001-19

STEP 8

STEP 10
Carefully lower rear axle and remove through side of
machine.

STEP 11
Remove and discard two seals from rear axle pivot
point.

BD01F295

Remove bolts and washers from rear wheels.


Remove both wheels from rear axle.

STEP 9

BD03A170

At front of trunnion, remove two Allen head bolts and


washers. Remove front cap: if necessary use two
M12 by 32 mm (1.25 inches) bolts in puller holes (A);
tighten bolts evenly to pull cap from axle and
trunnion. Remove and discard O-ring from cap.
Repeat this step at rear of trunnion except remove
and retain shim(s) after removal of rear cap. Remove
pivot sh aft using accep table sleeve or rod if
necessary.

Bur 5-4010

Issued 8-06

Printed in U.S.A.

6001-20

Rear Axle Mounting

6
5

1
4
3
2

6
5

7
10
6

3
11
5

12

BS01D132

1.
2.
3.
4.

Bur 5-4010

TRUNNION
O-RING
SEAL
FRONT CAP

5.
6.
7.
8.

WASHER
BOLT
WASHER
BOLT

9.
10.
11.
12.

REAR AXLE
PIVOT PIN
SHIM(S)
REAR CAP

Issued 8-06

Printed in U.S.A.

6001-21

Installation

STEP 13

NOTE: If shim(s) (11) have been lost or pivot pin


(10) has been replaced, do Step 12 to determine
required shim(s) otherwise go to Step 13.

STEP 12
6

10
12

BD01D482A

A
B
BS01E091A

Install pivot pin (10) and caps (4 and 12) in trunnion


(1) without rear axle or shim(s). Install washers (5)
a n d b o l t s ( 6 ) . T i g h t e n b o l t s s e c u r e l y. P u s h
assembled pivot pin and caps to rear of machine as
far as possible. Measure and record gap (A) between
rear cap (12) and trunnion. Select shims from the
following:
NOTE: Shims are available in following sizes: 0.50
mm (0.020 inch), 1.0 mm (0.039 inch), and 1.50 mm
(0.059 inch).
MEASURED
GAP (mm)

SHIM(S) REQUIRED
(mm)

0.07 to 0.55

None

0.56 to 1.09

0.50

1.10 to 1.59

1.0

1.60 to 2.09

1.50

2.10 to 2.59

0.50 plus 1.50

2.60 to 3.02

1.0 plus 1.50

BD01D499

Clean front (A) and rear (B) pivot area of rear axle
where seals (3) will be installed.

STEP 14
A
3
4
12

2
BS01E092

Lubricate two new seals (3) and new O-rings (2)


using Molydisulfide Grease. Install seals, smooth
side out, into front and rear of axle housing (A) until
flush with housing or recessed 2.0 mm (0.079 inch).
Install an O-ring in each cap (4 and 12).

STEP 15
Carefully move rear axle under machine. Raise axle
into position in trunnion and align pivot holes in
trunnion with pivot holes in axle.
Bur 5-4010

Issued 8-06

Printed in U.S.A.

6001-22

STEP 16
11
12

STEP 17
4

10

1
BS01E091

BD01F295

Lubricate pivot pin (10) using Molydisulfide Grease.


At rear of trunnion (1), install pivot pin into trunnion
and axle (A). Install shim pack (11), rear cap (12)
with O-ring installed, and two washers and bolts (6).
At front of trunnion install front cap (4) with O-ring
installed, and two washers and bolts (6). Tighten
bolts (6) to a torque of 651 to 678 Nm (480 to 500
pound feet).

BS06G052

Install both wheels on front axle and secure. Tighten


bolts to a preliminary torque of 298 Nm (220 pound
feet) in sequence indicated; then tighten to a torque
of 640 to 720 Nm (475 to 530 pound feet) in same
sequence.

STEP 18
Remove hydraulic jack supporting rear axle and jack
stands supporting loader.

Bur 5-4010

Issued 8-06

Printed in U.S.A.

6001-23

STEP 19

STEP 21
If necessary, fill axle with gear lubricant specified in
Section 1002.

STEP 22
Refer to Section 7002 and bleed brakes.

STEP 23
Put articulation lock in OPERATING position.

BD03A169

Install a new O-ring face seal in elbow. Connect


brake hose to elbow.

STEP 20

BD03A162

Connect rear drive shaft to rear axle. Install two


straps and four bolts. Tighten bolts to a torque of 61
to 81 Nm (45 to 60 pound feet).

Bur 5-4010

Issued 8-06

Printed in U.S.A.

6001-24

NOTES

Bur 5-4010

Issued 8-06

Printed in U.S.A.

6002

Section
6002
TRANSMISSION SPECIFICATIONS, PRESSURE
CHECKS, AND TROUBLESHOOTING

CNH America LLC.


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

Bur 5-2840

Copyright 2006 CNH Ameica LLC.


All rights reserved.
Printed in U.S.A.
Issued August, 2006

6002-2

TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Shift Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission ECM Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Sensor Data Collection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Automatic Problem Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Modulation Substitute Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Limp-Home Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission/Transmission ECM Shutdown Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Clutch Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Selections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Automatic/Manual Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Upshifting in Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Downshifting in Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Upshifting in Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Downshifting in Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Downshift Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cold Start Protection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Pedal Transmission Declutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION PRESSURE TEST POINTS DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHART FOR RECORDING PRESSURE READINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRESSURE TEST RESULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
All or Most Pressures Low and/or Flow Test Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Some Pressures Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Not Enough Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Machine Stops or Hesitates While Shifting - Intermittent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONVERTER OUT PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FLOWMETER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flowmeter Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONSUMPTION TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION SHIFTER LOGIC INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RELATIONSHIP BETWEEN TRANSMISSION ECM, VALVES, AND CLUTCHES . . . . . . . . . . . . . . . . . . . . . .

Bur 5-2840

Issued 8-06

3
3
9
9
9
9
9
10
10
10
10
10
11
11
11
11
11
11
12
12
12
12
12
12
13
15
16
16
16
16
16
17
17
17
17
17
17
17
17
17
17
18
19
19
19

Printed in U.S.A.

6002-3

SPECIAL TOOLS
CAS-1953A Transmission supplemental fitting kit.
Includes: CAS-2324 special 90 degree adapter and
CAS-2325 plug and cap set.
CAS-1804 Master pressure test kit

CAS-1808 Flowmeter kit


CAS-2702 Flowmeter adapter
CAS-2278 Flow test kit

SPECIFICATIONS
Main pressure and clutch pressure ................................................................................16 to 18 bar (232 to 261 psi)
Converter in pressure .......................................................................................................8 to 10 bar (116 to 145 psi)
Pressure reduction for solenoids ........................................................................................7 to 9 bar (102 to 131 psi)
Converter out pressure.....................................................................................................3.5 to 6.5 bar (51 to 96 psi)
Lubrication pressure ...........................................................................................................0.2 to 1.2 bar (3 to 18 psi)
Minimum pump output (at 2000 rpm) .....................................................................................80 L/min (21 U.S. gpm)
Transmission oil operating temperature..........................................................................80 to 120 C (176 to 248 F)
Clutch KV........................................................................................................................16 to 18 bar (232 to 261 psi)
Clutch KR .......................................................................................................................16 to 18 bar (232 to 261 psi)
Clutch K1 ........................................................................................................................16 to 18 bar (232 to 261 psi)
Clutch K2 ........................................................................................................................16 to 18 bar (232 to 261 psi)
Clutch K3 ........................................................................................................................16 to 18 bar (232 to 261 psi)
Clutch K4 ........................................................................................................................16 to 18 bar (232 to 261 psi)

Bur 5-2840

Issued 8-06

Printed in U.S.A.

6002-4

1
3

12

9
6
8

11
14
7

13
10

BS01A190

1.
2.
3.
4.
5.
6.
7.

TRANSMISSION ELECTRONIC CONTROL MODULE


DOWNSHIFT BUTTON
DECLUTCH ROCKER SWITCH
MANUAL/AUTOMATIC ROCKER SWITCH
SHIFTER
SUPPLY SYSTEM CONNECTIONS B+ AND RETURN
TRANSMISSION

8.
9.
10.
11.
12.
13.
14.

INDUCTIVE TRANSMITTER - INTERMEDIATE SPEED SENSOR


INDUCTIVE TRANSMITTER - TURBINE SPEED SENSOR
INDUCTIVE TRANSMITTER - ENGINE SPEED SENSOR
HALL SENSOR - OUTPUT SPEED SENSOR
TRANSMISSION CONTROL VALVE CABLE
DECLUTCH LIMIT SWITCH
PLUG

COMPONENT LOCATIONS SYSTEMS

Bur 5-2840

Issued 8-06

Printed in U.S.A.

6002-5

12
11
1

2
10
3

9
4

15

14
8
13

BS03A262

1.
2.
3.
4.
5.
6.
7.
8.

CLUTCH SHAFT KR
POWER TAKE OFF
CLUTCH SHAFT KV
CLUTCH SHAFT K2
CLUTCH SHAFT K3
OUTPUT FLANGE REAR
OUTPUT FLANGE CONVERTER SIDE
OUTPUT SHAFT

9.
10.
11.
12.
13.
14.
15.

TRANSMISSION PUMP
INPUT FLANGE
CONVERTER
INDUCTIVE TRANSMITTER FOR ENGINE SPEED
CLUTCH SHAFT K4
CONVERTER RELIEF VALVE
CLUTCH SHAFT K1

COMPONENT LOCATIONS TRANSMISSION LAYOUT

Bur 5-2840

Issued 8-06

Printed in U.S.A.

6002-6

BS01A191

1. ATTACHMENT FOR OIL FILLER PIPE WITH OIL DIPSTICK


2. TRANSMISSION SUSPENSION BORES

3. OUTPUT FLANGE CONVERTER


SIDE
4. OIL DRAIN PLUG

COMPONENT LOCATIONS FRONT VIEW

Bur 5-2840

Issued 8-06

Printed in U.S.A.

6002-7

5
9
10
8

BS01A192

1.
2.
3.
4.
5.

CONVERTER BELL HOUSING


BREATHER
TRANSMISSION CASE COVER
FILTER HEAD
FILTER

6.
7.
8.
9.
10.

OUTPUT FLANGE REAR


OIL DRAIN PLUG
OUTPUT FLANGE CONVERTER SIDE
TRANSMISSION CASE
PARKING BRAKE

COMPONENT LOCATIONS SIDE VIEW

Bur 5-2840

Issued 8-06

Printed in U.S.A.

6002-8

BS01B048

1.
2.
3.
4.

LIFTING LUGS
POWER TAKE OFF
TRANSMISSION CONTROL VALVE
TRANSMISSION SUSPENSION BORES

5. OUTPUT FLANGE REAR


6. FILTER
7. FILTER HEAD

COMPONENT LOCATIONS REAR VIEW

Bur 5-2840

Issued 8-06

Printed in U.S.A.

6002-9

TRANSMISSION OPERATION
General

Transmission ECM Tasks

The transmission is equipped with a Transmission


ECM (Electronic Control Module). This module
controls modulation and shifting that were normally
a s s o c i a t e d w i t h hy d r a u l i c a l l y m o d u l a t e d
transmissions, providing smoother shifts and
enhanced clutch life.

The Transmission ECM performs a variety of tasks in


the overall system. The Transmission ECM:

The Transmission ECM relies on signals from several


sensors that are incorporated into the design. These
sensors measure the speed of several components,
as well as other sensors that measure temperature.
These solenoids and sensors are further defined in
the following paragraphs.
In a d d i t i o n , th e t ra n s m i s s i o n i n c o r p o ra t e s a
two-piece transmission case for ease of transmission
maintenance, helical cut gears that help reduce
noise, and all external hoses have been eliminated
(all oil passages are internal).

A. Determines which clutches to engage in the


transmission.
B. Protects the engine and transmission turbine
from overspeed conditions dur ing
downloading.
C. Receives speed information from the engine
speed sensor, the turbine speed sensor, the
intermediate shaft speed sensor and the
transmission output shaft speed sensor.
T h e s e s p e e d s e n s o r s a r e c h e ck e d t o
deter mine if nor mal sensor operation is
present. The data is also used to control
modulation during shifting and to determine
the appropriate shift patterns.
D. Detects system failures and determines the
appropriate alternative actions.

Transmission ECM
Modulation and shifting are controlled by the
Tr a n s m i s s i o n E l e c t r o n i c C o n t r o l M o d u l e
(Transmission ECM). This module replaces the oil
and springs that are found in hydraulically modulated
transmissions.
T h e Tr a n s m i s s i o n E C M c o n t r o l s t h e c l u t c h
e n g a g e m e n t , p r ov i d i n g s m o o t h e r s h i f t s a n d
enhanced clutch life, whether the transmission is set
to the automatic or manual shift mode.
The Transmission ECM also informs the Information
Center, by the use of diagnostic codes, of any
transmission error and the hours of operation that the
error occurred.

E. Provides various diagnostic messages to the


Information Center.
F. Provides other information to the information
center, which in turn displays engine speed,
wheel speed, gear shift selection, and actual
gear selection.
G. Provides a method to
transmission clutch control.

calibrate

the

H. Establishes clutch modulation pressure during


transmission shifts.

Electrical Shift Solenoids


Electrical Shift Solenoids control the modulation of
the clutches, eliminating the need for a modulation
valve, and providing a smooth shift while maintaining
constant control over clutch engagement as follows:
A. A temperature sensor relays the
temperature to the Transmission ECM.

oil

B. The Transmission ECM times the rate the


solenoid energizes and de-energizes.
C. As the transmission changes gears, there is
reduced hesitation from one gear to the next.

Bur 5-2840

Issued 8-06

Printed in U.S.A.

6002-10

Transmission Sensor Data


Collection
The Transmission ECM collects and uses information
from four sensors to accurately shift the transmission
and determine if any clutches are slipping. These
sensors are:
Engine (Speed) Sensor - monitors engine speed to
determine the load on the engine for shift points and
sends the engine rpm to the Transmission ECM,
which sends the information to the tachometer in the
Information Center.
Turbine (Speed) Sensor - assists the engine speed
sensor in deter mining the load going into the
transmission and helps determine shift points.
Intermediate (Shaft Speed) Sensor - determines
differential gear speed in the transmission to check
for clutch slippage.
Output (Speed) Sensor - monitors transmission
output shaft speed to help determine the load on the
transmission and to assist in determining shift points.
Sends output shaft speed to Transmission ECM
which sends the information to the speedometer in
the Information Center.
T h e t ra n s m i s s i o n E C M a l s o r ev i ew s vo l t a g e
infor mation from the shifter and transmission
solenoids to determine if there are any short circuits
or open circuits in the system.

Automatic Problem Modes


If the Transmission ECM detects an error condition in
the transmission system, it will generate a service
code in the Information Center and will enter one of
three modes:
A. Clutch Modulation Substitute Mode
B. Limp-Home Mode
C. Transmission/Transmission ECM Shutdown
Mode

Clutch Modulation Substitute Mode


In this mode, the transmission clutch modulation is
time dependant rather than load dependant. The
transmission will go into the Clutch Modulation
Substitute Mode if any of the four speed sensors fail.
If the output speed sensor is working and the
transmission is in gear, the shift points in Automatic
mode will be speed dependant but the modulation
will be a predetermined amount of time.
If the output speed sensor is not working and the
transmission is in gear, the shift points will be load
d e p e n d a n t bu t t h e m o d u l a t i o n w i l l s t i l l b e a
predetermined amount of time.
If the transmission is shifted from neutral into a
direction in the Clutch Modulation Substitute Mode in
automatic, the transmission will shift into 4th gear
and shift down until it gets the correct output speed
from the turbine.

Limp-Home Mode
In this mode, the transmission will go into second
gear, forward or reverse, no matter what gear is
selected. If second gear is not obtainable, the
Transmission ECM selects a series of prioritized
g e a r s u n t i l a n o p e r a b l e g e a r i s fo u n d . T h e
transmission will go into the Limp Home Mode if
there is a fault on one clutch, a fault on one clutch
valve, or a fault on more than one speed sensor.

Transmission/Transmission ECM
Shutdown Mode
In this mode, the Transmission ECM has detected a
s e ve r e fa i l u r e t h a t d i s a b l e s c o n t r o l o f t h e
transmission. The transmission will go into Shutdown
Mode if there is a fault on more than one clutch, a
fault on the solenoid power supply, or invalid voltage.
In this mode, the Transmission ECM will shut off all
solenoid valves and the power supply and the
transmission shifts into and stays in neutral.
If the Transmission ECM generates a code, the
wren ch over th e se r vice m anual ico n will be
displayed on the Information Center.

Bur 5-2840

Issued 8-06

Printed in U.S.A.

6002-11

Transmission Clutch Calibration

Gear Selections

The Transmission ECM has the capability to find the


optimal adjustment of the clutch filling parameters for
each individual transmission, providing the ability to
individually adjust the optimum fill time for the
individual transmission in the machine. Clutch Filling
Parameter Calibration is performed on each machine
at the plant and should be repeated at the first 250
hours of use and every 1000 hours thereafter.

The transmission provides 4 forward and 3 reverse


gear selections. The transmission ratios were
designed to give optimized speed and torque for
each gear selection. The torque converter is a single
stage torque converter (one locking unit in the torque
converter).

Before doing the following transmission clutch


calibration procedures make sure of the following:

The automatic/manual switch is located on the right


control panel. The transmission is in automatic mode
when the top of the automatic/manual switch is
depressed. The Transmission Display Center
indicates when the machine is in the automatic
mode.

1. The machine is running and the transmission oil


is warm.
2. Engine low idle speed is correct.

Automatic/Manual Modes

3. The transmission is in neutral.


4. The park brake is applied.

Upshifting in Automatic Mode

5. If steps 1 through 4 have been accomplished,


calibrate the transmission clutches as follows:

Upshifting is determined by machine speed and the


torque on the transmission.

A. Press and hold the enter key for 2 to 3


seconds and the monitor will change to
SELECT.

The transmission will shift from first or second gear


up to the highest gear selected as the accelerator is
depressed, machine speed increases, and required
torque is reduced.

B. Use the down arrow and high light CONFIG,


press the enter key.
C. Press the down arrow and high light CALIB
G/B, press the enter key.

If the machine speed is increasing, but the operator


is not depressing the accelerator (such as when
going down a hill), the transmission will not upshift.

D. Monitor will state CALIB G/B CONFIRM


PLEASE, press the enter key.

As the operator depresses the accelerator and the


torque on the transmission is lowered, the
transmission will upshift.

E. If the conditions are not correct for clutch


calibration the monitor will display the problem
that needs to be corrected.

Downshifting in Automatic Mode

F. Clutch calibration status will be displayed on


the monitor, ADJUST K1, K2, K3, K4, KV,
KR.
G. After completing the Clutch Calibration
procedure, turn the machine OFF for 15
seconds. This sets the calibration in the
controller.

Downshifting is determined directly by machine


speed and transmission torque. The transmission will
downshift to first or second gear as machine speed
decreases and transmission torque increases. For
example, if the unit begins to climb a hill in forth gear
and the machine speed decreases, as the torque
requirement increases, the transmission will
downshift into third, then second, and down to first
gear, if necessary.

Upshifting in Manual Mode


In the manual mode, the transmission starts out in
the selected gear and stays in that gear until the
operator selects another gear or direction. The
transmission can be upshifted without reducing
engine speed or machine speed.
If the gear selected is two or more gears higher than
the present gear, the transmission will shift up
through the gears at 2.5 second intervals until the
selected gear has been reached.
Bur 5-2840

Issued 8-06

Printed in U.S.A.

6002-12

Downshifting in Manual Mode

Manual Mode

The transmission can be downshifted in the manual


mode without reducing engine speed or machine
speed.

In the manual mode, the downshift button toggles


between 1st and 2nd gear. The manual mode is
useful in short haul operations. In this mode, the
downshift button functions in two ways in 1st and 2nd
gear.

If 1st gear is selected from 3rd or 4th gear, the


transmission will downshift into 2nd gear for 1.2
seconds and then will shift into 1st gear.

Downshift Button
The downshift button is located on front of the
joystick control lever in machines with a single lever
configuration, and on top of the control tower in
machines with a three lever configuration.

When the operator is in 2nd gear and pushes the


downshift button, the transmission instantly shifts into
1st gear. When the operator pushes the downshift
button again, the transmission upshifts into 2nd gear.
If the machine is in 2nd gear and the downshift
button is pushed, the transmission instantly shifts into
1st gear. When the operator shuttles the shifter, the
transmission upshifts back into 2nd gear.

With the number of different ways the downshift


button functions, the operator can tailor the use of the
machine to the application at hand.

Cold Start Protection System

Automatic Mode

The transmission has a cold start protection system.


When the transmission sump temperature is minus
10 C (14 F), the Transmission ECM will keep the
transmission in neutral.

In the Automatic Mode, the downshift button only


shifts down. The downshift button allows the operator
to downshift through the entire range of gears. This is
useful in long haul applications or roading.
Each time the button is pushed the transmission will
instantly downshift one gear from 4th to 3rd, then
from 3rd to 2nd, and then from 2nd to 1st.
The transmission will automatically downshift and
then upshift, as needed, to the last gear that was
selected with the downshift button.
Example: If the downshift button was used to shift
from 4th to 3rd gear, the transmission will
automatically shift from 3rd down and then back up to
3rd again. It will not shift into 4th until the
transmission has been returned to the full range
automatic mode.
The transmission will retur n to the full range
automatic mode when:
A. Another gear is selected.
B. The shifter is moved into neutral and then into
forward or reverse.
C. The autoshift switch is recycled.

When the transmission sump temperature warms up


to minus 10 C (14F) (within approximately one
minute), the machine will operate in all gears.

Brake Pedal Transmission


Declutch
A transmission declutch feature concentrates more
engine power on the loader when digging in heavy or
tough conditions, providing smoother stops and
starts. Total disconnection of the transmission from
the engine is prevented. This feature will function in
1st, 2nd, or 3rd gear only. It will not function in 4th
gear.
When the transmission declutch switch is in the on
p o s i t i o n a n d t h e b ra ke p e d a l i s p u s h e d , t h e
Transmission ECM reduces the pressure to the
transmission forward or reverse clutch.
T h e Tr a n s m i s s i o n E C M w i l l n o t c o m p l e t e l y
disconnect the clutch from the engine, but gradually
reduces the forward or reverse clutch pressure down
to a lower level.
When the brake pedal is released, the Transmission
ECM gradually increases the forward or reverse
clutch back up to system clutch pressure.
If the direction is changed while the transmission is
declutched, the selected forward or reverse clutch
will be filled and maintain a low pressure until the
brake pedal is released. Then the selected forward or
reverse clutch pressure will gradually increase up to
system clutch pressure.

Bur 5-2840

Issued 8-06

Printed in U.S.A.

6002-13

TRANSMISSION PRESSURE TEST POINTS DIAGRAM


No.

IDENTIFICATION/LOCATION

CONNECTION

DESIGNATION ON
VALVE BLOCK
H

Measuring Points for Pressure Oil and Temperature


51

Before the Converter - Opening Pressure 8 bar (116 psi)

M10x1

52

Behind the Converter - Opening Pressure 2.5 bar (36 psi)

M14x1.5

53

Clutch Forward 16+2 bar (232 + 29 psi)

KV M10x1

55

Clutch Reverse 16+2 bar (232 + 29 psi)

KR M10x1

56

Clutch 16+2 bar (232 + 29 psi)

K1 M10x1

57

Clutch 16+2 bar (232 + 29 psi)

K2 M10x1

58

Clutch 16+2 bar (232 + 29 psi)

K3 M10x1

60

Clutch 16+2 bar (232 + 29 psi)

K4 M10x1

63

Behind the Converter Temperature 100 C, Short Time 120 C

M14x1/5

65

System Pressure 16+2 bar (232 + 29 psi)

M10x1

Measuring Points for Delivery Rates


15

Connection to the Heat Exchanger

1 5/16 - 12 UNF-2B

16

Connection from the Heat Exchanger

1 5/16 - 12 UNF-2B

Inductive Transmitter and Speed Sensor


21

Inductive Transmitter for Turbine Speed

34

M18x1.5

Output Speed Sensor

47

Inductive Transmitter for Central Gear Train Speed

M18x1.5

48

Inductive Transmitter for Engine Speed

M18x1.5

Connections
49

Plug Connection on the Hydraulic Control Unit

68

System Pressure

M16x1.5

69

Pilot Pressure

M16x1.5

NOTE: See next page for Measuring Point, Transmitter, Sensor and Connection locations.

Bur 5-2840

Issued 8-06

Printed in U.S.A.

6002-14

BC01B047

MEASURING POINTS AND CONNECTIONS

Bur 5-2840

Issued 8-06

Printed in U.S.A.

6002-15

CHART FOR RECORDING PRESSURE READINGS


Use this chart to record the pressure readings.
P.I.N. Number:

Date:
TEST POINTS

Shift
Speed

P
65

V
53

R
55

1
56

2
57

3
58

4
60

5
51

6
52

LP

1st F
2nd F
3rd F
4th F
1st R
2nd R
3rd R
Neut
P= MAIN PRESSURE

1= FIRST GEAR CLUTCH

4= FOURTH GEAR CLUTCH

V= FORWARD CLUTCH

2= SECOND GEAR CLUTCH

5= CONVERTER IN

R= REVERSE CLUTCH

3= THIRD GEAR CLUTCH

6= CONVERTER OUT

Bur 5-2840

LP= LUBE PRESSURE

Issued 8-06

Printed in U.S.A.

6002-16

PRESSURE TEST RESULTS


All or Most Pressures Low and/or
Flow Test Low
Possible causes include:
1. Oil level not correct.
2. Oil type and grade not correct.
3. Oil operating temperature high.
4. Screen for suction tube plugged.
5. Suction tube or gaskets leak.
6. Main pressure valve, springs, or valve bore.
7. Reduction valve, springs, or valve bore.

Not Enough Power


Possible causes include:
1. Check Electrical Troubleshooting in this Section
to verify actual gear selected.
2. Engine RPM below Stall Test specified RPM.
(Refer to Section 2002 for specifications.)
A. Check engine and fuel system for problem.
B. Check that torque converter installation is
correct.
3. Engine RPM above Stall Test specified RPM.
(Refer to Section 2002 for specifications.)

8. Charge pump seals or gaskets leak.

A. Check converter pressures and flow.

9. Charge pump worn.

B. Check that torque converter installation is


correct.

10. Oil supply flange not sealing correctly.

Some Pressures Low


Possible causes include:
1. Circuit isolation does not correct low pressure.
A. Control valve or gasket.
B. Channel plate or gasket.
2. Circuit isolation corrects low pressure.
A. Clutch shaft or seals.
B. Clutch drum or piston.

Bur 5-2840

Machine Stops or Hesitates While


Shifting - Intermittent
Possible causes include:
1. Check orifice and O-ring. (See Section 6007 for
replacing.)
2. Check for foreign material plugging orifices or
sticking valves.
3. Check for reduced pressure at test pressure
points.
4. See Electrical Troubleshooting in this Section for
electrical system problem.

Issued 8-06

Printed in U.S.A.

6002-17

CONVERTER OUT PRESSURE CHECK


Test Equipment Required

3. Install the pressure gauge.

0 to 28 bar (400 psi) gauge with hose long enough to


take readings in the cab and CAS-2324 Special
Adapter.

4. Heat the oil to an operating temperature of 80 to


100 C (176 to 212 F).

Test Procedure
1. Block the machine tires.

5. While in the cab, put the transmission in


NEUTRAL. Run the engine at full throttle. Record
the reading in the chart on page 16. Pressure
must be a minimum of 3.5 to 6.5 bar
(51 to 96 psi).

2. Apply the parking brakes.

LUBRICATION PRESSURE CHECK


Test Equipment Required

3. Install the pressure gauge in the cooler return


line at the transmission.

0 to 7 bar (100 psi) gauge.

4. Heat the oil to an operating temperature of 80 to


100 C (176 to 212 F).

Test Procedure

5. While in the cab, run the engine at full throttle.


Put the transmission in each gear and record the
reading in the chart on page 16. Pressure must
be 0.2 to 1.2 bar (3 to 18 psi).

1. Block the machine tires.


2. Apply the parking brakes.

FLOWMETER TEST
Test Equipment Required
CAS-1808 Flowmeter Kit; CAS-2702 Flowmeter
Adapter.

Flowmeter Test Procedure


1. Block the machine tires.

3. Heat the oil to an operating temperature of 80 to


100 C (176 to 212 F).
4. Remove the filter and install the CAS-2702
adapter.
5. Install the flowmeter between the adapter and
the filter.
6. While in the cab, run the engine at full throttle.
Put the transmission in NEUTRAL and record the
flow measurement. The correct flow is 80 L/min
(21 U.S. gpm) at 2000 rpm.

2. Apply the parking brakes.

CONSUMPTION TEST PROCEDURE


1. Block the machine tires.
2. Apply the parking brakes.
3. Heat the oil to an operating temperature of 80 to
100 C (176 to 212 F).
4. Install the flowmeter to converter outlet line (line
to cooler) in series.

6. Repeat the procedure with the transmission in


FORWARD in third gear. The flow must be 9.1
L/min (2 U.S. gpm).
7. Repeat the procedure with the transmission in
REVERSE in third gear. The flow must be 9.1
L/min (2 U.S. gpm).

5. While in the cab, run the engine at full throttle.


Put the transmission in NEUTRAL and record the
flow measurement. The flow must be 9.1 L/min
(2 U.S. gpm).

Bur 5-2840

Issued 8-06

Printed in U.S.A.

6002-18

TRANSMISSION OVERHEATING
1. Operate machine in normal operating conditions and observe:
A. Verify actual oil temperature at test point. Normal operating temperature can be 56C (100F) above the
ambient temperatures.
B. Use a stop watch to establish the exact length of time required to reach the overheating condition.
C. Observe engine temperature, does the engine overheat? Which overheats first - engine or transmission?
2. When the transmission reaches overheated condition, shift to Neutral and maintain engine RPM at a fast idle
(1250 to 1450 RPM).
A. Oil temperature returns to Normal - establish length of time.
1. Check oil level, type and grade is correct (See Section 1002).
2. Check operators gear selection is correct for conditions.
3. Make sure brakes are fully released.
4. Check the engine full throttle and stall speeds are correct as specified (See Section 2002).
B. Oil temperature remains overheated.
1. Check for dirty radiator - airflow restricted.
2. Check for engine overheating problem.
3. Check for faulty oil temperature gauge and sender or switch (See Section 4002).
3. Perform all the pressure and flow tests.
4. Compare the pressure and flow test results to the specifications in this section to determine if any circuits are
not within specifications.
5. Refer to Pressure Test Results to determine possible cause of any test results not within specifications.

Bur 5-2840

Issued 8-06

Printed in U.S.A.

6002-19

ERROR CODES
In case of possible errors in the system, an amber or red warning appears on the instrument panel, combined with
a recorded error number. See section 4005 for error code retrieval procedures and definitions.

TRANSMISSION SHIFTER LOGIC INFORMATION


Function

Shifter

Shifter Wire
Color

Shifter Tower
Connector

Shifter Shroud
Connector

Harness
Wire #

Harness
ped/cab #

Trans. ECM #

power

B+

black/red

19A_H

43

45

forward

yellow

25F

44

43

reverse

pink

25R

45

64

neutral

gray

25T_B

46

67

gear2(3-4)

B2

green

25W

48

65

gear1(1-2)

B1

blue

25Z

49

63

downshift

DS

purple

25Y

50

22

NOTE: Power is supplied through the fuse A to the transmission shifter via 19A wire. This is 24 Volt. Within the
shifter are limit switches to transfer the signal voltages to the outputs. In forward V is high. In reverse R is high. In
neutral N is high. In first gear, B1 is high and B2 is low. In second gear, B1 and B2 are low. In third gear, B1 is low
and B2 is high. In fourth gear, B1 and B2 are high. Downshift, DS, is activated when the end of the shifter is
engaged.

RELATIONSHIP BETWEEN TRANSMISSION ECM, VALVES, AND CLUTCHES


Transmission ECM
Function

Transmission
ECM Pin #

Transmission
Valve

Clutch #

Transmission
Valve Pin #

Wire #

Trans/Cab
Pin #

A1P1

56

Y1

K4

25K

16

A1P2

10

Y2

KR

25L

17

A1P3

32

Y3

K1

25M

18

A1P4

55

Y4

K3

25N

19

A1P5

Y5

KV

25P

20

A1P6

51

Y6

K2

25J

21

VPSI

12,13

all Y

all K

25S

22

TEMP

39

TEMP

none

36T

TEMP

46

TEMP

none

36R

12

Bur 5-2840

Issued 8-06

Printed in U.S.A.

6002-20

NOTES

Bur 5-2840

Issued 8-06

Printed in U.S.A.

6003

Section
6003
TRANSMISSION

CNH America LLC.


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

Bur 5-2850

Copyright 2006 CNH Ameica LLC.


All rights reserved.
Printed in U.S.A.
Issued August, 2006

6003-2

TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TORQUES (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 5-2850

Issued 8-06

3
3
4
4
5
16

Printed in U.S.A.

6003-3

SPECIAL TOOLS

CAS2885 TRANSMISSION VALVE


ADJUSTMENT TOOL SET
CAS2807 TRANSMISSION
INPUT/OUTPUT SHAFT SEAL
INSTALLATION TOOL

CAS2869 TRANSMISSION
OUTPUT SHAFT SEAL
INSTALLATION TOOL
(521 AND 621
MODELS ONLY)

CAS2803 TRANSMISSION
TORQUE CONVERTER SEAL
INSTALLATION TOOL

BS02C093 THRU 096

CAS40075 TRANSMISSION TOOL KIT

CAS2802 ALIGNMENT
DOWEL SET

CAS2799 CLUTCH PACK


H0LDER AND SPRING
COMPRESSOR TOOLS
CAS2801 TRANSMISSION
MOUNTING BRACKETS

CAS2796 NESTING
PLATE

CAS2798 GEAR
PULLER COLLET SET

CAS2800 CLUTCH
ASSEMBLY HOLDING
KNOB SET

CAS2797 LIFTING
EYEBOLT SET

CAS2868 CLUTCH SPRING


COMPRESSOR
(521 AND 621
MODELS ONLY)

BS02C097 THRU 104

CAS40079 TRANSMISSION OVERHAUL KIT

SPECIAL TORQUES
Oil pipes
Studs ............................................................................................................................... 9 Nm (80 pound inches)
Socket head screw ...................................................................................................... 23 Nm (204 pound inches)
Screw plug.......................................................................................................................... 51 Nm (38 pound feet)
Clutch K1, K2, K3, K4 Stud ............................................................................................. 17 Nm (150 pound inches)
Plugs................................................................................................................................. 25 Nm (221 pound inches)
Output shaft
Output shaft screws (apply Loctite 243 to threads) ..................................................... 23 Nm (204 pound inches)
Housing cover screws (apply Loctite 574 to threads).................................................. 46 Nm (407 pound inches)
Output flange screws................................................................................................... 34 Nm (301 pound inches)
Oil feed housing and transmission pump
Transmission pump screws ......................................................................................... 46 Nm (407 pound inches)
Oil feed housing screws .............................................................................................. 25 Nm (221 pound inches)
Engine connection and converter
Input shaft screws ............................................................................................................ 115 Nm (85 pound feet)
Converter housing screws.................................................................................................. 68 Nm (50 pound feet)
Cover............................................................................................................................ 23 Nm (204 pound inches)
Converter cover........................................................................................................... 46 Nm (407 pound inches)
Input flange .................................................................................................................. 34 Nm (301 pound inches)
Bur 5-2850

Issued 8-06

Printed in U.S.A.

6003-4

SPECIAL TORQUES (CONTINUED)


Duct plate
Screws......................................................................................................................... 25 Nm (221 pound inches)
Screw plug................................................................................................................... 30 Nm (265 pound inches)
Hydraulic control unit ........................................................................................................ 9.5 Nm (84 pound inches)
Filter
Filter head screws ....................................................................................................... 25 Nm (221 pound inches)
Oil distribution cover screws........................................................................................ 25 Nm (221 pound inches)
Speed sensor and inductive transmitter
Speed sensor screw.................................................................................................... 23 Nm (204 pound inches)
Inductive transmitter .................................................................................................... 30 Nm (265 pound inches)
Cover plate .................................................................................................................. 23 Nm (204 pound inches)
Screw plug...................................................................................................................... 140 Nm (103 pound feet)

SPECIFICATIONS
Clutch KV and KR plate clearance ......................................................................... 2.7 to 2.9 mm (0.106 to 0.114 in)
Clutch K1plate clearance........................................................................................ 2.4 to 2.6 mm (0.094 to 0.102 in)
Clutch K2 and K3 plate clearance .......................................................................... 1.8 to 2.0 mm (0.071 to 0.079 in)
Clutch K4 plate clearance....................................................................................... 1.2 to 1.4 mm (0.047 to 0.055 in)

Bur 5-2850

Issued 8-06

Printed in U.S.A.

6003-5

DISASSEMBLY
STEP 1

STEP 4

GD98M833

GD98M837

Fasten transmission on an assembly stand using


CAS2801 transmission mounting brackets.

R e m ove t wo s o cke t h e a d s c r ews a n d i n s t a l l


CAS2885 transmission valve adjustment tool set.
Remove remaining 21 socket head screws securing
control valve. Loosen and remove hex rods (part of
CAS2885) from studs then remove control valve.

STEP 2

STEP 5

GD98M835

Remove and discard oil filter.

STEP 3

GD98M838

Remove both gaskets and the intermediate plate.

STEP 6

GD98M836

Remove hex head screws securing filter head.


Remove filter head from transmission.

GD98M839

Remove socket head screws and hex nuts. Remove


duct plate. Remove flat gasket.
Bur 5-2850

Issued 8-06

Printed in U.S.A.

6003-6

STEP 7

STEP 10

GD98M844

GD98M847

Bend lock plate away from hex head screws.


Remove two hex head screws, lock plate, and
washer. Remove input flange from shaft.

Using proper size rod, press input shaft and


converter from cover.

STEP 11

STEP 8

GD98M845

Put alignment mar ks on conver ter cover and


housing to aid in assembly. Remove 12 nuts and
hex head screws.

GD98M848

Remove retaining ring then remove bearing.

STEP 12

STEP 9

GD98M849
GD98M846

C o n n e c t s u i t a bl e l i f t i n g e q u i p m e n t t o s h a f t .
R e m o v e c o v e r, s h a f t , a n d c o n v e r t e r f r o m
transmission and place in hydraulic press.

Bur 5-2850

R e m o ve fo u r h ex h e a d s c r e w s a n d r e m o ve
diaphragm and input shaft.

Issued 8-06

Printed in U.S.A.

6003-7

STEP 13

STEP 16

GD98M850

GD98M853

Put input shaft and diaphragm in vise as shown.


Remove 12 hex head screws to separate
diaphragm and input shaft.

Remove the socket head screws for removal of the


transmission pump.

STEP 17

STEP 14

GD98M854
GD98M851

Remove the inductive transmitter.

STEP 15

Apply a bearing separator on the splines shoulder of


the stator shaft and pull the pump out of the housing
bores, using two-leg puller.
NOTE: If traces of wear should be encountered in
the pump housing or the cam disk, the complete
pump has to be replaced.

STEP 18

GD98M852

Remove the hex head screws and remove the


converter housing.
GD98M855

Separate the transmission pump from stator.


Separate the cam plate from pump.
Bur 5-2850

Issued 8-06

Printed in U.S.A.

6003-8

STEP 19

STEP 23
Turn the transmission 180 degrees and remove the
rear output flange.

STEP 24

GD98M856

Remove the hex head screws and remove the oil


feed housing. Remove the flat gasket.

STEP 20

GD98M862

Remove the speed sensor and both inductive


transmitters.

STEP 25

GD98M860

Remove the hex head screws, cover, and flat gasket.

STEP 21
GD98M863

Remove the hex nuts and the two covers.

STEP 26

GD98M861

Remove the lock plate, hex head screws, and pry the
converter side output flange from the shaft.

STEP 22
Pry the shaft seal out of the housing bore.

GD98M864

Install CAS2802 alignment dowel set.


NOTE: The following steps describe the common
removal of all clutches.

Bur 5-2850

Issued 8-06

Printed in U.S.A.

6003-9

STEP 27

STEP 30
Remove CAS2800 clutch assembly holding knob
set and lift cover free.

STEP 31

BK00D029

Install CAS2800 clutch assembly holding knob set.


With knobs installed on all clutches in housing cover,
install CAS2797 lifting eyebolt set and lifting device to
transmission cover.

GD98M867

Remove the socket head screws and remove the


output shaft and both oil baffle plates.

STEP 28

STEP 32

BK00D028

Separate the cover along with clutches from the


transmission housing, using lifting device.

GD98M872

Remove clutch K2.

STEP 29

STEP 33

BK00D026

Place clutch disc carriers onto CAS2796 nesting


plate.

Bur 5-2850

GD98M873

Remove clutch K1 while lifting clutch K4.

Issued 8-06

Printed in U.S.A.

6003-10

STEP 34

STEP 37

GD98M877

GD98M874

Remove the bearing outer race and pull output shaft


out of the housing bore.

Remove clutch K3.

STEP 35

STEP 38

GD98M875
GD98M878

Remove clutch K4 while lifting input shaft slightly.

STEP 36

Remove the rectangular ring and separate ball


bearing from the shaft.
NOTE: The following steps are for the disassembly
of the clutch KV. The disassembly of the clutch KR is
similar.

STEP 39

GD98M876

Remove clutches KV and KR together with input


shaft.
GD98M979

Remove the sealing ring. Pull the tapered roller


bearing from the shaft. Remove the opposite tapered
roller bearing.
Bur 5-2850

Issued 8-06

Printed in U.S.A.

6003-11

STEP 40

STEP 43

GD98M881

BK00D020

Separate the clutch disc carrier from the shaft.

Remove snap ring.

STEP 41

STEP 44

GD98M882

Remove the snap ring and remove the clutch disc


pack.

BK00D019

Remove the compression spring.

STEP 45

STEP 42

GD98M885
BK00D018

Preload compression spring using CAS2799 clutch


pack holder and spring compressor tool.

Bur 5-2850

Remove piston from clutch pack holder. Remove and


discard the O-rings from piston.

Issued 8-06

Printed in U.S.A.

6003-12

STEP 46

STEP 48

GD98M886

GD98M889

Remove the snap ring.

Remove the snap ring and remove the ball bearing.

STEP 47

NOTE: The following steps are for disassembly of


clutch K3. Disassembly of clutches K1 and K2 is
similar

STEP 49

GD98M887

GD98M890

Remove the rectangular ring. Pull the tapered roller


bearing from the shaft.

STEP 50

GD98M888

Press the idler gear from the shaft using a bearing


separator. Remove released needle bearing.

GD98M892

Remove the thrust washer, thrust bearing, and thrust


washer.

Bur 5-2850

Issued 8-06

Printed in U.S.A.

6003-13

STEP 51

STEP 54

GD98M893

Remove the idler gear.

BK00D018

Preload compression spring using CAS2799 clutch


pack holder and spring compressor tool.

STEP 52

STEP 55

GD98M894

Remove the needle bearings and thrust bearing.

BKOOD020

Remove the snap ring.

STEP 53

STEP 56

GD98M895

Remove the snap ring and remove the clutch disc


pack.

Bur 5-2850

BK00D019

Remove the compression spring.

Issued 8-06

Printed in U.S.A.

6003-14

STEP 57

STEP 59

BS00G001

GD98M800

Remove the sealing ring. Remove bearing using


bearing puller. Tap assembly until piston drops out of
the clutch pack carrier. Then, remove and discard
O-rings from piston.

Remove and discard two sealing rings. Pull two


bearings from shaft using bearing puller. Remove the
snap ring and separate the clutch disc carrier from
the shaft.

STEP 58

STEP 60

GD98M801

BK00D022

Remove the clutch disc carrier from the shaft.


NOTE: The following steps are for the disassembly
of the clutch K4.

Remove the snap ring and remove the clutch disc


pack.

STEP 61

BK00D018

Preload compression spring using CAS2799 clutch


pack holder and spring compressor tool.

Bur 5-2850

Issued 8-06

Printed in U.S.A.

6003-15

STEP 62

NOTE: The following two steps are for disassembly


of the input shaft.
NOTE: A snap ring is used to lock turbine shaft in
input shaft. Snap ring will be destroyed when turbine
shaft is pressed from input shaft.

STEP 64

BK00D020

Remove the snap ring.

STEP 63

GD98M803

If turbine shaft is to be removed from input shaft, use


proper size diameter sleeve or rod and press turbine
shaft out of input shaft.

STEP 65
Remove bearings from input shaft using a bearing
puller.

BK00D019

Remove the compression spring.

Bur 5-2850

Issued 8-06

Printed in U.S.A.

6003-16

ASSEMBLY
NOTE: The following steps are for the reassembly of
the oil pipes.

STEP 69

STEP 66

2
3

GD98M607

Install a new O-ring on plug. Tighten the plug to a


torque of 51 Nm (38 pound feet).

STEP 70
GD98M603

Install suction tube (1), pressure pipes (2), and


lubrication pressure pipe (3) in housing.

STEP 67
Secure suction tube (1) and pressure pipes (2) with
socket head screw and hex nuts. Tighten to a torque
of 23 Nm (204 pound inches)

STEP 68
GD98M608

Install all bearing outer races in housing bores.

STEP 71

GD98M605

Tilt the cover 180 degrees. Install the suction tubes


and pressure pipes into the housing bores using a
rolling tool.
NOTE: Pipe end of the pressure pipes must be
slightly below the housing plane face.

GD98M609

Install both oil pipes into the housing cover. Tilt the
cover 180 degrees and install pipes into the housing
bores using a rolling tool.
NOTE: The pipe end must be slightly below the
housing plane face.

Bur 5-2850

Issued 8-06

Printed in U.S.A.

6003-17

STEP 72

STEP 75

GD98M610

BK00D019

Install the studs. Tighten the studs to a torque of 9


Nm (80 pound inches).
NOTE: The following steps are for the assembly of
clutches KV and KR, starting with assembly of the
clutch disc carrier.

STEP 73

BK00D018

Install compression spring and two spring cups in


clutch disc carrier. Preload compression spring
using CAS2799 clutch pack holder and spring
compressor tool.

STEP 76
GD98M612

Check that drain hole is clear and free of foreign


matter. Install both O-rings in recesses of the piston
and apply oil.

STEP 74

BK00D020

Install the snap ring.


NOTE: The following steps are for the KV and KR
clutch disc packs. The disc stacking of clutches KV
and KR is identical.
GD98M613

Install piston in clutch disc carrier.


Bur 5-2850

Issued 8-06

Printed in U.S.A.

6003-18

STEP 77

STEP 79
A

GD98M617
225B

1.
2.
3.
4.
5.
6.
7.
A

PLATE CARRIER
PISTON
OUTER PLATE - ONE-SIDED COATED
INNER PLATES
OUTER PLATES - COATED ON BOTH SIDES
SNAP RING
END SHIM
RUNNING CLEARANCE 2.7 TO 2.9 MM (0.106 TO 0.114
IN)

Install end shim and snap ring.

STEP 80

Install clutch disc plates in KV and KR clutch disc


carriers in position and sequence shown above.
Install outer plates (3) with steel faced side facing
piston and end shim (7).
NOTE: Snap rings of different thickness are
available for adjustment of the running clearance. To
ensure correct adjustment, do not apply oil to clutch
discs until after adjustment is completed.

STEP 78

GD98M618

Adjust running clearance to 2.7 to 2.9 mm (0.106 to


0 . 1 1 4 i n ) . P r e ss d ow n o n t h e e n d s h i m w i th
approximately 10 kg (20 lb). Measure and record
dimension (A) from carrier face to end shim using
depth gauge as shown.
Example
Dimension A . . . . . . . . . . . . . . . . . 7.25 mm (0.29 in)

GD98M616

Install the clutch disc pack.

Bur 5-2850

Issued 8-06

Printed in U.S.A.

6003-19

STEP 81

STEP 84

GD98M619

GD98M621

Use tools to lift the end shim against snap ring


(upward) until contact is obtained. Measure and
record dimension (B) from carrier face to end shim
using depth gauge as shown. Subtract this
measurement from the measurement of Step 80. The
difference is the running clearance.

Apply Loctite 243 to stud. Tighten stud to a torque of


17 Nm (150 pound inches).

STEP 85

Example
Dimension A . . . . . . . . . . . . . . . . . 7.25 mm (0.29 in)
Dimension B . . . . . . . . . . . . . . . . . 4.45 mm (0.18 in)
Difference = Running. . . . . . . . . . . 2.80 mm (0.11 in)
Clearance
Required running clearance is 2.7 to 2.9 mm (0.106
to 0.114 in). Use snap ring(s) of different thickness as
necessary to obtain correct running clearance.

STEP 82
GD98M622

Remove clutch disc pack, apply oil to discs, and


install clutch disc pack, end shim, and snap ring as
determined in Step 81.

Install ball bearing until contact is obtained. Secure


using snap ring.

STEP 83

STEP 86

GD98M623

GD98M620

Install idler gear to align and engage all inner discs,


then remove idler gear.

Bur 5-2850

Install needle bearing.

Issued 8-06

Printed in U.S.A.

6003-20

STEP 87

STEP 90

GD98M624

Support the idler gear on the bearing inner race.


Press the idler gear against the shoulder.

BP00G020

Install gear and shaft into heated bore.

STEP 91

STEP 88

BK00D024
GD98M625

Secure idler gear using snap ring.

Heat bearing.

STEP 92

STEP 89

WARNING: Always wear heat protective


gloves to prevent burning your hand when
handling heated parts.
SM121A

BK00D023

Use heat gun to heat assembled clutch disc carrier


inner bore.
BK00D025

Install heated bear ing on shaft against shaft


shoulder.

Bur 5-2850

Issued 8-06

Printed in U.S.A.

6003-21

STEP 93

STEP 96

Check operation of the clutch using compressed air.


NOTE: The following steps are for assembly of
clutch K1, K2, and K3.

STEP 94

GD98M632

Check that drain hole is clear and free of foreign


matter. Install both O-rings in recesses of piston and
apply oil.
GD98M630

STEP 97

Press bearing against shoulder of shaft. Apply


Loctite 243 to the stud and install the stud. Tighten
the stud to a torque of 17 Nm (150 pound inches).

STEP 95

GD98M633

Install piston in clutch disc carrier.

STEP 98
GD98M631

Install the clutch disc carrier until contact is obtained.

GD98M634

Install the compression spring and spring cup.

Bur 5-2850

Issued 8-06

Printed in U.S.A.

6003-22

STEP 99

STEP 101
A

BK00D019

232A

1.
2.
3.
4.
5.
6.
7.
A.

BK00D018

Install compression spring and two spring cups in


clutch disc carrier. Preload compression spring
using CAS2799 clutch pack holder and spring
compressor tool.

STEP 100

PLATE CARRIER
PISTON
OUTER PLATE - ONE-SIDED COATED
INNER PLATES
OUTER PLATES - COATED ON BOTH SIDES
SNAP RING
END SHIM
CLUTCH K1 RUNNING CLEARANCE 2.4 TO 2.6 MM
(0.094 TO 0.102 IN); CLUTCHES K2 AND K3 RUNNING
CLEARANCE 1.8 TO 2.0 MM (0.071 TO 0.079 IN)

Install clutch disc plates in K1, K2, and K3 clutch disc


carriers in position and sequence shown above.
Install outer plate (3) with steel faced side facing
piston.
NOTE: Snap rings of different thickness are
available for adjustment of the running clearance. To
ensure correct adjustment, do not apply oil to clutch
discs until after adjustment is completed.

STEP 102

BK00D020

Install the snap ring.


NOTE: The following steps are for K1, K2 and K3
clutches. The assembly of clutches K1, K2, and K3 is
identical except for running clearance dimensions.

Bur 5-2850

GD98M636

Install the clutch disc pack.

Issued 8-06

Printed in U.S.A.

6003-23

STEP 103

STEP 105

GD98M637

Install the end shim and snap ring.

GD98M639

Use tools to lift the end shim against snap ring


(upward) until contact is obtained. Measure and
record dimension (B) from carrier face to end shim
u s i n g d e p t h g a u g e a s s h ow n . S u b t r a c t t h i s
measurement from the measurement of Step 104.
The difference is the running clearance.

STEP 104

Example
Dimension A . . . . . . . . . . . . . . . . . . .8.2 mm (0.32 in)
Dimension B . . . . . . . . . . . . . . . . . . .6.1 mm (0.24 in)
Difference = Running Clearance . . .2.1 mm (0.08 in)

GD98M638

Adjust running clearance for K1 to 2.4 to 2.6 mm


(0.094 to 0.102 in); adjust running clearance for K2
and K3 to 1.8 to 2.0 mm (0.071 to 0.079 in). Press
down on the end shim with approximately 10 kg (20
lb). Measure and record dimension (A) from carrier
face to end shim using depth gauge as shown.

Required running clearance for K1 is 2.4 to 2.6 mm


(0.094 to 0.102 in); for K2 and K3 required running
clearance is 1.8 to 2.0 mm (0.071 to 0.079 in). Use
snap ring(s) of different thickness as necessary to
obtain correct running clearance.

STEP 106
Remove clutch disc pack, apply oil to discs, and
install clutch disc pack, end shim, and snap ring as
determined in Step 105.

STEP 107

Example
Dimension A . . . . . . . . . . . . . . . . . . 8.2 mm (0.32 in)

3
2
1

GD98M640

Install the thrust washer (1), thrust bearing (2), and


thrust washer (3).
NOTE: Install the thrust washer (1) with the chamfer
facing the thrust bearing.
Bur 5-2850

Issued 8-06

Printed in U.S.A.

6003-24

STEP 108

STEP 111

GD98M641

BK00D024

Install both needle bearings.

Heat bearing.

STEP 109

STEP 112
WARNING: Always wear heat protective
gloves to prevent burning your hand when
handling heated parts.
SM121A

GD98M642

Install idler gear until all inner discs are engaged.

STEP 110
BK00D025

Place heated bearing on the shaft.

STEP 113

Check operation of the clutch using compressed air.

GD98M643

Install the thrust washer (3), thrust bearing (2), and


thrust washer (1). Install the thrust washer (1) with
the chamfer facing the thrust bearing.
NOTE: Ensure the thrust washer (1) is overlapping
with the chaff collar to accommodate all the inner
discs.

Bur 5-2850

Issued 8-06

Printed in U.S.A.

6003-25
NOTE: The following steps are for assembly of
clutch K4.

STEP 116

STEP 114
WARNING: Always wear heat protective
gloves to prevent burning your hand when
handling heated parts.
SM121A

GD98M649

Apply Loctite 243 to the stud and install the stud.


Tighten the stud to a torque of 17 Nm (150 pound
inches).

STEP 117
GD98M647

Heat the gear to about 120 C (248 F) and install


until seated in position.

STEP 115

GD98M650

Check that drain hole is clear and free of foreign


matter. Install both O-rings in recesses of the piston
and apply oil.

STEP 118
GD98M648

Install retaining ring to secure gear.

GD98M651

Install piston in clutch disc carrier. Be sure piston


bottoms out.

Bur 5-2850

Issued 8-06

Printed in U.S.A.

6003-26

STEP 119

STEP 121
A

BK00D019

BS02C131

1.
2.
3.
4.
5.
6.
7.
A.

PLATE CARRIER
PISTON
OUTER PLATE - ONE-SIDED COATED
INNER PLATES
OUTER PLATES - COATED ON BOTH SIDES
SNAP RING
END SHIM
RUNNING CLEARANCE 1.2 TO 1.4 MM (0.047 TO 0.055
IN)

Install clutch disc plates in K4 clutch disc carrier in


position and sequence shown above. Install outer
plate (3) with steel faced side facing piston.
BK00D018

Install compression spring and two spring cups in


clutch disc carrier. Preload compression spring
using CAS2799 clutch pack holder and spring
compressor tool.

NOTE: Snap rings of different thickness are


available for adjustment of the running clearance. To
ensure correct adjustment, do not apply oil to clutch
discs until after adjustment is completed.

STEP 122

STEP 120

GD98M653

Install clutch disc pack.


BK00D020

Install snap ring.


NOTE: The following steps are for installing the
clutch disc pack in clutch K4.

Bur 5-2850

Issued 8-06

Printed in U.S.A.

6003-27

STEP 123

STEP 125

GD98M654

Install end shim and snap ring.

GD98M656

Use tools to lift the end shim against snap ring


(upward) until contact is obtained. Measure and
record dimension (B) from carrier face to end shim
u s i n g d e p t h g a u g e a s s h ow n . S u b t r a c t t h i s
measurement from the measurement of Step 124.
The difference is the running clearance.

STEP 124

Example
Dimension A . . . . . . . . . . . . . . . . . . .7.2 mm (0.28 in)
Dimension B . . . . . . . . . . . . . . . . . . .6.0 mm (0.24 in)
Difference = Running . . . . . . . . . . . .1.2 mm (0.04 in)
Clearance
Required running clearance is 1.2 to 1.4 mm (0.047
to 0.055 in). Use snap ring(s) of different thickness as
necessary to obtain correct running clearance.
GD98M655

Adjust running clearance to 1.2 to 1.4 mm (0.047 to


0 . 0 5 5 i n ) . P r e s s d ow n o n t h e e n d s h i m w i t h
approximately 10 kg (20 lb). Measure and record
dimension (A) from carrier face to end shim using
depth gauge as shown.

STEP 126
Remove clutch disc pack, apply oil to discs, and
install clutch disc pack, end shim, and snap ring as
determined in Step 125.

STEP 127

Example
Dimension A . . . . . . . . . . . . . . . . . . 7.2 mm (0.28 in)

GD98M657

Install the idler gear until all inner discs are engaged,
then remove idler gear.

Bur 5-2850

Issued 8-06

Printed in U.S.A.

6003-28

STEP 128

STEP 131
1
2
3

GD98M658

Assemble two thrust washers and thrust bearing.


NOTE: Upper and lower thrust washers are the
same thickness.

GD98M661

Assemble thrust washer (3), thrust bearing (2), and


thrust washer (1). Install the thrust washer (1) with
the chamfer facing the thrust bearing.

STEP 132

STEP 129

GD98M662
GD98M659

Install the assembled clutch disc carrier until all the


inner discs are engaged.

Install both needle bearings.

STEP 130

STEP 133

GD98M660
GD98M663

Install the idler gear.

Bur 5-2850

Install snap ring to secure clutch disc carrier.

Issued 8-06

Printed in U.S.A.

6003-29

STEP 134

STEP 138
WARNING: Always wear heat protective
gloves to prevent burning your hand when
handling heated parts.
SM121A

BK00D024

Heat bearing.

STEP 135
WARNING: Always wear heat protective
gloves to prevent burning your hand when
handling heated parts.

GD98M666

Heat gear to about 120 C (248 F) and install on


input shaft until contact is obtained.

SM121A

STEP 139

BK00D025

Install heated bearing on the shaft shoulder.

STEP 136
Repeat Steps 134 and 135 to install bearing on
opposite end of shaft.

GD98M667

Secure gear with snap ring.

STEP 140

STEP 137
Check operation of the clutch using compressed air.
NOTE: The following steps are for the reassembly of
the input shaft.

GD98M668

Install snap ring into recess of turbine shaft.

Bur 5-2850

Issued 8-06

Printed in U.S.A.

6003-30

STEP 141

STEP 144

GD98M669

GD98M672

Install the turbine shaft until the snap ring snaps into
the recess of the input shaft.

Install output shaft into housing bore until contact is


made.

STEP 142

NOTE: The following steps are for the installation of


the output shaft and clutches. All clutches have a
common installation.

WARNING: Always wear heat protective


gloves to prevent burning your hand when
handling heated parts.

STEP 145

SM121A

K1
AB

K3

K4

AN

KR

K2
KV

GD98M673
BK00D024

Heat bearings and install on turbine shaft until


bearings are against shoulder.

Install bearing outer races into housing cover until


contact is obtained.

STEP 146

STEP 143

BK00F003
GD98M671

Install the clutches onto CAS2796 nesting plate.

Install bearing then install rectangular ring.


Bur 5-2850

Issued 8-06

Printed in U.S.A.

6003-31

STEP 147

STEP 150

BK00D029

GD98M681

Using CAS2797 lifting eye bolt set and acceptable


liftin g eq uipm en t, in stall ho using cove r o nto
clutches. Install CAS2800 clutch assembly holding
knob set to secure clutch shafts to cover.

Install the sealing rings and insert rings in their


respective grooves. Apply grease to the sealing rings
and align the rings centrally.

STEP 151

STEP 148
KR
KV
K4

K2

K3

K1

GD98M692
GD98M679

The above photo shows the position of the single


clutches in the housing cover.

Install both the O-rings into the annular groove of the


oil pipes and apply grease.

STEP 152

STEP 149
AN

KV
K2

Tilt the housing cover 180 degrees.

KR
K4
K1

K3

AB

GD98M866

The above shows the position of the single clutches


and the input and output clutches.

Bur 5-2850

Issued 8-06

Printed in U.S.A.

6003-32

STEP 153

STEP 156

BK00D028

GD98M686

Install output gear and shaft in transmission housing.


Install alignment screws. Carefully lower the cover
and clutches into the gear box housing.

Install screen sheet on output shaft. Press front and


rear bearings on output shaft until contact with
shoulder of output shaft is made.

STEP 154

STEP 157

Remove CAS2800 clutch assembly holding knob set.

STEP 155

GD98M688

Install the screening plate.


GD98M685

STEP 158

Separate the housing cover from the gearbox, using


a lifting device.
NOTE: The following steps are for the reassembly of
the output shaft.

GD98M689

Install the output shaft.

Bur 5-2850

Issued 8-06

Printed in U.S.A.

6003-33

STEP 159

STEP 162

GD98M690

GD98M697

Apply Loctite 243 to the socket head screws and


install the screws. Tighten the screws to a torque of
23 Nm (204 pound inches).

Heat the output flange to about 90 C (194 F). Apply


Loctite 574 to the contact area and assemble the
flange with the washers and hex head screws.
Tighten the screws to a torque of 34 Nm (301 pound
inches). Bend corner of lock plate over hex head
screws.

STEP 160

STEP 163
Repeat Steps 161 and 162 to install shaft seal and
output flange on converter side.
NOTE: The following steps are for the assembly of
the oil feed housing and transmission pump.

STEP 164

GD98M691

Install rectangular rings in grooves of clutch shafts.


Apply grease to rings and align rings.

STEP 161

GD98M702

Install two alignment studs and install the gasket.

GD98M696

Position shaft seal with sealing lip facing oil chamber.


A p p l y g r e a s e t o s e a l i n g l i p. U s e C A S 2 8 0 7
transmission output shaft seal installation tool to
install seal.

Bur 5-2850

Issued 8-06

Printed in U.S.A.

6003-34

STEP 165

STEP 168

GD98M703

Install the oil feed housing with washers and hex


head screws. Screw the hex head screws in only until
contact is obtained, do not tighten.

GD98M706

Install transmission pump.

STEP 169

STEP 166

GD98M707

GD98M704

Install the two alignment screws and install the stator


shaft.

Apply grease to new O-rings. Install the O-rings on


the socket head screws.

STEP 170

STEP 167

GD98M708

GD98M705

Apply oil and install the O-ring.

Bur 5-2850

Secure the transmission pump with the socket head


screws. Tighten screws to a torque of 46 Nm (407
pound inches).

Issued 8-06

Printed in U.S.A.

6003-35

STEP 171

STEP 173

GD98M709

GD98M712

Install the oil feed housing with the hex head screws
and flat washers. Tighten the screws to a torque of
25 Nm (221 pound inches).

Position converter housing. Secure with hex head


screws. Tighten the screws to a torque of 68 Nm (50
pound feet).

STEP 172

STEP 174

GD98M711

GD98M713

Position the gasket and cover. Secure the cover with


the hex head screws. Tighten the screws to a torque
of 23 Nm (204 pound inches).

P u t in p u t s h a f t in a v i s e a s s h ow n . Po s i t io n
diaphragm on input shaft and secure using 12 hex
head screws. Tighten screws to a torque of 115 Nm
(85 pound feet).

NOTE: The following steps are for the assembly of


the engine connection and converter.

STEP 175

GD98M714

Position diaphragm and input shaft on converter.


Apply Loctite 262 to threads of hex head screws.
Install screws and tighten to a torque of 115 Nm (85
pound feet).
Bur 5-2850

Issued 8-06

Printed in U.S.A.

6003-36

STEP 176

STEP 178

GD98M715

GD98M718

Position converter cover on converter housing. Make


sure alignment marks made during removal of cover
are aligned. Install input flange, two hex head
screws, lock plate, and washer. Pull cover against
housing by tightening two hex head bolts evenly.

STEP 179

GD98M716

Position converter. Check and ensure that impulse


disk of converter is centered on the bore for the
inductive transmitter.

STEP 177
GD98M719

Secure converter cover using 12 hex head screws


and nuts. Tighten screws to a torque of 46 Nm (407
pound inches).

GD98M717

Position converter cover as shown. Install bearing


against shoulder in cover. Secure using retaining
ring.

Bur 5-2850

Issued 8-06

Printed in U.S.A.

6003-37

STEP 180

NOTE: The following steps are for installation of


transmission control valve.

STEP 183

GD98M720

Tighten input flange hex head screws to a torque of


34 Nm (301 pound inches). Lock screws by bending
corners of lock plate over screws.

STEP 181

258

Install CAS2885 transmission valve adjustment tool


set. Be sure hex rods (par t of tool set) are not
installed on studs. Mount the gasket (1), intermediate
plate (2), and gasket (3).

STEP 184
Install the screw plug with new O-ring. Tighten the
plug to a torque of 30 Nm (265 pound inches).

STEP 185

GD98M724

Install new sealing rings and both plugs in duct plate.

STEP 182

GD98M727

Install control valve on duct plate and CAS2885


studs. Install hex rods on studs and tighten against
control valve. Install 21 socket head screws. Tighten
screws to a torque of 9.5 Nm (84 pound inches).
Remove CAS2885 transmission valve adjustment
tool set. Install remaining two socket head screws.
Tighten screws to a torque of 9.5 Nm (84 pound
inches).
GD98M725

Install the gasket and place the duct plate against


shoulder. Install socket head screws and hex nuts.
Tighten to a torque of 25 Nm (221 pound inches).

Bur 5-2850

NOTE: The following steps are for the installation of


the filter.

Issued 8-06

Printed in U.S.A.

6003-38

STEP 186

STEP 189

GD98M729

GD98M735

Install new O-rings in recesses of oil filter head.


Position filter head on transmission and secure using
two socket head screws. Tighten screws to a torque
of 25 Nm (221 pound inches).

Apply grease to the new O-ring and install the speed


sensor with the socket head screw. Tighten the screw
to a torque of 23 Nm (204 pound inches).

STEP 190

STEP 187

GD98M736

Install a new transmission filter.

With new O-rings, install the inductive transmitters.


Tighten to a torque of 30 Nm (265 pound inches).

STEP 188

STEP 191

GD98M730

Install the breather.

STEP 192

GD98M733

Install new O-rings in oil distribution covers. Install


the two oil distribution covers on the housing with hex
nuts and flat washers. Tighten to a torque of 25 Nm
(221 pound inches).

Bur 5-2850

GD98M737

Install the gasket and the cover plate. Tighten to a


torque of 23 Nm (204 pound inches). With a new
O-ring, install the screw plug. Tighten to a torque of
140 Nm (103 pound feet).
Issued 8-06

Printed in U.S.A.

6004

Section
6004
FRONT AXLE

CNH America LLC.


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

Bur 5-3190

Copyright 2006 CNH Ameica LLC.


All rights reserved.
Printed in U.S.A.
Issued August, 2006

6004-2

TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GEAR TOOTH CONTACT PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WEAR MEASUREMENT ON MULTI-DISC BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WHEEL END AND BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LEAKAGE TEST OF THE BRAKE HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLY OF DIFFERENTIAL CARRIER AND BRAKE TUBES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLY OF LIMITED SLIP DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLY OF DRIVE PINION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLY OF THE BRAKE TUBES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLY OF BRAKE TUBES AND DIFFERENTIAL CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLY OF DIFFERENTIAL CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Determine Shim Thickness for a Perfect Tooth Contact Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Install the Drive Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjust Rolling Moment of Drive Pinion Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLY OF LIMITED SLIP DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjust Backlash and Bearing Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 5-3190

Issued 8-06

3
4
6
6
7
7
13
23
23
23
24
27
28
29
30
32
32
33
34
36
40

Printed in U.S.A.

6004-3

SPECIAL TOOLS
Planetary bearing puller collet set ............................................................................................................... CAS2881
Brake housing seal installer......................................................................................................................... CAS2880
Differential bearing cone puller collet set..................................................................................................... CAS2871
Differential bearing preload wrench ............................................................................................................. CAS2851
Brake housing inner bearing cup installer ................................................................................................... CAS2877
Brake housing outer bearing cup installer ................................................................................................... CAS2878
Brake housing inner bearing cup installer ................................................................................................... CAS2879
Wear ring installer adapter .......................................................................................................................... CAS2874
Wear ring installer adapter ......................................................................................................................... CAS2875
Pinion depth gauge set................................................................................................................................ CAS2872
Pinion depth gauge block ............................................................................................................................ CAS2873
Puller body and screw ................................................................................................................................. CAS2882
Support bracket ........................................................................................................................................... CAS2883
Slide hammer puller adapter ..................................................................................................................... CAS10846
Slide hammer ..............................................................................................................................................OEM4252
Replacer ...................................................................................................................................................... CAS2297
Magnetic base with indicator ................................................................................................................... CAS10066A
Heat gun .................................................................................................................................................... CAS10810
Lifting sling...................................................................................................................................................OEM4106
Engine stand................................................................................................................................................OEM4135
Snap ring pliers............................................................................................................................................OEM6484
Snap ring pliers............................................................................................................................................OEM6177
Snap ring pliers............................................................................................................................................OEM6492
Step plate set (includes 8061, 8067, and 8073) ..........................................................................................OEM4288
Step plate ............................................................................................................................................................8061
Step plate ............................................................................................................................................................8067
Step plate ............................................................................................................................................................8073

Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-4

GEAR TOOTH CONTACT PATTERNS


Ideal Tooth Contact Pattern

Pinion Distance Must Be Increased

BS01D011

BS01D009

COAST SIDE (CONCAVE)

BS01D013
BS01D012

COAST SIDE (CONCAVE)

DRIVE SIDE (CONVEX)

BS01D014

DRIVE SIDE (CONVEX)

Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-5

Pinion Distance Must Be Decreased

BS01D016
BS01D010

DRIVE SIDE (CONVEX)

BS01D015

COAST SIDE (CONCAVE)

Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-6

LUBRICATION
4

4
4

3
2
2

2
BS00M069

1. OIL DRAIN HOLE (AXLE CASING)


2. OIL DRAIN HOLE (OUTPUTS)

BS00M070

3. OIL FILLER HOLE


4. BRAKE BLEEDER

5. BLEEDER

WEAR MEASUREMENT ON MULTI-DISC BRAKE

BS00M071

BD00M234

NOTE: A wear measurement on the multi-disc brake has to be made at least once a year, especially in case of a
changed braking behavior.
A wear measurement has to be made on both wheel ends.
Remove screw plug, actuate brake and determine dimension X using a feeler gauge.
If dimension X is less than or equal to 4.0 mm (0.16 in) the lined discs on both output sides have to be replaced.
Replace O-ring when installing the level plug. Tighten plug to 70 Nm (52 pound-feet).

Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-7

WHEEL END AND BRAKES


Disassembly

STEP 3

STEP 1

BD00M238

Pry the cover off the wheel end.


BD00M235

STEP 4

Fasten the axle on a stand.

STEP 2

BD03B008

BD00M236

Use OEM4252 slide hammer and CAS10846-3


adapter, remove the slotted pin from wheel end lock
nut.

STEP 5

BD00M237
BD03B009

Loosen the screw plugs and drain the oil from the
axle casting.

Bur 5-3190

Using CAS2876 locknut socket and CAS2883


support bracket, loosen and remove the locknut.

Issued 8-06

Printed in U.S.A.

6004-8

STEP 6

STEP 9

BD00M241

Use acceptable lifting equipment and hold the wheel


end in place. Loosen and remove the bolts.

BD00M244

Remove the shim(s) from the sun gear shaft.

STEP 10
STEP 7

BD00M245
BD03B010

Pull the sun gear shaft out of the planet gears.

Separate the wheel end from the axle casing.

STEP 11
STEP 8

BD03B011
BD00M243

Pull the stub shaft out of the sun gear shaft.

Lift planet carrier out of the brake housing using


OEM4054 pulling attachment.

NOTE: Watch for released shim(s).

Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-9

STEP 12

STEP 15

BD03B012

Remove the snap rings from the planet gear shaft


using OEM6492 snap ring pliers.

BD03B015

Using suitable puller, remove planetary ring gear


from brake housing.

STEP 13
STEP 16

BD03B013

Remove the planet gear using CAS2848 gear puller


and 8061 step plate.

BD03B016

Remove O-rings from the annular grooves of the ring


gear.

STEP 14

STEP 17

BD03B014

Remove the bearing from the planetar y using


CAS2881 collet set, CAS2882 puller body and screw,
and 8061 step plate.

Bur 5-3190

BD03B017

Remove O-ring from recess of the brake housing.

Issued 8-06

Printed in U.S.A.

6004-10

STEP 18

STEP 21

BD03B021

Remove the brake disc pack from the brake housing.

Use compressed air to raise piston out of the brake


housing.

STEP 19

STEP 22

BD00M253

BD03B019

Drive slotted pins in the support shim until they are


flush with the top of the support shim.

Remove the support shim out of the piston.

STEP 20

STEP 23

BD00M257

BD03B020

Remove the circlip using OEM6484 external pliers.

Bur 5-3190

BD03B022

Drive slotted pins out of the support shim.

Issued 8-06

Printed in U.S.A.

6004-11

STEP 24

STEP 27

BD00M259

Preload the cup springs using a press and remove


the retaining ring.

BD00M262

Lift the piston out of the brake housing.

STEP 28
STEP 25

BD00M263
BD00M260

Pull the pin out of the support shim and remove the
released cup springs.

STEP 26

Remove and discard the guide ring, support rings


and U-rings from the grooves of the brake housing.
NOTE: If replacing brakes only, go to step 44.

STEP 29

BD00M261

Press the gripping rings off of the pins.

Bur 5-3190

BD03B023

Using CAS2850 puller bridge and 8073 step plate,


remove the brake housing from the wheel end shaft.

Issued 8-06

Printed in U.S.A.

6004-12

STEP 30

STEP 32

BD03B024

Use acceptable lifting equipment and lift the brake


housing from the wheel end shaft.

Remove the shaft seal from the brake housing.

STEP 31

STEP 33

BD00M267

If the wheel end pressure ring or bearing needs to be


replaced, remove the bearing from the wheel end
shaft.

STEP 34

BD00M266

If necessary drive both bearing outer rings out of the


brake housing.

BD00M269

If the wheel end pressure ring needs to be replaced,


remove the pressure ring from the wheel end shaft.

Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-13

Assembly

WARNING: Always wear heat protective


gloves to prevent burning your hand when
handling heated parts.

STEP 35

SM121A

STEP 38

BD00M271

Install a new pressure ring on the wheel end shaft.

STEP 36

BD00M273

Heat the bearing inner ring and install it onto the


wheel end shaft.

STEP 39

BD01F107

Install the CAS2874 pressure ring installer adapter


on the wheel end shaft.

STEP 37

BD03B026

Freeze the bearing outer ring. Press the bearing


outer ring into the brake housing using CAS2879.

STEP 40
Freeze the bearing outer ring. Press the bearing
outer ring into the brake housing using CAS2853.

BD01F105

Press the pressure ring over the collar of the wheel


end shaft using CAS2860 pressure ring installer.

Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-14

STEP 41

STEP 42

BD03B024
BD03B027

Use a solution of 50% water and 50% mineral spirits


to wet the outer diameter of the shaft seal. Using
CAS2880 install the shaft seal with the sealing lip
showing to the oil chamber. See illustration below.

Use acceptable lifting equipment and install the


brake housing over the wheel end shaft until contact.
WARNING: Always wear heat protective
gloves to prevent burning your hand when
handling heated parts.
SM121A

STEP 43

BS00M073

SHAFT SEAL
1. BRAKE HOUSING
2. SHAFT SEAL
* GREASE FILLING

Bur 5-3190

BD00M277

Heat the bearing inner ring and install it into the


brake housing until contact.

Issued 8-06

Printed in U.S.A.

6004-15

STEP 44

STEP 45

BD00M263

BD00M279

Clean the groove of the brake housing with solvent.


Install the guide ring into the groove and fix it with
Loctite 415.
NOTE: Upon installation the guide ring must have
contact on the whole circumference and the orifice
must show upwards (12 oclock).

STEP 46

BS00M072

1.
2.
3.
4.

BRAKE HOUSING
GUIDE RING
SUPPORT RING
U-RING

5. U-RING
6. SUPPORT RING
7. WHEEL END SHAFT

Install the guide ring, support rings and U-rings in the


grooves of the brake housing.

Bur 5-3190

BD00M280

Apply oil on the sliding surface of the piston. Care


fully insert the piston into the brake housing.

Issued 8-06

Printed in U.S.A.

6004-16

STEP 47

BD00M281

Insert the pins into the assembly fixture until contact.

STEP 48
BS00M074

1. PIN
2. GRIPPING RINGS
3. CUP SPRINGS

4. SUPPORT SHIM
5. RETAINING RING
X. 10.5 MM +0.3 (0.41 IN +0.02)

STEP 50

BD00M282

1. GRIPPING RINGS

Press the gripping rings onto the pins until contact on


the assembly fixture.
ATTENTION: Observe the installation position,
install the gripping rings with the orifices offset by
180 to each other.

BD00M284

Insert the assembled pins into the support shim and


install the snap ring.

STEP 49
STEP 51

BD00M283

Install the cup springs onto the pins. See illustration


below.
Bur 5-3190

BD00M285

Insert the assembled support shim into the piston.


Issued 8-06

Printed in U.S.A.

6004-17

STEP 52

STEP 54

1
BD00M286

BD00M288

1. SPLINE

Install the circlip into the brake housing.

Drive the stop bolt into the planet carrier. Then coat
the spline with anti-corrosive antiseize.

STEP 53

STEP 55

BD03B028

BD00M289

Insert the planet carrier into the spline of the wheel


end shaft until contact.

BD03B034

1. BRAKE HOUSING
2. CIRCLIP
3. SLOTTED PIN

4. SUPPORT SHIM
5. PISTON
X INSTALLATION DIMENSION
5.0 MM 0.5 MM

Drive slotted pins into the bores of the support shim


to lock the circlip.

Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-18

STEP 56

STEP 58
2

BD03B016

Grease both O-rings.

STEP 59

3
4
BS06A166

1. BRAKE PISTON
2. BRAKE DISC

3. PLATE 4 MM
4. PLATE 2 MM
BD03B030

Install the discs (2), plates (3), and plates (4) as


shown. Lubricate the brake disc with clean axle oil.

Install two aligning dowels in the brake housing,


install ring gear onto the brake housing.

NOTE: The number of brake discs may vary from


your machine, the procedure is the same.

NOTE: Make sure alignment is correct on ring gear.

STEP 60

STEP 57

BD03B029

Insert O-ring into the recess of the brake housing.

Bur 5-3190

BD01C009

Heat the bearing inner rings with a hot air gun.

Issued 8-06

Printed in U.S.A.

6004-19
WARNING: Always wear heat protective
gloves to prevent burning your hand when
handling heated parts.

WARNING: Always wear heat protective


gloves to prevent burning your hand when
handling heated parts.

SM121A

STEP 61

SM121A

STEP 63

BD00M292

BD00M294

Install the bearings with the big radius showing to the


planet carrier (downwards).

Heat the bearing inner rings and install into the


planet gears.

STEP 62

STEP 64

BD00M293

Put the planet gears onto the bearing inner rings.

Bur 5-3190

BD03B031

Install the snap rings on the planet gear shafts using


OEM6492 snap ring pliers.

Issued 8-06

Printed in U.S.A.

6004-20

Adjust end play of sun gear shaft 0.5 to


2.0 mm (0.02 to 0.08 inch)

STEP 67

STEP 65

BD00M298

Insert the sun gear shaft onto the stub shaft until
contact.
BD00M296

Determine dimension I, from the mounting face of the


brake housing up to the face of the stop bolt.
Dimension I e.g. . . . . . . . . . . . 46.20 mm (1.82 inch)

STEP 68

STEP 66

BD00M299

BD00M297

Insert the stub shaft into the spline of the axle bevel
gear until contact.

Bur 5-3190

Determine dimension II from the face of the sun gear


shaft up to the mounting face of the axle casing.
Dimension II e.g. . . . . . . . . . . 43.00 mm (1.69 inch)
Example:
Dimension I
+46.20 mm (1.82 inch)
Dimension II
43.00 mm (1.69 inch)
Difference
3.20 mm (0.13 inch)
Required end play e.g.
1.00 mm (0.04 inch)
Difference = shim e.g. s =
2.20 mm (0.09 inch)

Issued 8-06

Printed in U.S.A.

6004-21

STEP 69

STEP 72

BD00M245

Insert the sun gear shaft into the planet carrier.

BD00M300

Install the washers and bolts by hand.


Tightening torque . . . . . . . 390 Nm (288 pound-feet)

STEP 70
STEP 73

BD00M244

Install the determined shim(s), e.g. S. = 2.20 mm


(0.09 inch) into the sun gear shaft with grease.

STEP 71

BD03B033

Install the locknut by hand and tighten it using


CAS2876 locknut socket and CAS2883 suppor t
bracket.
Tighten torque . . . 700+300 Nm (516 +221pound-feet)

STEP 74

BD03B032

Install O-ring and hold into place with grease, install


output housing onto axle.
BD00M302

Secure the locknut with the slotted pin.

Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-22

STEP 75

STEP 76

1
BD00M303

1. O-RING

BD00M304

Insert the cover into the wheel end.

Install an O-ring on the cover.

Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-23

LEAKAGE TEST OF THE BRAKE HYDRAULICS


NOTE: Prior to start the test, ventilate the brake hydraulics and then actuate it several times.

High Pressure Test


Low Pressure Test

STEP 77

Reduce test pressure to p = 5 bar (72.5 psi) and


close the shutoff valve again.
During a 5 minute testing time a pressure drop is not
allowed.

BD00M305

Increase test pressure up to p =100 bar (1450 psi)


maximum and close connection to HD pump by
means of shutoff valve. During a 5 minute testing
time, a pressure drop of maximum 2 bar (29 psi) is
allowed.
ATTENTION: If the maximum pressure of 100 bar
(1450 psi) is exceeded, there will be an excessive
piston adjustment and a repeated disassembly of the
brake or the adjusting is required to reset the gripping
rings to the adjusting dimension.

Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-24

DISASSEMBLY OF DIFFERENTIAL CARRIER AND BRAKE TUBES


STEP 1

STEP 3

BD00M235

Fasten the axle on a stand.

BD00M241

Use acceptable lifting equipment to hold the wheel


end in place. Loosen and remove the bolts.

STEP 2
STEP 4

BD00M236

BD03B032

Separate the wheel end from the axle housing.


Remove O-ring.

STEP 5

BD00M237

Loosen the screw plugs and drain the oil from the
axle casing.
BD00M243

Pull the stub shaft out of the sun gear shaft. Repeat
steps 3 through 5 for the other wheel end.
NOTE: Pay attention to the released shim(s).
Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-25

STEP 6

STEP 9

BD00M395

BD00M398

Remove the bolts from the differential carrier.

Drive out the slotted pins from the differential carrier.

NOTE: Mark the location of the differential carrier to


the axle casing.

STEP 10

STEP 7

BD01F072

BD03B035

Use suitable lifting equipment and lift the differential


carrier out of the axle casing.

Loosen and remove both adjusting nuts using


CAS2851 wrench.

STEP 11

STEP 8

BD00M400

Heat the axle drive housing with a hot air gun.


BD03B036

NOTE: Bolts are installed with Loctite.

Fasten the differential carrier on OEM4135 engine


stand using CAS2847 mounting bracket.

Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-26

STEP 12

STEP 13

BD00M401

Loosen the bolts and take off both bearing brackets.


NOTE: Make an alignment mark between the
bearing bracket and the housing.

BD00M402

Remove both bearing outer rings from the differential


carrier.

STEP 14

ATTENTION: Loosen the bolts by hand only.

BD00M403

Use acceptable lifting equipment and lift the


differential out of the differential carrier.

Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-27

DISASSEMBLY OF LIMITED SLIP DIFFERENTIAL


STEP 15

STEP 17

BD00M406
BD01F089

Using CAS2294 cone puller and 8065 step plate,


remove the bearing inner ring from the differential
housing.

Place the differential in a press to prevent it from


turning. Remove the bolts and the released housing
cover.

STEP 18

STEP 16

BD00M407

Remove all the single parts from the differential


housing.
BD01F096

Remove the bearing inner ring from the housing


cover using CAS2294 cone puller and 8065 step
plate.

STEP 19

BD00M408

Press off the ring gear from the differential housing.

Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-28

DISASSEMBLY OF DRIVE PINION


STEP 20

STEP 23

BD00M409

Heat the pinion shaft locknut with a hot air gun.


NOTE: Locknut is held with Loctite Type No. 262.

BD00M412

Remove the shaft seal from the differential carrier.

STEP 24
Use a rubber hammer to remove the drive pinion out
of the differential carrier.

STEP 21

STEP 25
Take off the spacer ring and pull the bearing inner
ring from the drive pinion shaft.

STEP 26

BD01F091

Using CAS1579A yoke holding wrench, loosen the


locknut and remove the washer behind it.

STEP 22
BD00M414

If necessary drive out both bearing outer rings from


the differential carrier.

BD00M411

Pull the input yoke from the drive pinion shaft.

Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-29

DISASSEMBLY OF THE BRAKE TUBES


STEP 27

STEP 30

BD00M334

BD00M337

Remove the screw plug with the vent valve from the
axle casing.

Disconnect the pipe union and remove the released


brake tube from the axle casing.

STEP 28

STEP 31

BD00M335

Loosen and remove the hexagon screw from the


axle.

BD00M338

Remove the vent valve from the connection part.

STEP 32
STEP 29

BD00M339
BD00M336

Loosen and remove the union screw from the axle.

Bur 5-3190

Loosen the connection part and remove it from the


axle. Repeat steps 28 to 32 for the other wheel end.

Issued 8-06

Printed in U.S.A.

6004-30

ASSEMBLY OF BRAKE TUBES AND DIFFERENTIAL CARRIER


STEP 33

STEP 36

2
3
4
1

BD00M340

1. VENT
VALVE

2. CONNECTION 3. O-RING 4. RECTANGULAR


PART
RING

BD00M343

1. O-RING

Install an O-ring into the groove of the brake tube.

Assemble the part as shown in the photo above.

STEP 37
STEP 34

2
1

BD00M344
BD00M341

Install the connection part on the axle casing.


Tightening torque . . . . . . . . .130 Nm (96 pound feet)

1. BRAKE TUBE
2. UNION SCREW

Insert the brake tube into the axle casing, assembling


the connection part through the union screw.

STEP 35

BD00M342

Install the union screw with a new O-ring on the axle.


Tightening torque . . . . . . . 190 Nm (140 pound-feet)
Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-31

STEP 38

Assemble the screw plug as shown in the above


photo.

STEP 41

BD00M345

Fasten the brake tube with the hexagon nut and


union nut.
Tightening torque . . . . . . . . . 70 Nm (52 pound-feet)

MD00M348

Install the screw plug on the axle casing.


Tightening torque . . . . . . . . 70 Nm (52 pound-feet)

STEP 39

BD00M346

Tightening torque . . . . . . . . . 80 Nm (60 pound-feet)


NOTE: Repeat steps 33 to 39 for the other wheel
end.

STEP 40
1
2
3

BD00M347

1. O-RING
2. SCREW PLUG
3. VENT VALVE

Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-32

ASSEMBLY OF DIFFERENTIAL CARRIER


NOTE: If the ring gear or drive pinion are damaged,
both parts have to be replaced together. For new
installation of a complete bevel gear set pay attention
to the same pair number of drive pinion and ring
gear.

STEP 44

Determine Shim Thickness for a


Perfect Tooth Contact Pattern
NOTE: Make the following measuring steps at
maximum accuracy. In exact measurements result in
a faulty tooth contact pattern and require a repeated
disassembly and assembly of the drive pinion as well
as of the differential.
BD00M350

STEP 42
Install the CAS2873 pinion depth gauge block and
CAS2289-1 gauge tube on the differential carrier.

Determine Dimension I (bearing width).


Dimension I e.g. . . . . . . . . . . 36.00 mm (1.417 inch)

STEP 45
STEP 43

BD00M351

1. 168.0 +0.05
BD01F106

Determine the gap between the measuring shaft and


the measuring pin with a feeler gauge.
Dim. B e.g. . . . . . . . . . . . . . . . 1.00 mm (0.039 inch)
Example A.:
Dimension A (tool constant)
Dimension B (gap)
Results in Dimension X

204.25 mm
------(8.041 inch)
+1.00 mm
------(0.039 inch)
s = 205.25 mm
-----(8.08 inch)

Read Dimension II (dimension for pinion).


Dimension II e.g. . . . . . . . . . 168.05 mm (6.62 inch)
Example B:
Dimension I
Dimension II
Results in Dimension Y
Example C:
Dimension X
Dimension Y
Difference = Shim e.g.

Bur 5-3190

36.00 mm
------(1.417 inch)
+168.05 mm
------(6.616 inch)
s = 204.05 mm
-----(8.04 inch)

205.25 mm (8.081 inch)


204.05 mm (8.033 inch)
s = 1.20 mm (0.048)

Issued 8-06

Printed in U.S.A.

6004-33

Install the Drive Pinion

STEP 49

STEP 46

BD01F065

BD00M352

Press the bearing inner ring on the drive pinion shaft


using CAS2297 and 8073 step plate.

Place the determined shim e.g. S. =1.20 mm (0.05


inch) into the bearing bore in the differential carrier.

STEP 47

BD01F063

Freeze the bearing outer ring and insert into the


differential carrier using CAS2293-1, CAS2293-2,
and 8073 step plate.

STEP 48

BD01F087

Freeze the bearing outer ring on the input side and


install using CAS2293-2 and 8073 step plate.
Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-34

Adjust Rolling Moment of Drive


Pinion Bearing

STEP 52

STEP 50

BD01F101

Press the dust shield onto the input yoke using


CAS2882 puller tube.
BD00M356

STEP 53

Install the spacer ring on the pinion shaft.


NOTE: As per experience the required rolling
movement is obtained by use of the spacer ring [e.g.
s=8.70 mm (0.34 inch)] available at disassembly.
However, a later checking of the rolling movement
must be done.
WARNING: Always wear heat protective
gloves to prevent burning your hand when
handling heated parts.
SM121A

STEP 51
BD00M359

Install the input yoke on the pinion shaft.

STEP 54

BD00M357

Insert the assembled drive pinion into the differential


carrier and install the heated bearing inner ring.

BD00M360

Install the washer on the pinion shaft.

Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-35

STEP 55

STEP 58

BD01F091

BD01F098

Install the locknut by hand. Using CAS1579A yoke


holding wrench tighten the locknut.
Tightening torque . . . . . . . 700 Nm (516 pound-feet)

Using CAS2288 and CAS2299, install the shaft seal


with the sealing lip showing to the oil chamber
(downwards).

NOTE: When tightening rotate the drive pinion in


both directions several times.

ATTENTION: Just before the installation wet the


outer diameter of the shaft seal with a solution of
50% water and 50% mineral spirits. Fill the space
between the sealing and dust lip with grease.

STEP 56

STEP 59

BD00M362

Check rolling movement. Rolling movement should


be 1.5 to 3.0 Nm (1.10 to 2.21 pound-feet).
NOTE: For new bearings it should be tried to
achieve the maximum value of the rolling movement.
ATTENTION: If the required rolling movement is not
obtained, correct it with an adequate spacer ring,
according to the following indications:
Rolling movement too low - install a thinner spacer
ring.
Rolling movement too high - install a thicker spacer
ring.

BD01F091

Put the input yoke in place and install the washer and
locknut. Using CAS1579A yoke holding wrench
tighten the locknut.
Tighten torque . . . . . . . . . 700 Nm (516 pound-feet)
ATTENTION: Apply Loctite, Type No. 262, onto the
thread of the locknut.

STEP 57
Remove the locknut again and pull off the input yoke
from the drive pinion shaft.

Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-36

ASSEMBLY OF LIMITED SLIP DIFFERENTIAL


STEP 60

STEP 63

BD00M427

BD00M430

Place both thrust washers into the differential


housing.

Insert the axle bevel gear and slide the splined shaft
into the clutch discs.

STEP 61

STEP 64

BD00M428

BD00M431

Starting with an outer clutch disc install alternately


the outer and inner clutch discs.

Assemble the differential spider and insert it into the


differential housing.

ATTENTION: Thickness of the disc pack must be


identical on both sides.

STEP 65

STEP 62

BD00M432

Insert the second axle bevel gear.


BD00M429

Insert the pressure ring into the differential housing.


Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-37

STEP 66

Determine the Disc Clearance


STEP 68

BD00M433

Insert the second pressure ring into the differential


housing.

BD00M435

Determine dimension I, from the mounting face of the


differential housing to the plane face of the outer
clutch disc.
Dimension I e.g. . . . . . . . . . . 38.05 mm (1.50 inch)

STEP 67

STEP 69

BD00M434

Starting with an inner clutch disc install alternately


the inner and outer clutch disc.
ATTENTION: The thickness of the clutch disc pack
must be identical on both sides.

BD00M436

Determine dimension II, from the contact surface of


the outer clutch disc to the mounting face of the
housing cover.
Dimension II e.g. . . . . . . . . . . 37.75 mm (1.48 inch)
38.05 mm

Dimension I

-------(1.50 inch)
+ 37.75mm

Dimension II
Difference = Disc clearance

-------(1.49 inch)
= 0.30 mm
------(0.01 inch)

NOTE: If the required disc clearance is not obtained,


correct it with the adequate outer clutch discs [s=2.1,
s=2.2, s=2.3, s=2.4 or s=2.5 mm (0.083, 0.087,
0.091, 0.094, 0.098 inch)], taking care that the
difference in thickness between the left and the right
disc pack must only be 0.1 mm (0.004 inch) at a
maximum.
Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-38

STEP 70

STEP 73

BD00M437

BD00M440

Fix the thrust washer with grease into the recess of


the differential housing cover.

Press both bearing inner rings onto the differential


housing.

STEP 71

STEP 74

BD00M438

BD00M441

Put the housing cover in place on the differential


housing. Heat the ring gear and install onto the
differential housing.

Use acceptable lifting equipment and insert the


differential into the differential carrier.

STEP 75
STEP 72

BD00M442
BD00M439

Put the differential in a press to prevent it from


turning and install the bolts on the ring gear.
Tightening torque . . . . . . . 410 Nm (302 pound-feet)

Place the bearing outer ring into the differential


carrier.

ATTENTION: Use new locking bolts.


Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-39

STEP 76

STEP 79

BC00M443

BD00M446

Install the adjusting nut by hand on the differential


carrier.

Install both bearing brackets and install the bolts and


washers.
Tighten torque . . . . . . . . . 280 Nm (207 pound-feet)

STEP 77

ATTENTION: Apply Loctite Type No. 262 onto


threads of the bolts.

BD00M444

Install the ring gear sided bearing outer ring.

STEP 78

BD00M445

Install the adjusting nut by hand on the differential


carrier.

Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-40

Adjust Backlash and Bearing


Preload

STEP 82

STEP 80

NOTE: As the adjusting nut makes firm contact with


the bearing, the adjusting nut will immediately begin
to turn much harder.

Tighten the adjusting nut slowly until firm contact is


made with the bearing.

STEP 83
To adjust the bearing preload, note the position of the
adjusting nut. Now tighten the nut two additional
notches.

STEP 84

BD00M447

Place a dial indicator right-angled at the outer


diameter of the tooth flank (ring gear).
Adjust the pinion to ring gear backlash to the low side
of specifications (see value etched on the outer
diameter of the ring gear) by alternately turning each
of the adjusting nuts to move the ring gear closer to
or further away from the pinion. Backlash is checked
using a dial indicator against a tooth on the ring gear.

As the bearing preload is adjusted as described in


steps 81, 82 and 83, pinion to ring gear backlash
may increase slightly. Check pinion backlash to
confirm that it is within specifications. If backlash is
outside of specified range, repeat step 80 through 84
again.

STEP 85

NOTE: Rotate the differential several times and


recheck the backlash.

STEP 81

BD00M449

Coat several teeth on the ring gear with marking ink


and roll the ring gear in both directions over the drive
pinion.
Compare the obtained tooth contact pattern with the
examples on page 4 and 5.

BD01F072

ATTENTION: If the tooth contact pattern differs,


there has been a measuring error at determination of
the shim. This must be corrected.

Go to the adjusting nut opposite the ring gear and


loosen the nut approximately one turn to release
pressure on the bearing. It should be very noticeable
that pressure is released on the bearing, as the
adjusting nut will turn much easier.

Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-41

STEP 86

1.

BD00M450

BD00M453

Install both adjusting nuts with the slotted pins on the


differential carrier.

Insert the stub shaft into the spline of the axle bevel
gear.

STEP 87

STEP 89

BD03B035

BD00M454

Use suitable lifting equipment and inser t the


differential carrier into the axle casing.

Install the thrust washer removed at disassembly in


the sun gear shaft with grease.

NOTE: Align the two alignment marks together.


ATTENTION: Apply sealing compound on the
mounting surface.

STEP 88

BD00M452

Install new bolts on the differential carrier.


Tighten torque . . . . . . . . . 250 Nm (185 pound-feet)
Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004-42

STEP 90

STEP 91

BD03B032

BD00M456

Install O-ring and hold into place with grease. Use


acceptable lifting equipment and place the wheel end
on the axle housing.

Install the bolts and washers on the wheel end.


Tightening torque . . . . . . . 390 Nm (288 pound-feet)
NOTE: Repeat steps 1 to 91 for the other wheel end.
NOTE: Prior to putting into operation of the axle, fill
with oil. See section 1002.

Bur 5-3190

Issued 8-06

Printed in U.S.A.

6004

Section
6004
REAR AXLE

CNH America LLC.


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

Bur 5-3200

Copyright 2006 CNH Ameica LLC.


All rights reserved.
Printed in U.S.A.
Issued August, 2006

6004-2

TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GEAR TOOTH CONTACT PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WEAR MEASUREMENT ON MULTI-DISC BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WHEEL END AND BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE HYDRAULICS LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACE HUB SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Pinion Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Pinion Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Pinion Bearing Rolling Torque Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting Backlash and Bearing Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contact Pattern Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 5-3200

Issued 8-06

3
3
3
4
6
6
7
7
13
13
24
24
24
25
25
26
28
28
28
31
34
35
36
38
39
40

Printed in U.S.A.

6004-3

SPECIFICATIONS
Lubricant Capacity............................................................................................................ 26.5 liters (28 U.S. Quarts)
Distance Between Gripping Rings and Shoulder of Pin ......................................10.5 to 10.8 mm (0.41 to 0.43 inch)
Top of Pins to Top of Support Shim .........................................................................4.0 to 4.5 mm (0.15 to 0.18 inch)
Sun Gear Shaft End Play.............................................................................................................1.00 mm (0.04 inch)
Drive Pinion Rolling Torque ................................................................................. 1.5 to 3.0 Nm (13.2 to 26.5 lb-inch)
Differential Carrier Disc Clearance ..............................................................................................0.40 mm (0.02 inch)

SPECIAL TORQUES
Bolts Securing Wheel End to Axle Housing......................................................................... 440 Nm (325 pound feet)
Nut Securing Input Flange (Apply Loctite 262 to Threads).................................................. 700 Nm (516 pound feet)
Bolts Securing Differential Ring Gear .................................................................................. 390 Nm (288 pound feet)
Bolts Securing Axle Housing to Center Section .................................................................. 290 Nm (215 pound feet)
Locknut Securing Planetary Carrier................................................................................... 1000 Nm (737 pound feet)

SPECIAL TOOLS
Slide hammer puller adapter . . . . . . . . . CAS10846-3
Slide hammer . . . . . . . . . . . . . . . . . . . . . . OEM4252
Pressure Ring Installer . . . . . . . . . . . . . . . CAS2860
Planetary Bearing Puller . . . . . . . . . . . . . . CAS2881
Planetary Bearing Puller . . . . . . . . . . . . . . CAS2849
Bearing Cone Puller . . . . . . . . . . . . . . . . . CAS2843
Bearing Cone Puller Body . . . . . . . . . . . . . CAS2844
Pinion Shaft Seal Installer . . . . . . . . . . . . . CAS2841
Seal Driver. . . . . . . . . . . . . . . . . . . . . . . . . CAS2859
Step Plate . . . . . . . . . . . . . . . . . . . . . . . . . CAS2510
Lifting Bracket . . . . . . . . . . . . . . . . . . . . . . OEM4106
Wheel Nut Socket . . . . . . . . . . . . . . . . . . 380100000
Bearing Cup Installer . . . . . . . . . . . . . . . . 380100001

Bur 5-3200

Issued 8-06

Printed in U.S.A.

6004-4

GEAR TOOTH CONTACT PATTERNS


Ideal Tooth Contact Pattern

Pinion Distance Must Be Increased

BS01D011

BS01D009

COAST SIDE (CONCAVE)

BS01D013
BS01D012

COAST SIDE (CONCAVE)

DRIVE SIDE (CONVEX)

BS01D014

DRIVE SIDE (CONVEX)

Bur 5-3200

Issued 8-06

Printed in U.S.A.

6004-5

Pinion Distance Must Be Decreased

BS01D016
BS01D010

DRIVE SIDE (CONVEX)

BS01D015

COAST SIDE (CONCAVE)

Bur 5-3200

Issued 8-06

Printed in U.S.A.

6004-6

LUBRICATION
4
5

2
1

2
BC06G003

1. OIL DRAIN HOLE (AXLE HOUSING)


2. OIL DRAIN HOLE (OUTPUTS)

3. OIL FILL PLUG & DIPSTICK


4. BRAKE BLEEDER

5. BREATHER
6. BRAKE INLET

NOTE: Refer to section 1002 of this service manual for proper lubricant.

WEAR MEASUREMENT ON MULTI-DISC BRAKE


A

BS00M071

BD00M234

NOTE: A wear measurement on the multi-disc brake must be made at least once a year. Wear measurement
should also be made if brake noise is heard, if braking power is reduced, or anytime it is suspected that braking
function is impaired.
Wear measurement must be made on both wheel end sides.
Remove plug, actuate brake and determine dimension (A) using a thickness gauge. If dimension (A) is less than or
equal to 4.0 mm (0.16 inch) the lined discs on both output sides must be replaced. Replace O-ring when installing
the plug. Tighten plug to a torque of 50 Nm (40 pound feet).

Bur 5-3200

Issued 8-06

Printed in U.S.A.

6004-7

WHEEL END AND BRAKE


Disassembly

STEP 3

NOTE: Tools and axle shown in the following


photographs may appear slightly different than the
tools and axle you may have. The use of the tools
and disassembly/assembly of axle is the same
regardless of appearance.

STEP 1

BD06G004

Use lifting bracket, OEM4106, to hold wheel end.


Loosen and remove the bolts and washers.

STEP 4

BD06G001

Fasten axle on a stand.

Carefully pull the wheel end from the axle housing.


Remove and discard O-ring from axle housing wheel
end.

STEP 5

STEP 2

BD06G005
BD06G002

Mount the wheel end on a stand.

BD06G003

Remove drain plugs and drain oil from axle housing.


Bur 5-3200

Issued 8-06

Printed in U.S.A.

6004-8

STEP 6

STEP 9

BD06G006

BD06G009

Using pry bar, remove cover from output shaft.


Remove and discard O-ring from cover.

Using OEM4054 pulling attachment, remove the


planetary carrier.

STEP 7

STEP 10

BD06G007

Remove pin from lock nut using OEM4252 slide


hammer and CAS10846-3 adapter.

BD06G012

Remove retaining ring.

STEP 11
STEP 8

BD06G013
BD06G008

Remove lock nut using socket 380100000.

Bur 5-3200

Using CAS2848 planetary gear puller and step plate


8061, remove planetary gear and outer bearing from
planetary carrier shaft. Using a suitable puller,
remove the inner bearing from carrier shaft.

Issued 8-06

Printed in U.S.A.

6004-9

STEP 12

STEP 15

BD06G014

Remove the bearing from the planetar y using


CAS2881 collet set, CAS2849 puller body and screw.

STEP 13
Repeat Steps 10, 11, and 12 to remove the
remaining three retaining rings, planetary gears, and
six bearings.

BD00M250

Put alignment marks on planetary ring gear and


brake housing to aid in assembly. Using suitable
puller, remove planetar y ring gear from brake
housing.

STEP 16

STEP 14

BD00M251

BD06G015

Inspect the stop pin for wear, if necessary drill a hole


into the pin, use CAS10846-3 adapter and OEM4252
striker and remove the pin.

Remove and discard two O-rings from planetary ring


gear.

STEP 17

BD06G017

Remove and discard O-ring from brake housing port,


remove the brake disc pack from brake housing.

Bur 5-3200

Issued 8-06

Printed in U.S.A.

6004-10

STEP 18

STEP 21

BD06G020

BD06G018

Using suitable tool, push the three pins down until


pins are even with top surface of shim.

Remove the support shim from the brake piston.

STEP 22

STEP 19

BD06G022
BD06G047

Remove the snap ring.

Remove three pins from support shim.

STEP 23

STEP 20

BD06G023
BD06G019

W E A R FAC E P R OT E C T I O N W H E N U S I N G
COMPRESSED AIR. Apply compressed air to brake
housing por t to push brake piston from brake
housing.

Bur 5-3200

Put support shim in a press and compress Belleville


washers. Remove retaining ring and pull pin with
Belleville washers and rings installed from support
shim. Repeat this step to remove the remaining five
retaining rings and pins from support shim.

Issued 8-06

Printed in U.S.A.

6004-11

STEP 24

STEP 27

BD00M263

BD00M260

Remove seven Belleville washers from each pin.

STEP 25

BD06G024

Using a press, remove four gripping rings from each


pin.

STEP 26

BS00M072

1.
2.
3.
4.

BRAKE HOUSING
GUIDE RING
SUPPORT RING
GROOVED RING

5. GROOVED RING
6. SUPPORT RING
7. WHEEL END SHAFT

Remove the guide ring (2), support rings (3 and 6),


and U-rings (4 and 5) from the grooves of the brake
housing.

BD00M262

Lift and remove the piston from the brake housing.

Bur 5-3200

Issued 8-06

Printed in U.S.A.

6004-12

STEP 28

STEP 31

BD06G028

BD01F102A

Using the CAS2850 brake housing puller bridge and


CAS2510 step plate, pull the brake housing from the
wheel end shaft and remove the inner bearing.

Remove the face seal from the brake housing.

STEP 32

STEP 29

BD06G029

BD06G026

Remove and discard the face seal metal ring from


the wheel end shaft.

Use acceptable lifting equipment and lift the brake


housing from the wheel end shaft.

STEP 33

STEP 30

If the wheel end pressure ring or bearing need to be


replaced, remove the bearing from the wheel end
shaft.

BD06G027

If replacement of bearing cups is necessary, drive


both bearing cups out of the brake housing.

Bur 5-3200

Issued 8-06

Printed in U.S.A.

6004-13

Cleaning and Inspection

Assembly

IMPORTANT: Do not use compressed air to dry


bearings. Allow bearings to air dry.

STEP 39

STEP 34
Clean all parts except friction plates in brake disc
p a c k u s i n g c l e a n i n g s o l v e n t . W E A R FAC E
PROTECTION WHEN USING COMPRESSED AIR.
Use compressed air to clear passages in planetary
ring gear and brake housing.

STEP 35
I n s p e c t b e a r i n g r o l l e r s fo r p i t t i n g , s c o r i n g ,
deformation, or other damage. Check inner face and
bearing cage for deformation, dents, and other
da ma ge. Che ck asso ciat ed b e ar ing cup s for
scratches, grooves, or cracks. Check bearings for
rough spots or binding by holding bearing and
rotating. If bearing binds or action is not smooth,
replace the bearing.

BD06G033

Apply Loctite 574 to the seal ring mounting surface.


WARNING: Always wear heat protective
gloves to prevent burning your hand when
handling heated parts.

STEP 36
Inspect bearing cups for pitting, scoring, cracks, or
other damage. Replace if any of these conditions are
seen.

SM121A

STEP 40

NOTE: If a bearing or bearing cup requires


replacement, the associated part must also be
replaced.

STEP 37
Check planetary ring gear, planetary gears, and
planetary carrier gear teeth for cracks, breaks,
chipping, or other damage. Replace the part if any of
these conditions are seen. Check planetary carrier
shaft splines for bro ken, cracke d, or twisted
condition. Replace if necessary.
BD06G034

STEP 38
Check wheel end shaft for cracked, broken, or
twisted splines. Replace if any of these conditions
are seen.

Bur 5-3200

Heat the seal ring to approximately 120 C (248 F),


place the face seal ring on the wheel end shaft.

Issued 8-06

Printed in U.S.A.

6004-14

STEP 41

STEP 43

BD06G035

BD06G037

Use special tool CAS2860 and drive the busing into


position onto the hub.

Using CAS2877 inner bearing cup installer, press the


inner bearing cup into the brake housing until seated
against the shoulder in the brake housing.

NOTE: Only use the special tool to install the sealing


ring to ensure proper seating.

STEP 42
WARNING: Always wear heat protective
gloves to prevent burning your hand when
handling heated parts.

STEP 44
Using CAS2878 outer bearing cup installer press the
outer bearing cup into the brake housing until seated
against the shoulder in the brake housing.

SM121A

BD06G036

Heat the wheel end shaft outer bearing to 120 C


(248 F) in a bearing oven. Wearing heat resistant
gloves or mittens, install the bearing on the wheel
end shaft until the bearing is against the shoulder on
the wheel end shaft.

Bur 5-3200

Issued 8-06

Printed in U.S.A.

6004-15

STEP 45

STEP 47
WARNING: Always wear heat protective
gloves to prevent burning your hand when
handling heated parts.
SM121A

BD06G032

A
A

A
1
BD06G039

Heat the wheel end shaft inner bearing to 120 C


(248 F) in a bearing oven. Wearing heat resistant
gloves or mittens, install the bearing on the wheel
end shaft until the bearing is against the bearing cup
in the brake housing.

BS00M073

1. FACE SEAL
2. BRAKE HOUSING
A FILL WITH GREASE

Wet the outer diameter of the face seal with a


solution of 50% water and 50% mineral spirits. Use
CAS2880 seal installer to install the face seal with
the seal lip positioned as shown. Apply grease to
seal as indicated by (A) above.

STEP 46

BD06G038

Use acceptable lifting equipment and install the


brake housing on the wheel end shaft.
Bur 5-3200

Issued 8-06

Printed in U.S.A.

6004-16

STEP 48

STEP 49
A

BD00M278

BD00M279

Clean the groove of the brake housing with cleaning


solvent. Install the guide ring in the groove. Make
sure the ends (A) of the guide ring are facing up
towards the top (B) of the brake housing and the
guide ring is installed completely in its groove in the
brake housing. Apply Loctite 415 to ID of guide ring
to secure guide ring in its groove.

STEP 50

BC06G002

GUIDE RING, SUPPORT RINGS AND U-RINGS LOCATION


1. SUPPORT RING
2. GROOVED RING
3. GROOVED RING

4. SUPPORT RING
5. GUIDE RING
A. BRAKE HOUSING

Install the support rings and U-rings in the grooves of


the brake housing.

Bur 5-3200

BD00M280

Apply oil on the sliding surface of the piston, support


rings, U-rings and guide ring. Carefully install piston
in the brake housing.

Issued 8-06

Printed in U.S.A.

6004-17

STEP 51

STEP 53

BD00M282

1. GRIPPING RINGS

Press the gripping rings on the pins. Ends of gripping


rings must be 180 opposite from each other.

BD00M284

Put the assembled pins into the support shim and


install the snap ring.

STEP 54
STEP 52

BD00M283
BD00M285

Put the assembled support shim in the piston.

STEP 55
3
A
2
1
BS00M074

1. PIN
4. SUPPORT SHIM
2. GRIPPING RINGS
5. RETAINING RING
3. BELLEVILLE SPRINGS A. 10.5 TO 10.8 MM (0.41 TO 0.43
INCH)

Install the Belleville springs on the pins. Make sure


dimension (A) is 10.5 to 10.8 mm (0.41 to 0.43 inch).

Bur 5-3200

BD00M286

Install the snap ring to secure the support shim, slot


of the snap ring must be between two pins.

Issued 8-06

Printed in U.S.A.

6004-18

STEP 56

STEP 58

BD00M287

BD06G051

Apply grease to new O-ring and install in the brake


housing port.

STEP 59

BS00M075

1. BRAKE HOUSING
2. SNAP RING
3. PIN

4. SUPPORT SHIM
5. PISTON
A. 4.0 TO 4.5 MM
(0.15 TO 0.18 INCH)

BD00M251

Install the six pins (3) in the support shim (4) to lock
the snap ring (2). Dimension (A) between top of pins
(3) and top of support shim (4) must be 4.5 to 5.0 mm
(0.18 to 0.20 inch).

Apply grease to new O-rings and install on planetary


ring gear.

STEP 60

STEP 57

BD06G052
BD06G049

Apply oil to the clutch discs. Install the outer and


inner clutch discs alternately starting with an outer
clutch disc.
Bur 5-3200

Install two alignment studs in the brake housing.


Position the planetar y r ing gear on the brake
housing. Make sure alignment marks made during
disassembly are aligned. Use a soft faced hammer
and tap the planetary ring gear into brake housing.
Issued 8-06

Printed in U.S.A.

6004-19

STEP 61

STEP 64
WARNING: Always wear heat protective
gloves to prevent burning your hand when
handling heated parts.
SM121A

BD06G053

If removed, drive the stop bolt into the planetary


carrier until contact.

STEP 62
BD06G055

WARNING: Always wear heat protective


gloves to prevent burning your hand when
handling heated parts.
SM121A

Heat the planetary gears outer bearings to 120 C


(248 F) in a bearing oven. Wearing heat resistant
gloves or mittens, install the bearings on the shafts
until the bearing is against the gear.

STEP 65

BD06G054

Heat the planetary gears inner bearings to 120 C


(248 F) in a bearing oven. Wearing heat resistant
gloves or mittens, install the bearings on the shafts
until the bearing is against the bottom of the shaft.

BD06G056

Install the retaining rings on the planetary gear


shafts.

STEP 63
Install the planetary gears on the bearings.

Bur 5-3200

Issued 8-06

Printed in U.S.A.

6004-20

STEP 66

STEP 69

BD06G057

BD06G060

Coat the spline with Loctite No. 767 antiseize


lubricant.

Rotate the housing until the planet carrier gears are


flush with the ring gear.

STEP 67

STEP 70

BD06G058

Align the slots of the brake disks.

BD06G061

Pivot the housing on the stand and install the lock


nut.

STEP 68
STEP 71

BD06G059

Install the planet carrier into the spline of the wheel


end shaft using OEM4054.

Bur 5-3200

BD06G062

Tighten the lock nut to a torque of 1000 Nm (737


pound feet) using socket 380100000, rotate the
brake housing several time in both directions and
recheck torque.

Issued 8-06

Printed in U.S.A.

6004-21

STEP 72

STEP 74

BD06G063

Install a new slotted pin into the wheel end lock nut.

BD06G065

Install the cover into the wheel end.

NOTE: If the slot is not aligned tighten the nut to


align the slot, never loosen the nut to align the slot.

STEP 73

BD06G064

Install a new O-ring on the wheel end cover.

Bur 5-3200

Issued 8-06

Printed in U.S.A.

6004-22

Sun Gear Shaft End Play Adjustment

STEP 79

STEP 75

BD06G068

BD06G066

Using two M18 bolts of suitable length, secure


planetary ring gear to brake housing.

STEP 76
Take a measurement from the straight edge to the
face of the planetar y gear ring, the difference
between this measurement and the measurement in
the next step will be dimension A.

STEP 77

Determine dimension B from the face of the stub


shaft to the mounting face of the axle housing.
Example:
Dimension B . . . . . . . . . . . . . 100.20 mm (3.95 inch)

STEP 80
Subtract dimension A from dimension B. Then
subtract 1.30 mm (0.05 inch) from the difference. The
difference is the required shim size.
Example:
Dimension B
Dimension A
Difference
Required end play
Difference = shim
size

100.20 mm (3.94 inch)


97.90 mm (3.85 inch)
2.30 mm (0.09 inch)
1.30 mm (0.05 inch)
1.00 mm (0.04 inch)

STEP 81

BD06G067

Mount the sun gear into the planet gears. Then,


determine dimension A, from the inner face of the
sun gear to the face of the planetary ring gear.
Example:
Dimension A . . . . . . . . . . . . . 97.90 mm (3.85 inch)

STEP 78
Install the stub shaft in the spline of the axle bevel
gear. Make sure the stub shaft is installed all the way
into the axle bevel gear.

Bur 5-3200

BD06G069

Install the shim set (size as determined in Step 80


above) into the sun gear shaft with grease.

Issued 8-06

Printed in U.S.A.

6004-23

STEP 82

STEP 84

BD06G072
BD06G070.

Remove the two M18 bolts securing the planetary


ring gear to brake the housing.

STEP 83

Use lifting bracket, OEM4106, and install the


assembled wheel end onto the axle housing.
NOTE: Turn the input flange to align splines of the
stub shaft into the sun gear.

STEP 85

BD06G071

Apply grease to a new O-ring and install O-ring in


brake port.

Bur 5-3200

BD00M300

Install the washers and bolts to secure the wheel end


to the axle housing. Tighten the bolts to a torque of
440 Nm (325 pound feet).

Issued 8-06

Printed in U.S.A.

6004-24

BRAKE HYDRAULICS LEAKAGE TEST


IMPORTANT: DO NOT EXCEED 100 BAR (1450
PSI) PRESSURE IN THE FOLLOWING STEPS. If
the maximum pressure of 100 bar (1450 psi) is
exceeded, the piston will move too much changing
the gripping rings adjustment. If the gripping rings
adjustment changes, the wheel end must be
removed and disassembled and the gripping rings
adjusted to the correct dimension (Step 51).

STEP 86

High Pressure Test


STEP 87
Operate the hand pump to increase pressure to 100
bar (1450 psi) maximum. Close connection to hand
pump using the shutoff valve. During a 5 minute
period, pressure shall not drop more than 2 bar (29
psi).

Low Pressure Test


STEP 88
Reduce pressure to 5 bar (72.5 psi) and close the
shutoff valve. During a 5 minute period pressure shall
not drop.

BD00M305

Connect a hand pump with pressure gauge to the


brake port as shown above. Fill the hand pump with
hydraulic oil. Build up pressure in the axle internal
brake lines then bleed air from the lines. After air is
bled, actuate the brakes a minimum of 5 times to a
pressure of 100 bar (1450 psi) by operating the hand
pump.

Bur 5-3200

Issued 8-06

Printed in U.S.A.

6004-25

REPLACE HUB SEAL


Removal

STEP 92

STEP 89

BD06G077

BD06G074

Remove drain plug and drain oil from the brake


housing.

Loosen and remove the lock nut using socket


380100000.

STEP 93

STEP 90

BD06G078

Use pry bar and remove the end cover.

Use lifting bracket, OEM4106, to hold wheel end.


Separate the output shaft using a puller.

STEP 91

STEP 94

BD06G075

BD06G076

Use a slide puller and remove the slotted pin from the
lock nut.

Bur 5-3200

BD06G079

Use a pry bar and remove the seal form the brake
housing.

Issued 8-06

Printed in U.S.A.

6004-26

STEP 95

STEP 98

BD06G080

BD06G082

Inspect the bushing for wear marks where the seal


makes contact, if required remove the bushing.

Put a bead of Loctite 574 on the bushing mounting


surface.

Installation

STEP 99
WARNING: Always wear heat protective
gloves to prevent burning your hand when
handling heated parts.

STEP 96

SM121A

BC06G005

Install the seal as shown above with wipers (3) facing


out towards bushing (4).

BD06G083

Heat the bushing to 120 C (248 F) and place the


bushing onto the output shaft.

STEP 97

BD06G081

Lubricate the outer diameter of the seal with water,


use driver CAS2859 and install the seal.

Bur 5-3200

Issued 8-06

Printed in U.S.A.

6004-27

STEP 100

STEP 103

BD06G084

BD06G087

Use special tool CAS2860 and drive the busing into


position onto the hub.

Install the lock nut, tighten the lock nut to a torque of


1000 Nm (737 pound feet) using socket 380100000,
rotate the brake housing several time in both
directions and recheck torque.

NOTE: Only use the special tool to install the sealing


ring to ensure proper seating.

STEP 104

STEP 101

BD06G088
BD06G085

Heat the inner bearing to 120 C (248 F).

Install a new slotted pin into the wheel end lock nut.
NOTE: If the slot is not aligned tighten the nut to
align the slot, never loosen the nut to align the slot.

STEP 102

STEP 105

BD06G086

Grease the seal lip of the shaft seal, use lifting


bracket, OEM4106, and install the wheel end onto
the brake housing.

Bur 5-3200

BD00M304

Install a new O-ring on the wheel end cover, install


the cover into the wheel end.
Issued 8-06

Printed in U.S.A.

6004-28

DIFFERENTIAL
Removal

STEP 108

STEP 106

BD06G127

BD06G002

Connect lifting equipment to the differential and


remove the differential from axle housing.
NOTE: Make sure that the right axle stub shaft
releases from the differential.

Disassembly
STEP 109

BD06G003

Remove drain plugs and drain oil from axle.

STEP 107
BD01F059

Remove the bearing from the differential housing


using CAS2848 puller, OEM4175 pulling attachment,
1103 puller legs, and 8065 step plate.

BD06G126

Fasten the axle to a stand, support the center of the


axle as shown, facing the input shaft attach suitable
lifting equipment to the left axle housing, remove the
mounting bolts and axle half.
ATTENTION: Differential can fall out of housing
when axle half is removed.
Bur 5-3200

Issued 8-06

Printed in U.S.A.

6004-29

STEP 110

STEP 113

BD01F075

Remove the bearing from the housing cover using


CAS2871 collet set, CAS2882 puller body, and 8067
step plate.

BD06G129

Remove all parts from the differential housing.

STEP 114

STEP 111

BD00M326
BD00M323

Place the differential in a press to prevent it from


turning. Remove the bolts.

Press the ring gear from the differential housing.

STEP 115

STEP 112

BD06G131

BD00M324

Remove the housing cover from the differential


housing.

Bur 5-3200

Pull the outer bearing ring and shims from both axle
housings.
NOTE: Make sure to identify the shims into which
axle housing they were removed.

Issued 8-06

Printed in U.S.A.

6004-30

7
6

5
4

3
2
1

9
10

12
3
6
8

4
11

7
BC06G001

1.
2.
3.
4.

Bur 5-3200

BEARING
HOUSING
WASHER, THRUST
SHIM

5.
6.
7.
8.

OUTER CLUTCH
PLATE
DIVIDER
GEAR, BEVEL

9.
10.
11.
12.

PINION, BEVEL
SHAFT
COVER
BOLT, M15 X 45

Issued 8-06

Printed in U.S.A.

6004-31

Assembly

STEP 118

NOTE: The ring gear and the drive pinion are a


matched gear set and cannot be serviced separately.

STEP 116
WARNING: Always wear heat protective
gloves to prevent burning your hand when
handling heated parts.
SM121A

BD06G151

Install the disk package starting with an outer clutch,


refer to illustration on page 30.

STEP 119

BD06G149

Heat the ring gear to 120 C (248 F) in a bearing


oven. Wearing heat resistance gloves or mittens,
install the ring gear on the differential.
NOTE: Make sure to align the bolt holes.

STEP 117
BD06G152

Install the divider in the differential housing.

STEP 120

BD06G150

Install both thrust washers into the differential carrier,


the brass thrust washer must be towards the bevel
gear as shown, refer to illustration on page 30.
NOTE: Be sure to apply oil to all parts before
assembly.

Bur 5-3200

BD06G153

Install the axle bevel gear. Make sure axle bevel gear
splines mate with splines of all inner clutch plates.

Issued 8-06

Printed in U.S.A.

6004-32

STEP 121

STEP 124

BD06G154

BD06G157

Assemble the differential spider and install into the


differential housing.

Starting with an clutch plate, install alternately the


plate and outer clutch.

STEP 122

NOTE: Thickness of disc packs must be the same


on both sides.

Determine Disc Clearance


STEP 125

BD06G155

Install the second axle bevel gear.

STEP 123

BD06G158

Determine dimension A, from mounting face of the


differential housing to face of the outer clutch disc.
Dimension A (Example). . . . . . 38.05 mm (1.50 inch)

BD06G156

Install the second divider in the differential housing.

Bur 5-3200

Issued 8-06

Printed in U.S.A.

6004-33

STEP 126

STEP 128

BD06G159

BD06G161

Determine dimension B, from contact surface of the


outer clutch disc to mounting face of the housing
cover.
Dimension B (Example). . . . . . 37.65 mm (1.48 inch)
Example B:
38.05 mm
Dimension A
-------(1.50 inch)
+37.65 mm
Dimension B
-------(1.48 inch)
= 0.40 mm
Difference = Disc clearance
------(0.02 inch)

Place the differential in a press to prevent it from


turning. Install new bolts and tighten bolts to a torque
of 390 Nm (288 pound feet).
NOTE: Use new bolts only.

STEP 129

NOTE: If required disc clearance of 0.040 mm (0.02


inch) is not obtained, install new outer clutch discs of
thickness necessary to obtain 0.040 mm (0.002 inch)
disc clearance. The left and right clutch packs must
be the same thickness. Outer clutch discs are
available in following thicknesses: 2.9 mm (0.114
inch), 3.0 mm (0.118 inch), 3.1 mm (0.122 inch).

STEP 127

BD06G162

Press both bearings on the differential.

BD06G160

Install the thrust washers with grease in the recess of


the housing cover.
NOTE: Mount the brass thrust washer (on top)
towards the bevel gear.

Bur 5-3200

Issued 8-06

Printed in U.S.A.

6004-34

Drive Pinion Removal

STEP 134

STEP 130
Heat lock nut securing flange with a hot air blower to
loosen Loctite, approximately 120 C (248 F).

STEP 131

BD06G134

Press the input pinion out of the housing.

STEP 135
BD06G132

Install holding wrench on input flange. Hold flange


using holding wrench, CAS1579A, and remove lock
nut and washer. Remove holding tool from flange.

STEP 132
Remove the input flange from the drive pinion.

STEP 133
BD06G135

Remove the spacer ring from the drive pinion.

STEP 136

BD06G133

Remove the shaft seal from the axle drive housing.

BD06G136

Press the bearing inner ring from the drive pinion


using CAS2843 and CAS2844 puller body and collet
set.

STEP 137
Drive out both bearing cups from the differential
carrier.
Bur 5-3200

Issued 8-06

Printed in U.S.A.

6004-35

Drive Pinion Installation

STEP 140

STEP 138

3
2
BD06G139

BD06G137

Find and record the housing dimension X.


Dimension X (Example). . . . . 205.30 mm (8.08 inch)

STEP 139

1. MATING NUMBER (MARKED MANUALLY)


2. PINION BASIC DIMENSION (STAMPED)
3. PINION DISTANCE DEVIATION + OR - (MARKED
MANUALLY)

Distance deviation is indicated in 1/100 mm. If no


distance deviation is indicated the pinion basic
dimension is identical with the pinion dimension.
Record this as dimension II.
Dimension II (Example) 168 -0.05 mm = 167.95 mm
. . . . . . . . . (6.614 inch -0.002 inch = 6.612 inch)

STEP 141
Calculation example A:
Dimension I
Dimension II
Results in dimension Y
BD06G138

Measure the thickness of the inner bearing and


record its measurement, dimension I.
Dimension I (Example) . . . . . 36.13 mm (1.422 inch)
NOTE: Deduct the thickness of the gauge blocks
being used to support the bearing from the overall
measurement,
IE: overall measurement 106.13 mm (4.178 inch)
minus gauge block thickness 70 mm (2.756 inch) will
equal dimension I.

Bur 5-3200

36.13 mm
-------(1.422 inch)
+167.95 mm
-------(6.612 inch)
= 204.08 mm
------(8.034 inch)

Calculation example B:
Dimension X
Dimension Y
Difference = shim
thickness

205.30 mm
-------(8.080 inch)
204.08 mm
-------(8.034 inch)
= 1.22 mm
------(0.046 inch)

NOTE: Shims are available in 0.10 mm (0.004 inch),


round up or down to the next available shim
thickness, s = 1.20 (0.044 inch)

Issued 8-06

Printed in U.S.A.

6004-36

STEP 142

STEP 145

BD06G140

Heat the bearing hole to approximately 120 C (248


F) and install the outer bearing until contact is made
using the outer bearing cup installer of 380100001.

STEP 143

BD06G143

Press the inner bearing on the drive pinion shaft.

Drive Pinion Bearing Rolling


Torque Adjustment
STEP 146

BD06G141

Install the shim set determined in Step 141 in the


bearing bore on the differential carrier.

STEP 144

BD06G144

Install an 9.03 mm (0.35 inch) thick spacer on the


pinion shaft.

BD06G142

Heat the bearing hole to approximately 120 C (248


F) and pull the bearing into to the bearing hole using
380100001.
Bur 5-3200

Issued 8-06

Printed in U.S.A.

6004-37

STEP 147

STEP 149

WARNING: Always wear heat protective


gloves to prevent burning your hand when
handling heated parts.
SM121A

BD06G147

Install the input flange on the pinion shaft.

STEP 150
BD06G145

Heat the pinion shaft outer bearing to 120 C (248


F) in a bearing oven. Wearing heat resistance gloves
or mittens, install the bearing on the pinion shaft until
contact.
NOTE: Prior to mounting the input flange and
tightening the nut, allow the bearing to cool to
ambient temperature.

STEP 148

Put the washer in place on the pinion shaft.

STEP 151
Install holding wrench, CAS1579A, on input flange.
Hold flange using holding tool and tighten nut to a
torque of 700 Nm (515 pound feet). Remove holding
wrench.
NOTE: When tightening rotate the pinion shaft in
both directions several times.

STEP 152

BD06G146

Press the dust shield on the input flange.

BD06G148

Check the rolling torque of the drive pinion bearing.


The rolling torque should be 1.5 to 3.0 Nm (13.3 to
26.5 lb-inch). If rolling torque is too low, install a
thinner spacer (Step 146); if rolling torque is too high,
install a thicker spacer (Step 146).

STEP 153
Remove the nut and input yoke from the drive pinion
shaft.

Bur 5-3200

Issued 8-06

Printed in U.S.A.

6004-38

Setting Backlash and Bearing


Preload
Deviation Value

-20

-10

+10

+20

Shim A

1.20

1.10

1.00

0.90

0.80

Shim B

0.80

0.90

1.00

1.10

1.20

STEP 154

STEP 155
2

BD06G163

Record the deviation value on the ring gear, the value


will be a + or -, use the table to determine shim
thicknesses needed.
Example: Deviation value of +10 requires the
following shims:
Shim A = 0.90
Shim B = 1.10

4
BC06G004

1.
2.
3.
4.

DIFFERENTIAL
DRIVE HOUSING
AXLE HOUSING
INPUT PINION

5. AXLE HOUSING
A. RING GEAR SIDE
B. CARRIER SIDE

STEP 156

BD06G164

Insert shim A (0.90 mm) and install the bearing outer


ring until seated.

Bur 5-3200

Issued 8-06

Printed in U.S.A.

6004-39

STEP 157

STEP 160

BD06G165

Insert shim B (1.10 mm) and install the bearing outer


ring until seated.

Contact Pattern Check


STEP 158

BD06G168

Position the axle housing on the drive housing, install


4 bolts, top center, bottom center, front center, rear
center, torque bolts evenly to 390 Nm (285 pound
feet).

STEP 161

BD06G166

Apply marking ink on several teeth of the ring gear.

STEP 159

BD06G169

Roll the input pinion several times in both directions


over the ring gear. Remove the differential and
compare the contact pattern with examples on page
4 and page 5.
NOTE: If the tooth contact pattern differs, the wrong
shim size was selected in Step 143. Remove
differential and repeat Steps 138 though 144.

BD06G167

Position the differential assembly in the axle drive


housing.

Bur 5-3200

Issued 8-06

Printed in U.S.A.

6004-40

Installation

STEP 164

STEP 162

BD06G172

BD06G170

Install a new O-ring on the axle housing. Position the


axle housing on the drive housing, install bolts and
torque bolts evenly to 290 Nm (215 pound feet).

Install the shaft seal with the sealing lip towards oil
sump using pinion shaft seal install CAS2841.
NOTE: Wet the outer diameter of the seal with a
solution of 50% water and 50% mineral spirits. Fill
the space between the sealing and dust lip with
grease.

STEP 163
STEP 165

BD06G171

Loosen and remove the nut and input flange.

BD06G173

Install the input flange. Install holding wrench,


CAS1579A, on input flange. Apply Loctite No. 262,
on the threads of the locknut. Install the washer and
locknut by hand. Hold flange using holding tool and
tighten nut to a torque of 700 Nm (516 pound feet).
NOTE: Rotate the input pinion several times in both
directions when tightening.

Bur 5-3200

Issued 8-06

Printed in U.S.A.

DRIVE SHAFTS, CENTER BEARING, AND UNIVERSAL


JOINTS

CNH America LLC.


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

Bur 5-3210

Copyright 2006 CNH Ameica LLC.


All rights reserved.
Printed in U.S.A.
Issued August, 2006

6005

Section
6005

6005-2

TABLE OF CONTENTS
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CENTER BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CENTER BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CENTER DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNIVERSAL JOINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 5-3210

Issued 8-06

3
3
3
4
4
5
5
6
6
7
7
7
8
8
8
9
9
9
10
10
10

Printed in U.S.A.

6005-3

SPECIAL TORQUES
Coupler to Flywheel Bolts...................................................................................... 53 to 62 Nm (39 to 46 pound feet)
Engine Drive Shaft to Coupler Bolts ...................................................................... 53 to 62 Nm (39 to 46 pound feet)
Engine Drive Shaft to Transmission Bolts.............................................................. 75 to 81 Nm (55 to 60 pound feet)
Center, Rear and Front Drive Shaft Bolts .............................................................. 75 to 81 Nm (55 to 60 pound feet)
Carrier Bearing Bolts ........................................................................................... 99 to 128 Nm (73 to 94 pound feet)
Lock Nut for Yoke on Front Drive Shaft.......................................................... 339 to 375 Nm (250 to 275 pound feet)

FRONT DRIVE SHAFT


Removal

STEP 4

STEP 1

Use an acceptable puller and remove the yoke from


the end of the front drive shaft.

STEP 5
Loosen the set screws that secure the center bearing
to the front drive shaft.

STEP 6
Remove any paint or rust from the rear of the front
drive shaft and apply WD40 or similar oil to loosen
any rust between the inner race and the front drive
shaft.

STEP 7
BD03A166

Loosen and remove the bolts and straps that fasten


the center drive shaft to the yoke of the front drive
shaft.

STEP 2

BD03A167

Loosen and remove the bolts and straps that fasten


the front drive shaft to the front axle.

STEP 8
BD03A183

Remove the lock nut that fastens the yoke to the front
drive shaft.

STEP 3

Use a prybar to disengage the front drive shaft from


the front axle and remove the front drive shaft from
the machine.
NOTE: If necessary, use a brass hammer to drive
the front drive shaft out of the center bearing.

Make an alignment mark on the yoke and the end of


the front drive shaft to make sure that the yoke is
installed correctly.
Bur 5-3210

Issued 8-06

Printed in U.S.A.

6005-4

FRONT DRIVE SHAFT


Installation

STEP 14

STEP 9
Apply antiseize compound to the bearing area of the
front drive shaft.

STEP 10
Place the front drive shaft into position in the center
bearing of the machine.

STEP 11
BD03A183

Install the lock nut and washer which fastens the


yoke to the front drive shaft. Tighten the lock nut to a
torque of 339 to 375 Nm (250 to 275 pound feet).

STEP 15
Tighten the set screws that secure the center bearing
to the front drive shaft alternately until they stop
turning and the hex head socket wrench starts to
spring.
BD03A167

Install the bolts and straps that fasten the front drive
shaft to the front axle. Tighten the bolts to a torque of
75 to 81 Nm (55 to 60 pound feet).

STEP 16

STEP 12
Apply antiseize compound to the splines on the front
drive shaft.

STEP 13
Install the yoke to the front drive shaft, making sure
the alignment marks made during removal are
aligned.
NOTE: If a new front drive shaft has been installed,
make sure the yoke being installed is 90 to the yoke
on the other end of the front drive shaft.

Bur 5-3210

BD03A166

Install the bolts and straps that fasten the front drive
shaft to the center drive shaft. Tighten the bolts to a
torque of 75 to 81 Nm (55 to 60 pound feet).

Issued 8-06

Printed in U.S.A.

6005-5

CENTER BEARING
Removal

STEP 20

STEP 17

Make an alignment mark on the yoke and the front


drive shaft to be sure that the yoke is installed
correctly.

STEP 21
Use an acceptable puller and remove the yoke from
the end of the front drive shaft.

STEP 22
Remove any paint or rust from the rear of the front
drive shaft and apply WD40 or similar oil to loosen
any rust between the inner race and the front drive
shaft.
BD03A166

STEP 23

Loosen and remove the bolts and straps that fasten


the center drive shaft to the front drive shaft.

Loosen the set screws that secure the center bearing


to the front drive shaft.

STEP 18

STEP 24

BD03A183

BD03A183

Loosen and remove the lubrication hose from the


center bearing

Loosen and remove the bolts, washers and nuts that


fasten the bearing housing to the front frame.

STEP 19

STEP 25
Install two longer bolts, at least 3 inches, to hold the
bearing housing during removal. Use an acceptable
puller to remove the bearing housing from the front
drive shaft.

BD03A183

Loosen and remove the lock nut that fastens the yoke
to the front drive shaft.
Bur 5-3210

Issued 8-06

Printed in U.S.A.

6005-6

CENTER BEARING
Installation

STEP 30

NOTE: The center bearing and the bearing housing


are not serviced separately. If the center bearing is
worn or damaged or if the bearing housing is
cracked, a new center bearing and bearing housing
must be used.

Apply antiseize compound to the splines on the front


drive shaft. Install the yoke to the front drive shaft,
making sure the alignment marks made during
removal are aligned.

STEP 31

STEP 26
Apply antiseize compound to the bearing area of the
front drive shaft.

STEP 27
Install the bearing housing so that the lubrication
fitting is at the top.

STEP 28

BD03A183

Install the washer and lock nut that fasten the yoke to
the front drive shaft. Tighten the lock nut to a torque
of 339 to 375 Nm (250 to 275 pound feet).

STEP 32

BD03A183

Apply Loctite 242 to bolt threads. Install the bolts,


washers and nuts that fasten the bearing housing to
the front frame. Tighten the bolts to a torque of 99 to
128 Nm (73 to 94 pound feet).

STEP 29
BD03A166

Install the straps and bolts that fasten the center


drive shaft to the yoke on the front drive shaft.
Tighten the bolts to a torque of 75 to 81 Nm (55 to 60
pound feet).

STEP 33
Install the lubrication hose into the fitting on the
bearing housing.
BC05M214

Turn the set screw down to the shaft and then back it
off 1/4th turn and lock it with the jam nut. Repeat the
procedure with the other set screw.

Bur 5-3210

STEP 34
Lubr icate the center bear ing with the grease
specified in Section 1002.

Issued 8-06

Printed in U.S.A.

6005-7

CENTER DRIVE SHAFT


Removal

Installation

STEP 35

STEP 39

BD03A166

BD03A165

Loosen and remove the bolts and straps that fasten


the center drive shaft to the yoke of the front drive
shaft.

Hold the center drive shaft in position and install the


bolts and straps that fasten the center drive shaft to
the transmission. Tighten the bolts to a torque of 75
to 81 Nm (55 to 60 pound feet).

STEP 36
Use a prybar to disengage the center drive shaft from
the yoke of the front drive shaft.

STEP 40

STEP 37

BD03A166

BD03A165

Loosen and remove the bolts and straps that fasten


the center drive shaft to the transmission.

Install the bolts and straps that fasten the center


drive shaft to the yoke of the front drive shaft. Tighten
the bolts to a torque of 75 to 81 Nm (55 to 60 pound
feet).

STEP 38
Hold the center drive shaft and remove from the
machine.

Bur 5-3210

Issued 8-06

Printed in U.S.A.

6005-8

REAR DRIVE SHAFT


Removal

Installation

STEP 41

STEP 45

BD01D323

BD01F304

Loosen and remove the bolts and straps that fasten


the rear drive shaft to the transmission.

STEP 42

Hold the rear drive shaft into position and install the
bolts and straps that fasten the rear drive shaft to the
rear axle. Tighten the bolts to a torque of 75 to 81 Nm
(55 to 60 pound feet).

Use a prybar to disengage the rear drive shaft from


the transmission.

STEP 46

STEP 43

BD01D323

BD01F304

Loosen and remove the bolts and straps that fasten


the rear drive shaft to the rear axle.

Install the bolts and straps that fasten the rear drive
shaft to the transmission. Tighten the bolts to a
torque of 75 to 81 Nm (55 to 60 pound feet).

STEP 44
Hold the rear drive shaft and remove from the
machine.

Bur 5-3210

Issued 8-06

Printed in U.S.A.

6005-9

ENGINE DRIVE SHAFT


Removal

Installation

STEP 47

STEP 50

BD01D342

BD01D342

Remove and discard the bolts and straps that fasten


the engine drive shaft to the transmission.

Place the engine drive shaft into position on the


transmission and install new straps and bolts.
Tighten the bolts to a torque of 61 to 81 Nm
(45 to 60 pound feet).

IMPORTANT: The bolts and straps that fasten the


engine drive shaft to the transmission must be
replaced when removed.

STEP 51

STEP 48

BD03A172
BD03A172

Loosen and remove the six bolts that fasten the


engine drive shaft to the engine.

Apply Loctite 242 to bolt threads. Install the six bolts


that fasten the engine drive shaft to the engine.
Tighten the bolts to a torque of 53 to 62 Nm (39 to 46
pound feet)

STEP 49
Remove the engine drive shaft from the machine.

Bur 5-3210

Issued 8-06

Printed in U.S.A.

6005-10

UNIVERSAL JOINTS
Removal

Installation
NOTE: The bearing race and journal that make up
the universal joint are not serviced separately. If the
bearing race or journal is worn or damaged, a new
universal joint must be used.

STEP 52
Remove the drive shaft from the machine.

STEP 53
STEP 55
2

Clean the slots in the yoke of the drive shaft.

STEP 56
Install the universal joint and install the bearings (2)
and the rings (1). Refer to the photo in Step 53.

STEP 57
Install the drive shaft.

BD01F304

1. RING

2. BEARING

Remove the ring (1) and the bearing (2) from the
drive shaft.
NOTE: The above photo shows the drive shaft on
the machine and is for reference of the ring and
bearing only.

STEP 54
Remove the universal joint from the drive shaft.

Bur 5-3210

Issued 8-06

Printed in U.S.A.

Section
6006

6006

WHEELS AND TIRES

CNH America LLC.


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

Bur 5-3220

Copyright 2006 CNH Ameica LLC.


All rights reserved.
Printed in U.S.A.
Issued August, 2006

6006-2

TABLE OF CONTENTS
WHEELS AND BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIRE PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHANGING TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING A WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Bolt Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 5-3220

Issued 8-06

3
3
3
3
3
3
4

Printed in U.S.A.

6006-3

WHEELS AND BOLTS


General Information

Torque Specification

The wheel bolts must be tightened after every 20


hours of operation until the wheel bolts stay tight:

Tighten the wheel bolts to 298 Nm (220 pound-feet)


in the sequence shown in Figure 1. Then a final
torque of 640 to 720 Nm (475 to 530 pound-feet) in
the same sequence.

A. If the machine is new.


B. If a wheel has been removed and installed.

TIRE PRESSURES
23.5 x 25 L3.......................................................................................................................................2.75 bar (40 psi)
23.5R25 Dirt/Traction.........................................................................................................................2.75 bar (40 psi)
23.5R25 Rock ....................................................................................................................................2.75 bar (40 psi)

CHANGING TIRES
The split rim wheels used on this machine
can be dangerous. When inflating a tire on
the machine, use a self-locking nozzle and
stand at the front or rear of the tire.
When inflating a tire off the machine, put
the wheel in a tire inflation cage. The
retaining ring and rim can come off with
enough force to result in death to a person
in front of the rim.
48-44

1. Have a qualified tire mechanic service the split


rim wheels used on this machine.
2. The correct tire equipment, especially a tire
inflation cage, is required. Using the wrong
procedure for a split rim wheel can result in
death.
IMPORTANT: When installing a Michelin tire,
lubricate the tire with a tire mounting lubricant and
inflate the tire to 551 kPa, 5.5 bar (80 psi) to make
sure that the tire is seated on the rim. Then decrease
the pressure to the specified pressure.

INSTALLING A WHEEL
1. Make sure the mounting surfaces of the rim and
axle flange are clean and free of dirt and grease.
2. Install the wheel, hardened washers and wheel
bolts.

4. Tighten the wheel bolts to 298 Nm (220


pound-feet) in the sequence shown in Figure 1.
Then tighten the wheel bolts in the same
sequence to 640 to 720 Nm (475 to 530
pound-feet).

3. Use a hand wrench (not an impact) to tighten the


wheel b olts to pu ll the whee l against the
planetar y housing. DO NOT use an impact
wrench to tighten the wheel bolts.

Bur 5-3220

Issued 8-06

Printed in U.S.A.

6006-4

BS06G052

WHEEL BOLT TORQUE SEQUENCE

Bur 5-3220

Issued 8-06

Printed in U.S.A.

Section
6007

6007

TRANSMISSION CONTROL VALVE

CNH America LLC.


245 E NORTH AVENUE
CAROL STREAM, IL 60188 U.S.A.

Bur 6-81450

Copyright 2006 CNH America LLC.


All rights reserved.
Printed in U.S.A.
Issued March, 2006

6007-2

TABLE OF CONTENTS
Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 6-81450

Issued 3-06

3
3
5
5

Printed in U.S.A.

6007-3

CONTROL VALVE
Disassembly

STEP 4

STEP 1

BD06A010

BD06A007

Mark the installation position of the wiring harness to


the valve block.

Loosen and remove the cap screws, remove the


cover. Remove the opposite cover.

STEP 5

STEP 2

BD06A011

Remove the wiring harness.


BD06A008

Loosen and remove the cap screws that secure the


distribution plate and intermediate plate to the valve
body, remove the intermediate plate and distribution
plate.

STEP 6

STEP 3

BD06A012

Loosen and remove the retaining plate cap screws,


remove the retaining plates and solenoids.

BD06A009

Remove the wiring harness retaining clamp.


Bur 6-81450

Issued 3-06

Printed in U.S.A.

6007-4

STEP 7

STEP 9

BD06A013

Loosen and remove two cap screws, install two


adjusting screws. Loosen and remove the remaining
cap screws.

BD06A015

Remove the components.

STEP 10

STEP 8

BD06A016

BD06A014

Remove the opposite solenoids, housing, and


components.

Separate the housing from the valve body by equally


loosening the adjusting screws.

Bur 6-81450

Issued 3-06

Printed in U.S.A.

6007-5

Inspection
1. Clean all metal parts in cleaning solvent.
2. Immerse end housings, valve housing, valve
plate, and distribution plate in cleaning solvent
and agitate cleaning solvent. WEAR EYE
PROTECTION WHEN USING COMPRESSED
AIR. Use compressed air to remove foreign
matter from interior of housings and plates and to
ensure that all bores are clear of foreign matter.

Assembly
NOTE: Apply clean engine oil (15W-40) to pistons
and springs, orifices, new O-rings, and filter screens
before assembly.

STEP 11

3. WEAR EYE PROTECTION WHEN USING


COMPRESSED AIR. Use compressed air to
ensure that orifices are clear of foreign matter.
4. Check filter screens for blockage, rips, or tears.
Replace if any of these conditions are seen.
5. Inspect the plates, housings and covers for
corrosion, cracks, breaks, chipping or other
damage. Check bores in housings for deep
scratches, gouges, and other damage. Replace
a housing or cover if any of the above conditions
are seen.
6. Check pressure regulators for cracks, breaks, or
other damage. Check connector contacts for
looseness or signs of corrosion. Replace a
pressure regulator if any of these conditions are
seen. Check resistance of pressure regulators
using a multimeter. Replace a pressure regulator
if resistance is not 17 to 21 ohms.
7. Check wiring harness connectors for signs of
breaks, cracks, or other damage. Check contacts
for foreign matter or corrosion. Check harness
wiring for signs of broken or cracked insulation
and broken or frayed wiring at connection to
connectors. Replace wiring harness if any of
these conditions are seen.
8. Check springs for cracks, breaks, distortion, or
signs of permanent set. Replace a spring if any
of these conditions are seen.
9. Inspect pistons for cracks, breaks, chipping,
grooves, or other damage. Replace if any of
these conditions are seen.

BD06A017

Place the valve body on the bench with the orifices


up.

STEP 12

3
1

1
2

2
BD06A018

1. VIBRATION DAMPER
2. PISTONS

3. PRESSURE REDUCING
VALVE

Install components in positions shown.

STEP 13

BD06A019

Preload the compression springs of the pistons,


install a roll pin of a diameter of 5.0 mm (0.20 inch).
Bur 6-81450

Issued 3-06

Printed in U.S.A.

6007-6

STEP 14

STEP 17

BD06A020

BD06A023

Install the adjusting screws, gasket, and housing


cover.

Install the cap screws and torque in a criss cross


pattern to 7.5 Nm (66.3 pound-inch).

STEP 15

STEP 18

BD06A021

BD06A024

Tighten the adjusting screws equally until the cover is


flush on the valve body.

Install the solenoids and secure them with the


retaining plates and cap screws. Torque the cap
screws to 5.5 Nm (48.5 pound-inch).

STEP 16

NOTE: Install the retaining plate with the neck


towards valve body, install controllers with
connectors as shown.

STEP 19

BD06A022

Push the pistons down through the pressure


controller wholes and remove the roll pins.

1
2

2
BD06A025

1. VIBRATION DAMPER
2. PISTONS

3. MAIN PRESSURE VALVE

Install components in positions shown.


Bur 6-81450

Issued 3-06

Printed in U.S.A.

6007-7

STEP 20

STEP 23

BD06A026

BD06A028

Preload the compression springs of the pistons,


install a roll pin of a diameter of 5.0 mm (0.20 inch).
Install the adjusting screws, gasket, and housing
cover.

Install the wiring harness with connector on side of


valve body marking made during disassembly.
Connect wiring harness to the solenoids.

STEP 24
STEP 21

BD06A029

Install the cap screws and torque in a criss cross


pattern to 7.5 Nm (66.3 pound-inch).

Install the gasket, install the wiring harness plug in


the cover. Install the cap screws and torque in a criss
cross pattern to 7.5 Nm (66.3 pound-inch).

STEP 22

STEP 25

BD06A023

BD06A027

Install the solenoids and secure them with the


retaining plates and cap screws. Torque the cap
screws to 5.5 Nm (48.5 pound-inch).

BD06A030

Install the wiring harness retaining clamp.

NOTE: Install the retaining plate with the neck


towards valve body, install controllers with
connectors as shown.
Bur 6-81450

Issued 3-06

Printed in U.S.A.

6007-8

STEP 26

STEP 28

BD06A031

BD06A033

Install the screens into the bores of the intermediate


plate towards the distribution plate.

Install the distribution plate, install the cap screws


and torque in a criss cross pattern to 9.5 Nm (84
pound-inch).

STEP 27
STEP 29

BD06A032

Install two adjusting screws. Place the intermediate


plate with the screens facing up.

Bur 6-81450

BD06A034

Install new o-rings on the plugs, install and torque


plugs to 6 Nm (53 pound-inch).

Issued 3-06

Printed in U.S.A.

SECTION INDEX

BRAKES
Section Title

Section Number

Removal and Installation of Brake Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7001


Hydraulic Brake Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7002
Brake Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7003
Brake Accumulators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7004
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7008

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

Bur 5-3230

Copyright 2006 CNH Ameica LLC.


All rights reserved.
Printed in U.S.A.
Issued August, 2006

7001
Section
7001
REMOVAL AND INSTALLATION OF BRAKE
COMPONENTS

CNH America LLC.


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

Bur 5-3240

Copyright 2006 CNH Ameica LLC.


All rights reserved.
Printed in U.S.A.
Issued August, 2006

7001-2

TABLE OF CONTENTS
BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE BRAKE AND PARKING BRAKE ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 5-3240

Issued 8-06

4
4
4
6
6
6
8
8
8

Printed in U.S.A.

7001-3

3
1
4

5
6

8
BC05M136

1.
2.
3.
4.

FRONT AXLE
REAR AXLE
BRAKE VALVE
PARKING BRAKE ACCUMULATOR

5.
6.
7.
8.

FRONT ACCUMULATOR
REAR ACCUMULATOR
BRAKE PUMP
CONNECTOR TO FAN VALVE

COMPONENT LOCATION ILLUSTRATION

Bur 5-3240

Issued 8-06

Printed in U.S.A.

7001-4

BRAKE VALVE
Removal

Installation

1. Park the machine on a level surface and lower


the loader bucket to the floor. Stop the engine.

1. Install the brake valve (1) in the cab or canopy.


Refer to the illustration on page 5.

2. Put blocks on both sides of each tire to prevent


machine movement.

2. Remove the plugs from the hydraulic lines and


connect the hydraulic lines to the brake valve (1).

3. Make sure the brake accumulators are


completely discharged. Push down and release
the brake pedals at least 30 times.

3. Stop the vacuum pump and remove.

4. Turn the master disconnect switch to the OFF


position.
5. Remove the cab skirts located under the cab or
canopy.
6. To release the pressure on the parking brake
accumulator, the line at the accumulator must be
SLOWLY cracked open. A pan will be needed to
catch the hydraulic oil.

4. Connect all of the electrical connections.


5. Turn the master disconnect switch to the ON
position.
6. Bleed the brake system. See Section 7002.
7. Install the cab skirts.
8. Check the hydraulic reservoir oil level and add oil
as required. See Section 1002 for the correct oil.

7. Connect a drain hose to the quick disconnect


couplings in each brake circuit to release any
pressure in the brake circuit.
8. Clean the brake valve (1) and lines, refer to the
illustration on page 5.
9. Put identification tags on all electrical and
hydraulic lines that are connected to the brake
valve (1).
10. Connect a vacuum pump to the hydraulic
reservoir. Start the vacuum pump
11. Disconnect the lines from the brake valve (1) and
put plugs in each line.
12. Remove the brake valve (1).

Bur 5-3240

Issued 8-06

Printed in U.S.A.

7001-5

1
6
2

3
9

10

BC05M137

1.
2.
3.
4.
5.

BRAKE VALVE
REAR ACCUMULATOR LINE
PARKING BRAKE LINE
BRAKE PUMP INPUT
BRAKE VALVE DISCHARGE

6.
7.
8.
9.
10.

FRONT BRAKE LINE


REAR BRAKE LINE
FRONT ACCUMULATOR
RETURN TO TANK
PARKING BRAKE ACCUMULATOR

BRAKE VALVE ILLUSTRATION

Bur 5-3240

Issued 8-06

Printed in U.S.A.

7001-6

SERVICE BRAKE AND PARKING BRAKE ACCUMULATORS


Removal

Installation

1. Park the machine on a level surface and lower


the loader bucket to the floor. Stop the engine.
2. Put blocks on both sides of each tire to prevent
machine movement.
3. Make sure the service brake accumulators (1)
and the parking brake accumulator (2) are
completely discharged. Push down and release
the brake pedal at least 30.
4. Turn the master disconnect switch to the OFF
position.
5. Remove the left cab skirt located under the cab
or canopy to gain access to accumulators.
6. To release the pressure on the parking brake
accumulator, the line at the accumulator must be
SLOWLY cracked open. A pan will be needed to
catch the hydraulic oil.
7. Connect a drain hose to the quick disconnect
couplings in each brake circuit to release any
pressure in the brake circuit.
8. Clean the brake accumulators (1), parking brake
accumulator (2) and lines. Refer to illustration on
page 7.
9. Put identification tags on the line that is
connected to the parking brake accumulator (2).

1. Mount the accumulators (1) in the accumulators


clamps (7), do not tighten clamps at this time.
Refer to illustration on page 7.
2. Connect the tubes to both brake accumulators
(1) and tighten.
3. Tighten accumulator clamp studs (7) to 17Nm
(13 pound feet).
4. Install the parking brake accumulator (2) into the
bracket.
5. Install the nut (3) and tighten.
6. Connect the line
accumulator (2).

to

the

parking

brake

7. Stop the vacuum pump and remove.


8. Install the left cab skirt.
9. Turn the master disconnect switch to the ON
position.
10. Bleed the brake system. See Section 7002.
11. Refer to Section 7008 and perform the Parking
Brake Test Procedure.
12. Check the hydraulic reservoir oil level and add oil
as required. See Section 1002 for the correct oil.

10. Connect a vacuum pump to the hydraulic


reservoir. Start the vacuum pump.
11. Disconnect the
accumulators (1).

tubes

from

both

brake

12. Loosen the clamp stud (8) on the accumulator


clamp (7).
13. Remove the accumulators
accumulator clamps (7).

(1)

from

the

14. Install plugs in the tubes.


15. Disconnect the
accumulator (2).

hose

from

parking

brake

16. Remove the nut (3), remove the parking brake


accumulator (2).
17. Install a plug in the hose.

Bur 5-3240

Issued 8-06

Printed in U.S.A.

7001-7

5
6
4

8
8

7
1

1
BC05M138

1.
2.
3.
4.

BRAKE ACCUMULATORS
PARKING BRAKE ACCUMULATOR
MOUNTING NUT
HOSE PARKING BRAKE ACCUMULATOR

5.
6.
7.
8.

TUBE FRONT BRAKE ACCUMULATOR


TUBE REAR BRAKE ACCUMULATOR
CLAMP ACCUMULATOR
CLAMP STUD

BRAKE AND PARKING BRAKE ACCUMULATORS ILLUSTRATION

Bur 5-3240

Issued 8-06

Printed in U.S.A.

7001-8

BRAKE PUMP
Removal

Installation

1. Park the machine on a level surface and lower


the loader bucket to the floor. Stop the engine.
2. Put blocks on both sides of each tire to prevent
machine movement.
3. Turn the master disconnect switch to the OFF
position.
4. Clean the brake pump (1) and lines, refer to the
illustration on page 9.
5. Put identification tags the lines
connected to the brake pump (1).

that

are

6. Connect a vacuum pump to the hydraulic


reservoir. Start the vacuum pump.

1. Install gear (6) onto the pump shaft, install


washer (7) and slotted nut (8), torque nut to 70 to
79 Nm (52 to 58 pound feet). Refer to the
illustration on page 9.
2. Install the cotter pin (9).
3. Install the brake pump (1), mounting bolts (2) and
washers (3).
4. Torque mounting bolts (2) to 57 to 65 Nm (42 to
48 pound feet).
5. Remove the plugs or caps and connect the lines
to the brake pump (1).
6. Stop the vacuum pump and remove.

7. Disconnect the lines from the brake pump (1)


and put plugs in each line.

7. Turn the master disconnect switch to the ON


position.

8. Remove the mounting bolts (2) and washers (3)


from the brake pump (1) and remove the brake
pump (1).

8. Bleed the brake system. See Section 7002.

Bur 5-3240

9. Check the hydraulic reservoir oil level and add oil


as required. See Section 1002 for the correct oil.

Issued 8-06

Printed in U.S.A.

7001-9

9
6

3
2
4

BC05M139

1. BRAKE PUMP
2. MOUNTING BOLT (2)
3. WASHER (2)

4. SUCTION HOSE
5. PRESSURE HOSE
6. DRIVE GEAR

7. WASHER
8. SLOTTED NUT
9. COTTER PIN

BRAKE PUMP ILLUSTRATION

Bur 5-3240

Issued 8-06

Printed in U.S.A.

7001-10

NOTES

Bur 5-3240

Issued 8-06

Printed in U.S.A.

7002

Section
7002
HYDRAULIC BRAKE TROUBLESHOOTING

CNH America LLC.


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

Bur 5-3250

Copyright 2006 CNH Ameica LLC.


All rights reserved.
Printed in U.S.A.
Issued August, 2006

7002-2

TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING THE HYDRAULIC BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHARGING THE ACCUMULATOR WITH DRY NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BLEEDING THE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE MODULATION PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing the Brake Modulation Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the Brake Modulation Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE PUMP OUTPUT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Valve Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 5-3250

Issued 8-06

3
3
4
5
5
6
7
7
8
9
10
11

Printed in U.S.A.

7002-3

SPECIFICATIONS
Brake pump output ..............................................................................................................42 to 45 L/min at 172 bar
(11 to 12 gpm at 2500 psi at 2000 rpm)
Accumulator nitrogen charge pressure...........................................................................48 to 59 bar (700 to 850 psi)
Accumulator valve cut in pressure......................................................................... 157 to 167 bar (2280 to 2420 psi)
Accumulator valve cut out pressure....................................................................... 190 to 196 bar (2755 to 2845 psi)
Brake warning pressure switch (normally closed) opening set point ......................106 to 115 bar (1530 to 1670 psi)
Brake redundant pressure switch (normally closed) opening set point ..... 55 to 69 bar decreasing (800 to 1000 psi)
Brake light pressure switch (normally open) closing set point .............................. 5 to 6 bar increasing (75 to 85 psi)
Modulation pressure front brake cylinders..................................................................80 to 87 bar (1160 to 1260 psi)
Modulation pressure rear brake cylinders...................................................................78 to 85 bar (1130 to 1230 psi)

SPECIAL TOOLS

G
94L95

CAS-10899 NITROGEN CHARGING KIT USED TO CHECK AND


CHARGE THE ACCUMULATOR WITH NITROGEN.
BC04A001

380001168 ACCUMULATOR CHARGING ADAPTER

Bur 5-3250

Issued 8-06

Printed in U.S.A.

7002-4

TROUBLESHOOTING THE HYDRAULIC BRAKE SYSTEM


NOTE: The hydraulic brake schematic is included in
the hydraulic schematic. Refer to the rear pocket of
this manual.
1. Check the oil level in the hydraulic reservoir; add
oil as necessary.
2. Push and release the brake pedal many times
with the engine stopped to remove all hydraulic
pressure from the brake system until there is no
pressure on the pedal.
3. Install two 207 bar (3000 psi) pressure gauges to
front and rear hydraulic brake accumulator test
ports, refer to page 7 for the locations of the test
ports.
4. Make sure that the pressure gauge hoses are
long enough so the gauges can be read while
sitting in the operators seat.
NOTE: The gauges can not be connected to the test
ports if hydraulic pressure remains in the system.
5. Start the engine. Run the engine at low idle while
reading the pressure gauges. The alar ms
(buzzer, master warning light and brake pressure
war ning light) should shut off when the
accumulator with the lowest pressure reaches
106 to 115 bar (1530 to 1670 psi), approximately
40 seconds at any engine speed.
6. After the alarms stop, run the machine at high
idle to finish charging the accumulators. The
pressure must increase on both gauges until 190
to 196 bar (2757 to 2843 psi) is reached. This is
the accumulator valve cut-out pressure. It is
normal for the pressure to drop slightly once the
cut-out pressure is reached.
7. With the engine running at high idle, push and
release the brake pedal rapidly while reading the
drop in pressure on the gauges. The pressure
drops may not be equal, but as the lowest
pressure reaches 157 to 167 bar (2280 to 2420
psi), the system pressure must start to increase.
This is the valve cut in pressure.

8. Stop the engine. Turn the ignition switch to the


ON position. Push and release the brake several
times while reading the pressure on the gauges.
Each push and release of the pedal will result in
a slight drop in pressure, but not necessarily
equal on the two gauges. As the lowest pressure
reaches 106 to 115 bar (1530 to 1670 psi) the
brake warning lamp and alarm buzzer must
actuate. If the warning lamp and alarm buzzer fail
to work, test the low brake pressure warning
switches and electrical circuit. If the warning
lamp and alarm buzzer actuate at a higher or
lower pressure than specified, test the low brake
pressure war ning switches and replace as
needed.
9. As the lowest pressure reaches 106 to 115 bar
(1530 to 1670 psi) the brake warning lamp and
alarm buzzer must actuate. If the warning lamp
and alarm buzzer fail to work, test the low brake
pressure warning switches and electrical circuit.
If the warning lamp and alarm buzzer actuate at
a higher or lower pressure than specified, test
the low brake pressure warning switches and
replace as needed.
10. After the low brake pressure light activates, press
the brake pedal eight more times.
11. Record the readings on the pressure gauges.
The pressure gauges should read at or above
48 to 59 bar (700 to 850 psi).
12. If the pressures are at or above 48 to 59 bar (700
to 850 psi), the test is complete.
13. If the pressures are not within the required
specifications, then the brake system must be
bled.
14. After bleeding the brake system, perform the
brake system check again.

NOTE: The brake cut-in and cut-out pressures of the


brake system charge valve are factory preset and are
not adjustable.

15. Continue to slowly push and release the brake


pedal several times until the gauge pressure
suddenly drops to zero. The last pressure
reading before the drop to zero is the nitrogen
charge pressure in the accumulator. Test the
pressure in both accumulators. If the pressure is
below 48 to 59 bar (700 to 850 psi), charge or
replace the accumulator(s) (see page 5).

NOTE: If the pressure on one of the pressure


gauges is lower than specified, the problem can be a
bad accumulator valve.

NOTE: Nominal temperature of 20 C (68 F), colder


temperature will reduce pressure, hotter temperature
will increase pressure.

Bur 5-3250

Issued 8-06

Printed in U.S.A.

7002-5

CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR


1. Make sure that the oil side of the accumulator is
completely discharged by doing the following:
A. Stop the engine.

B. Push down and release the brake pedal many


times to release the pressure.
2. Connect a drain hose to the test connector in
each brake circuit to release any pressure in the
brake circuit.
3. Close valves B and C on the nitrogen charging
kit, refer to the illustration.

4. Turn the stem out of valve F until the stem stops.


94L95

5. Remove the cap screws and guard from the


accumulator.
6. Remove the cap from the accumulator valve
stem.
7. Connect valve F to the accumulator valve stem.

NITROGEN CHARGING KIT

8. Make sure that valve D is open.


9. Turn the stem into valve F and read the pressure
gauge E.
10. The pressure must be 48 to 59 bar (700 to 850
psi). If the pressure is too low, charge the
accumulator with dry nitrogen.

CHARGING THE ACCUMULATOR WITH DRY NITROGEN


NOTE: Check the pressure in the accumulator
according to the instructions in Checking the
Nitrogen Charge in the Accumulator. Keep the
nitrogen charging kit connected to the accumulator.
1. Close (turn counterclockwise) valve A and open
valve B. Close valves C and D.
2. Turn the stem out of valve F until the stem stops
moving. Disconnect valve F from the
accumulator valve stem.
3. Connect the nitrogen charging kit to a dry
nitrogen tank.
4. Slowly turn valve A clockwise and read gauge E
until the pressure is 48 to 59 bar (700 to 850 psi).
Stop turning valve A.

5. If the pressure increases above 59 bar


(850 psi), quickly open and close valve D and
read gauge E. If the pressure is still too high,
close valve A (turn counterclockwise) a small
amount and quickly open and close valve D. The
pressure shown on gauge E is the charge
pressure.
6. Connect valve F to the accumulator valve stem.
Turn the stem into valve F until the stem stops
m o v i n g a n d o p e n va l ve D t o c h a r g e t h e
accumulator.
7. After the accumulator stops charging, turn the
stem out of valve F until the stem stops moving.
8. Close valve B and disconnect the nitrogen
charging kit from the accumulator valve stem.
9. Install the cap on the accumulator valve stem.
I n s t a l l t h e g u a r d a n d c a p s c r ew s o n t h e
accumulator.

Bur 5-3250

Issued 8-06

Printed in U.S.A.

7002-6

BLEEDING THE BRAKE SYSTEM


1. Check the level of hydraulic fluid in the reservoir.
Add fluid to the reservoir if necessary.
IMPORTANT: If machine is equipped with
quick-attached components, disconnect them from
machine prior to proceeding.

8. Start the engine and run at low idle.


9. Push the brake pedal all the way down and
slowly release for one cycle.
10. Close all four wheel end bleed screws.
11. Fully depress the brake pedal three times in 5
second cycles.
12. With the brake pedal partially depressed, open
the bleed screw on the left front axle. Hold the
brake pedal in position until the oil is clear (no
bubbles). Close the bleed screw.
13. Open the bleed screw on the right front axle.
Repeat step 12.

14. Open the bleed screw on the left rear axle.


Repeat step 12.

BD03A092

1. SAFETY LINK

2. Raise loader arms and install the safety link (1)


for safe access to the front axle bleed screws.

15. Open the bleed screw on the right rear axle.


Repeat step 12.
16. Replace all bleed screws, caps and plugs.
17. Check the hydraulic fluid and add as necessary.

3. Apply the parking brake.


4. Keep the engine speed at high idle until both
brake accumulators are fully charged.
NOTE: This will be approximately 30 seconds after
the low brake pressure light goes out.
5. Stop the engine.
6. Pump the brake pedal until there is no hydraulic
pressure in the brake system (approximately 20
pumps).
7. Remove the plastic and rubber caps from each
wheel end and slowly open all four bleed screws.
NOTE: Attach a hose to the bleed screws to prevent
spilling any fluids.

Bur 5-3250

Issued 8-06

Printed in U.S.A.

7002-7

BRAKE MODULATION PRESSURE CHECK

4
BD06F145

1. FRONT AXLE TEST PORT


2. REAR AXLE TEST PORT

Testing the Brake Modulation


Pressure
1. Make sure the hydraulic accumulator cut-in and
cut-out pressures are correct. Refer to page 4 of
this section.

3. FRONT BRAKE ACCUMULATOR TEST PORT


4. REAR BRAKE ACCUMULATOR TEST PORT

6. Start the engine.


7. Operate the machine at low idle and watch the
pressure gauges on the brake accumulators until
the gauges rise above 170 bar (2645 psi).
8. Apply and hold the brakes for 10 to 15 seconds.

2. Stop the engine. Pump the brake pedal until


there is no pressure in the brake system.

9. Make a note of the pressure on the gauges for


the front and rear brakes.

3. Remove the cab skirts to gain access to the


brake test ports.

10. The front brake pressure should read 80 to 87


bar (1160 to 1260 psi). This is the modulation
pressure for the front axle.

4. Connect two 207 bar (3000 psi) pressure gauges


to the front brake test port (1) and the rear brake
test port (2).
5. Connect two 207 bar (3000 psi) pressure gauges
to the front brake accumulator test port (4) and
the rear brake accumulator test port (3).

Bur 5-3250

11. The rear brake pressure should read 78 to 85 bar


(1130 to 1230 psi). This is the modulation
pressure for the rear axle
12. If the pressures are not within the specified
ra n g e, i t w i l l b e n e c e s s a r y t o a d j u s t t h e
modulation pressures.

Issued 8-06

Printed in U.S.A.

7002-8

Adjusting the Brake Modulation


Pressure
NOTE: The adjusting bolt to adjust the modulation
pressure is located in the cab, under the brake pedal.

1. Remove the tamper evident cover (1).


NOTE: This is a tamper evident cover and it will be
necessary to install a new cover after the modulation
pressure is adjusted.
2. Turn the adjusting bolt (2) to adjust the
modulation pressure.
NOTE: The rear brake modulation pressure cannot
be adjusted separately from the front brake
modulation pressure.
3. Repeat steps 5 through 10 in the Testing the
Brake Modulation Pressure procedure.

4. Repeat these steps until the brake modulation


pressure is within the specified range.

BD00N121

1. TAMPER RESISTANT COVER


2. ADJUSTING BOLT

Bur 5-3250

Issued 8-06

Printed in U.S.A.

7002-9

SERVICE BRAKE SYSTEM PERFORMANCE (STORED ENERGY)


1

4
BD06F145

1. FRONT AXLE TEST PORT


2. REAR AXLE TEST PORT

3. FRONT BRAKE ACCUMULATOR TEST PORT


4. REAR BRAKE ACCUMULATOR TEST PORT

NOTE: Prior to doing this procedure make sure that


the accumulator pressures are correct.
1. Check the level of the hydraulic fluid in the
reservoir, add as needed.

6. Start the engine and let idle until both the front
and rear accumulators 3 and 4 are fully charged.
The accumulators are fully charged at 190 to 196
bar (2755 to 2842 psi).
7. Stop the engine.
8. Push the brake pedal down slowly, allowing for
full piston actuation.
NOTE: Depress the brake pedal at the rate of three
strokes per minute.
9. Continue pressing the brake pedal down. The
low brake pressure light should activate when the
pressure reaches 106 to 115 bar (1530 to 1670
psi). After the low brake pressure light activates,
press the brake pedal eight more times.

1
BD00M030

1. ARTICULATION LOCK

2. Install the articulation lock (1) before doing this


test.
3. Remove the left side cab skirt to gain access to
the brake accumulator test ports.
4. Pump the brake pedal until there is no hydraulic
pressure in the brake system (approximately 20
pumps).

10. Record the readings on the pressure gauges.


The pressure gauges should read at or above
48 to 59 bar (700 to 850 psi).
11. If the pressures are at or above 48 to 59 bar (700
to 850 psi), the test is complete.
12. If the pressures are not within the required
specifications, then the brake system must be
bled.
13. After bleeding the brake system, perform the
brake system check again.

5. Connect two 207 bar (3000 psi) pressure gauges


to the test ports 3 and 4.

Bur 5-3250

Issued 8-06

Printed in U.S.A.

7002-10

BRAKE PUMP OUTPUT TEST


1. Connect the flowmeter to the brake pump as
shown, refer to the illustration below.
2. Make sure the load control of the flowmeter is
open. Start the engine. Run the engine at full
throttle. Make sure the oil is at operating
temperature.

3. Measure the flow at 0 bar (0 psi). Record the flow


reading. Slowly close the load valve on the
flowmeter and read the flow at 170 bar (2500
psi). Record the flow reading.
4. Divide the flow reading at 170 bar (2500 psi) by
the reading at 0 bar (0 psi). Multiply the result by
100. This is the percent efficiency of the pump. If
the efficiency of the pump is less than 85%,
repair or replace the pump.

5
NOTE

4
3
2

BS03B021

1. BRAKE PUMP
3. FLOWMETER INLET HOSE
5. FILTER INLET MANIFOLD
2. PUMP OUTPUT ELBOW
4. FLOWMETER OUTLET HOSE
6. FILTERS
NOTE: IF UNIT IS EQUIPPED WITH AUXILIARY STEERING A TEE FITTING WILL HAVE TO BE USED IN THIS LOCATION

Bur 5-3250

Issued 8-06

Printed in U.S.A.

7002-11

NOTES

Bur 5-3250

Issued 8-06

Printed in U.S.A.

7002-12

1
2
3
1
4

30

31

32
14

33
34

21

30
7

35

29

36

8
9
15

27
28

10

15

26

11
16
24

14
12

25
14
17
5
23
22
21

15

19

18

13
5
20
BC05G011

BRAKE VALVE EXPLODED VIEW

Bur 5-3250

Issued 8-06

Printed in U.S.A.

7002-13
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

CAP SCREW (T 22 NM (16 LB-FT))


O-RING
BUSHING
SLEEVE
SPRING
SPRING RETAINER
SPRING RETAINER
CIRCLIP
SHAFT SEAL
SLEEVE LVE
GUIDE RING
O-RING

Bur 5-3250

13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.

CAP (T 60 NM (44 LB-FT))


SPOOL
PLUG (T 10 NM (88.5 LB-IN))
PLUG (T 60 NM (44 LB-FT))
PLUG (T 22NM (16 LB-FT))
VALVE SEAT
THROTTLE SCREW
PLUG (T 22NM (16 LB-FT))
CAP
SLEEVE
SPRING RETAINER
SLEEVE

25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.

CHECK VALVE
CARTRIDGE
PLUG (T 60 NM (44 LB-FT))
JET
WVI UNIT
PLUG (T 60 NM (44 LB-FT))
PLUG (T 100 NM (74 LB-FT))
RV UNIT
SPRING RETAINER
SLEEVE
THRUST RING
SLEEVE LVV

Issued 8-06

Printed in U.S.A.

7002-14

NOTES

Bur 5-3250

Issued 8-06

Printed in U.S.A.

7003

Section
7003
BRAKE PUMP

CNH America LLC.


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

Bur 5-2920

Copyright 2006 CNH Ameica LLC.


All rights reserved.
Printed in U.S.A.
Issued August, 2006

7003-2

TABLE OF CONTENTS
BRAKE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 5-2920

Issued 8-06

4
4
4
4

Printed in U.S.A.

7003-3

14
17

15
16

10

18
10
19
7

13

8
9
11
12
7

10

11

5
4
2

1
BC06F594

1.
2.
3.
4.
5.
6.
7.

RETAINING RING
SEAL RETAINER
0-RING
OUTER LIP SEAL
INNER LIP SEAL
SHAFT END COVER HOUSING
QUAD RING

8.
9.
10.
11.
12.
13.

BACKUP SEAL
CHANNEL SEAL
DOWEL PIN
THRUST PLATE
GEAR HOUSING
PORT END COVER HOUSING

14.
15.
16.
17.
18.
19.

WASHER
BOLT
DRIVEN GEAR
DRIVE GEAR
DRIVE SCREW
NAME PLATE

PUMP ILLUSTRATION

Bur 5-2920

Issued 8-06

Printed in U.S.A.

7003-4

BRAKE PUMP
Disassembly
1. Secure the pump by the port end cover (13) in a
soft jawed vise.
2. Draw a line the length of the pump to assist
during assemble.
3. Loosen and remove bolts (15).
4. Tap the shaft end cover housing (6) with soft
hammer to loosen it, remove the shaft end cover
housing (6).
5. Remove the backup seal (8), channel seal (9),
and thrust plate (11).
6. Remove the drive gear (17) from the gear
housing (12).
7. Remove the driven gear (16) from the gear
housing (12).
8. Tap the gear housing (12) with a soft hammer to
loosen it, remove the gear housing (12).
9. Remove the backup seal (8), channel seal (9),
and thrust plate (11).
10. Remove the retaining ring (1) form the shaft end
cover housing (6).
11. Remove the seal retainer (2), O-ring (3), and
outer lip seal (4) from the shaft end cover
housing (6).
12. Remove the inner lip seal (5) from the shaft end
cover housing (6).

Inspection
1. Discard all seals and quad rings. Clean all parts
in cleaning solvent. Check all machined surfaces
for damage or wear.
2. Hold a straightedge across each gear housing
and use a feeler gauge to measure the amount
of wear caused by the gear teeth in the gear
pocket. If the wear in any gear pocket is more
than 0.18 MM. (0.007 inch), use a new gear
housing.
3. Inspect the thrust plates for scoring, pitting, or
other damage.
4. Inspect the gears for wear and damage. There
must be no scoring on the gear hubs or on the
outside edges of the gear teeth. There must be
no more than 0.05 MM. (0.002 inch) wear in the
seal area of the drive shaft. If any gear must be
discarded, you must use a new hydraulic pump.

Assembly
1. Install a new lip seal (3) into the seal retainer (2)
so the lip of the seal will be facing away from the
gears when the seal retainer (2) is installed into
the shaft end cover housing (6).
2. Install a new lip seal (4) into the shaft end cover
housing (6) with the lip of the seal facing towards
the gears.
3. Install a new O-ring (3) onto the seal retainer (2),
lubricate the O-ring with hydraulic oil.
4. Press the seal retainer (2) into the shaft end
cover housing (6) and install the retaining ring
(1).
5. Place the shaft end housing (6), facing down,
into a soft jawed vise.
6. Install new backup seals (8) and channel seals
(9) into the thrust plates (11).
7. Place a thrust plate (11) onto the shaft end cover
housing (6).
IMPORTANT: Be sure to place the thrust plate (11)
onto the shaft end cover housing (6) in the position
shown in the illustration on page 3.
8. Lubricate the driven gear (16) with hydraulic oil,
slide the driven gear (16) through the thrust plate
(11) into the shaft end cover housing (6).
9. Lubricate the drive gear (17) with hydraulic oil,
slide the drive gear (17) through the thrust plate
(11) into the shaft end cover housing (6).
10. Install a new quad ring (7) into the gear housing
(12). Check that dowel pins (10) are in place
either in the gear housing (12) or the shaft end
cover housing (6).
11. Align the marks made during disassembly,
carefully place the gear housing (12) onto the
gears.
12. Slide the thrust plate (11) onto the shafts of the
gears.
IMPORTANT: Be sure to place the thrust plate (11)
onto the gears in the position shown in the illustration
on page 3.
13. Install a new quad ring (7) into the gear housing
(12). Check that dowel pins (10) are in place
either in the gear housing (12) or the port end
cover housing (13).
14. Align the marks made during disassembly, place
the port housing (12) onto the gear housing (12).
15. Install bolts (15) with clean and dry threads,
washers (14). Torque bolts to 192 5.5 Nm
(141.5 4 pound feet).

Bur 5-2920

Issued 8-06

Printed in U.S.A.

BRAKE ACCUMULATORS

CNH America LLC.


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

Bur6-47761

Copyright 2004 CNH America LLC.


All rights reserved.
Printed in U.S.A.
Issued April, 2003/Revised February, 2004

7004

Section
7004

7004-2

TABLE OF CONTENTS
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHARGING THE ACCUMULATOR WITH DRY NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Temperature/Charge Pressure Brake Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 6-47761

Revised 2-04

3
3
3
4
4

Printed in U.S.A.

7004-3

SPECIAL TOOL
E

C
F

G
D

A
94L95

CAS10899 NITROGEN CHARGING KIT

BC04A001

380001168 ACCUMULATOR CHARGING ADAPTER

DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR


1. Remove cover from accumulator charge port.
Loosen the Allen screw in the charge port.

6. Connect valve F to the valve stem on the


adapter.

NOTE: Do not turn the Allen screw more than 1/8 of


a turn or gas will escape uncontrolled.

7. Turn the T-handle inward on valve F to engage


the pin in the valve stem, open valve G.

2. Install adapter on accumulator, use the


CAS10899 nitrogen charging kit to discharge the
accumulator, refer to illustrations above. The tool
must be disconnected from the nitrogen tank.

8. Open valve D and check the charge pressure on


gauge E.

3. Close valves B, C and D.


4. Adjust the regulator A to the minimum pressure
setting by turning the knob counterclockwise.
5. Turn the T-handle on valve F fully out.

9. To discharge the accumulator, partially open


valve B. The accumulator charge will bleed down
through the regulator.
10. Once the accumulator is fully discharged,
disconnect valve F from the valve stem and
remove adapter.

CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR


1. Make sure that the oil side of the accumulator is
completely discharged by doing the following:
A. Stop the engine.
B. Push down and release the brake pedal 21
times to release the pressure.
2. Connect a drain hose to the test connector in
each brake circuit to release any pressure in the
brake circuit.
3. Close valves B and C on the nitrogen charging
kit, refer to the illustration.
4. Turn the stem out of valve F until the stem stops.

5. Remove the cap from the accumulator. Loosen


the Allen screw in the charge port.
NOTE: Do not turn the Allen screw more than 1/8 of
a turn or gas will escape uncontrolled.
6. Connect adapter to accumulator.
7. Connect valve F to the adapter valve stem.
8. Make sure that valve D and G are open.
9. Turn the stem into valve F and read the pressure
gauge E.
NOTE: See chart below for pressure readings.
10. If the pressure is too low, charge the accumulator
with dry nitrogen.

Bur 6-47761

Revised 2-04

Printed in U.S.A.

7004-4

CHARGING THE ACCUMULATOR WITH DRY NITROGEN


NOTE: Check the pressure in the accumulator
according to the instructions in Checking the
Nitrogen Charge in the Accumulator. Keep the
nitrogen charging kit connected to the accumulator.

6. Connect valve F to the adapter valve stem. Turn


the stem into valve F until the stem stops moving
and open valve G and D to charge the
accumulator.

1. Close (turn counterclockwise) valve A and open


valve B. Close valves C, D, and G.

7. After the accumulator stops charging, turn the


stem out of valve F until the stem stops moving
and close valve G.

2. Turn the stem out of valve F until the stem stops


moving. Disconnect valve F from the adapter
valve stem.
3. Connect the nitrogen charging kit to a dry
nitrogen tank.
4. Slowly turn valve A clockwise and read gauge E
until the pressure is equal to charge pressure
required for accumulator being charged. Stop
turning valve A.
5. If the pressure increases above required
pressure, quickly open and close valve D and
read gauge E. If the pressure is still too high,
close valve A (turn counterclockwise) a small
amount and quickly open and close valve D. The
pressure shown on gauge E is the charge
pressure.

8. Close valve B and disconnect the nitrogen


charging kit from the adapter valve stem, remove
the adapter.
9. Torque the Allen screw to 20 Nm (15 lb-ft), install
the cover on the accumulator valve stem.

TEMPERATURE
0 C
32 F
5 C
41 F
10 C
50 F
15 C
59 F
20 C
68 F
25 C
77 F
30 C
86 F
35 C
95 F
40 C
104 F

CHARGE PRESSURE
51.2 BAR
743 PSI
52.2 BAR
757 PSI
53.1 BAR
770 PSI
54.1 BAR
784 PSI
55.0 BAR
798 PSI
55.9 BAR
811 PSI
56.9 BAR
825 PSI
57.8 BAR
839 PSI
58.8 BAR
852 PSI

TEMPERATURE/CHARGE PRESSURE BRAKE


ACCUMULATOR

Bur 6-47761

Revised 2-04

Printed in U.S.A.

Section
7008

7008

PARKING BRAKE

CNH America LLC.


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

Bur 5-2930

Copyright 2006 CNH Ameica LLC.


All rights reserved.
Printed in U.S.A.
Issued August, 2006

7008-2

TABLE OF CONTENTS
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PARKING BRAKE TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 5-2930

Issued 8-06

3
3
4
4
5

Printed in U.S.A.

7008-3

PARKING BRAKE
Disassembly

STEP 7

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

STEP 2
Place wheel chocks on each wheel to prevent
machine movement.

STEP 3
BD03A185

Loosen the jam nut, tur n adjusting bolt


counterclockwise until the brake pads are loose.

STEP 8

BD01F143

Install the articulation lock.

STEP 4
Place the master disconnect switch in the OFF
position.

STEP 5

BD03A186

Pump the brake pedal at least 30 times to discharge


the accumulators.

Remove the retainer pin and brake pin.

STEP 9

STEP 6

BD03A187
BD03A184

Remove the two brake pads from the parking brake


assembly.

Loosen and remove the cover from the parking


brake.
Bur 5-2930

Issued 8-06

Printed in U.S.A.

7008-4

Inspection

STEP 14
Disengage the parking brake.

STEP 10
Clean and inspect all parts for wear and damage.
Inspect the brake disc for wear and damage.
Replace all parts that are worn or damaged.

NOTE: Hydraulic pressure will not be applied to the


parking brake until the parking brake rocker switch is
turned off, the service brakes applied and the
transmission is put into gear.
A. Place the parking brake rocker switch in the
OFF position.

Assembly

B. Apply the service brake and put the machine


into gear.

STEP 11

C. The parking brake light on the cluster will turn


off at this time.
Place the transmission back into neutral before
proceeding.

STEP 15

BD03A187

Install the two brake pads in the parking brake


assembly.

STEP 12
BD0CA185

Turn the adjusting bolt clockwise until both brake


pads contact the brake disc, then turn the adjusting
bolt counterclockwise one turn. Tighten the jam nut
to secure the adjusting bolt.

STEP 16
Install the cover on the parking brake.

STEP 17
BD03A186

Install the brake pins and retainer pins.

STEP 13
Start the machine and run the engine at low idle with
the bucket resting on the ground.
IMPORTANT: It will be necessary to have an
assistant help for this procedure. An operator must
be present in the cab at all times to apply the service
brakes and shut down the machine in the event of
mechanical failure.

Bur 5-2930

Perfor m the Parking Brake Test Procedure as


described in this section.

STEP 18
Remove the articulation lock.

STEP 19
Place the master disconnect switch to the ON
position.

Issued 8-06

Printed in U.S.A.

7008-5

PARKING BRAKE TEST PROCEDURE


STEP 20

STEP 25

While testing, the machine must be on a clear level


surface with the bucket in the travel position.
WARNING: Always know the location of all
workers in your area. Warn them before you
start working the machine. Always keep all
other persons away from your area. Serious
injury or death can result if you do not follow
these instructions.
SA015

STEP 21
Start the machine and run the engine at low idle in
third gear neutral.

BD06F142

Use up or down arrow and highlight config, press the


enter key to select the config menu.

STEP 22
Place the Transmission-Auto switch to the manual
position.

STEP 26

STEP 23
Place the Parking Brake switch to the ON position.

STEP 24

BD06F143

Press the up or down arrow and high light brake test,


press the enter key.

BD06F141

Press and hold the enter key for 2 to 3 seconds until


the instrument cluster monitor display changes to the
select screen.

Bur 5-2930

Issued 8-06

Printed in U.S.A.

7008-6

STEP 27

STEP 33
Verify that the machine does not move.

STEP 34
Reduce the engine speed to low idle and return the
transmission to neutral.

STEP 35

BD06F144

Monitor will display Test Park Brake if all conditions


are met to test the brake, press the enter key.
NOTE: If all conditions are not met to test the brake
the monitor will display the condition that needs
corrected prior to proceeding.

STEP 28

BD06F141

Press the escape switch on the key pad to exit the


test mode.

Monitor will display Test Park Brake Ready.

STEP 29
Shift the gear selector into third gear forward and
slowly increase the engine speed to wide open
throttle.

STEP 36
If any machine movement was detected, the parking
brake must be adjusted, see procedures this section.

STEP 30
Verify that the machine does not move.

STEP 31
Reduce the engine speed to low idle and return the
transmission neutral.

STEP 32
Shift the gear selector to third gear reverse and
slowly increase the engine speed to wide open
throttle.

Bur 5-2930

Issued 8-06

Printed in U.S.A.

SECTION INDEX

HYDRAULICS
Section Title

Section Number

Removal and Installation of Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8001


Hydraulic Specifications, Troubleshooting, and Pressure Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8002
Cleaning the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8003
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8004
Loader Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8005
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8006
Coupler Solenoid Locking Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8007
Ride Control Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8013
Ride Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8014

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

Bur 5-3260

Copyright 2006 CNH Ameica LLC.


All rights reserved.
Printed in U.S.A.
Issued August, 2006

8001
Section
8001
REMOVAL AND INSTALLATION OF HYDRAULIC
COMPONENTS

CNH America LLC.


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

Bur 5-4050

Copyright 2006 CNH Ameica LLC.


All rights reserved.
Printed in U.S.A.
Issued August, 2006

8001-2

TABLE OF CONTENTS
LOADER CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Valve Pilot Line Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loader Control Valve Line Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOTE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Joystick and 2 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Joystick and 1 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Joystick Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIFT CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUCKET CYLINDER - Z-BAR LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUCKET CYLINDERS - XT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
XT Loader Bucket Cylinder Removal And Installation Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RIDE CONTROL ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RIDE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAN REVERSING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THERMAL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 5-4050

Issued 8-06

3
3
4
5
6
8
8
9
11
12
12
13
13
14
15
15
17
17
18
20
20
22
24
24
25
26
27
27
28
29
29
30
31
31
32
33
33
34
35
35
35

Printed in U.S.A.

8001-3

LOADER CONTROL VALVE


Removal

STEP 5

STEP 1
Park the machine on a level surface.
IMPORTANT: If machine is equipped with
quick-attached components, disconnect them from
machine prior to proceeding.

STEP 2

BD06H198

Relieve the pressure in the ride control accumulator


with the manual bleeder valve located on the top of
the ride control valve. Remove the plug and turn the
valve two turns counter-clockwise.

STEP 6
Loosen the filler cap on the reservoir to release the
air pressure in the reservoir.
BD03A092

Raise the lift arms and install the safety link on the lift
arm cylinder.

STEP 3

STEP 7
Drain the hydraulic reservoir.

STEP 8

Stop the engine and apply the parking brake.


IMPORTANT: With the engine NOT running, pump
the brake repeatedly to be sure the brake
accumulators have no hydraulic pressure, put the
ignition switch in the ON position then move the
loader control valve back and forth several times to
release any hydraulic pressure in the pilot control
circuit, turn ignition switch OFF.

STEP 4
Place the master disconnect switch in the OFF
position.
BD03A093

Loosen and remove the bolts and washers that


fasten the access cover plate for the loader control
valve. Remove the cover plate.

Bur 5-4050

Issued 8-06

Printed in U.S.A.

8001-4
REAR OF MACHINE

6
7
5

3
2

BC05M094

1. GREEN WHITE GREEN


2. RED WHITE GREEN
3. YELLOW BLACK GREEN

4. ORANGE BLACK GREEN


5. GREEN WHITE GREEN
6. RED WHITE GREEN

7. GREEN BLACK GREEN


8. RED BLACK GREEN
9.

HYDRAULIC VALVE PILOT LINE CONNECTIONS

Bur 5-4050

Issued 8-06

Printed in U.S.A.

8001-5

1
3
4

BC05M093

1. DUMP LINE
2. ROLLBACK LINE
3. LOWER LINE LEFT

4. RAISE LINE RIGHT


5. LOADER VALVE

6. LOWER LINE RIGHT


7. RAISE LINE LEFT

LOADER CONTROL VALVE LINE CONNECTIONS

Bur 5-4050

Issued 8-06

Printed in U.S.A.

8001-6

Installation

STEP 9
Disconnect the hoses (3, 4, 7, 8 if equipped 1, 2, 5,
and 6) from the remote control valve(s) at the loader
control valve. Refer to the illustration on page 4 for
color coding. Install a plug in each hose and a cap on
each fitting.

IMPORTANT: Before installing the fittings or


connecting the tubes to the fittings, install new
O-rings on the fittings.

STEP 16

NOTE: Line 1, 2, 5, and 6 will need to be tagged as


right or left of valve.

STEP 10
Loosen and remove tilt cylinder lines (1 and 2). Install
a plug in each line and a cap on each fitting.

STEP 11
Loosen and remove lines (3 and 4). Install a plug in
each line and a cap on each fitting.

STEP 12

BC05M096

Loosen and remove lines (6 and 7). Install a plug in


each line and a cap on each fitting.

Install and align the loader control valve with the


valve mounting plate.

STEP 13

STEP 17

Loosen and remove supply and return lines. Install a


plug in each line and a cap on each fitting.

Install the bolts and washers that fasten the loader


control valve to the valve mounting plate. Tighten the
bolts.

STEP 14
Attach proper lifting equipment to lift loader control
valve.

STEP 18

STEP 15

STEP 19

Tighten the left lift cylinder lines (6 and 7).

Install and tighten the supply and return lines.

STEP 20
Install and tighten right lift cylinder lines (3 and 4).

STEP 21
Install and tighten tilt cylinder lines (1 and 2).

STEP 22
BC05M096

Loosen and remove the three bolts and washers that


hold the loader control valve to the valve mounting
plate. Remove the loader control valve.

Bur 5-4050

Connect the hoses (3, 4, 7, 8 if equipped 1, 2, 5, and


6) to the remote control valve(s) at the loader control
valve. Refer to the illustration on page 4 for color
coding.

Issued 8-06

Printed in U.S.A.

8001-7

STEP 23

STEP 27

Fill the hydraulic reservoir with oil. Refer to Section


1002 for the correct oil.

Run engine at half throttle.

STEP 28
STEP 24
Tighten the accumulator manual bleeder valve
located on the top of the ride control valve to a torque
of 3.5 Nm (31 lb-in). Install the plug and torque to
7 Nm (62 lb-in).

Slowly and completely extend and retract all


cylinders at least 10 times to remove any air from the
circuits.

STEP 29
Stop the engine and check for leaks.

STEP 25
Place the master disconnect switch in the ON
position.

STEP 30

STEP 26

STEP 31

Install the access cover on the front of the machine.

Check the level of the hydraulic oil and add hydraulic


oil as required.

BD03A092

Raise the loader arms and remove the safety link.

Bur 5-4050

Issued 8-06

Printed in U.S.A.

8001-8

REMOTE CONTROL VALVE


Removal

STEP 37

STEP 32
Park the machine on a level surface and lower the
bucket to the floor. Stop the engine and apply the
parking brake.
IMPORTANT: With the engine NOT running, pump
the brake repeatedly to be sure the brake
accumulators have no hydraulic pressure, put the
ignition switch in the ON position then move the
loader control valve back and forth several times to
release any hydraulic pressure in the pilot control
circuit, turn ignition switch OFF.

BD06F208

Open and remove the access panel.

STEP 33
Place the master disconnect switch in the OFF
position.

STEP 38

STEP 34
Unlatch and open the right hand side access door.

STEP 35
Lift the access door up and remove the access door
from the pins.

STEP 36
BD06F209

Remove the front access panel.

STEP 39

BD06F207

Unlatch and open the window on the right hand side.

BD06F210

Disconnect the electrical connectors for the remote


control valve.

STEP 40
Loosen the filler cap on the reservoir to release any
air in the reservoir. Connect a vacuum pump to the
hydraulic reservoir, turn on the pump.
Bur 5-4050

Issued 8-06

Printed in U.S.A.

8001-9

STEP 41

Installation

Put identification tags on each hose and disconnect


one at a time from the remote control valve. Install
plugs in the hoses and caps on the fittings.

STEP 45

STEP 42
Loosen and remove the screws and washers holding
the hydraulic control tower cover. Remove the cover.

STEP 43
Loosen and remove the screws that fasten the
remote control valve to the hydraulic control tower.

STEP 44
Remove the remote control valve from the hydraulic
control tower.

Install new O-rings on the adapters for the remote


control valve.

STEP 46
Install the remote control valve and screws in the
hydraulic control tower and tighten the screws.

STEP 47
Install the cover over the remote control valve and
install the screws and washers.

STEP 48
Remove the plugs from the hoses and the caps from
the fittings and connect the hydraulic hoses to the
fittings according to the identification tags. (Refer to
illustrations on pages 11, 12, and 13 as necessary.

STEP 49
Turn off the vacuum pump and disconnect from the
hydraulic reservoir.

STEP 50

BD06F210

Connect the electrical connectors for the remote


control valve.

STEP 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.

Bur 5-4050

Issued 8-06

Printed in U.S.A.

8001-10

STEP 54

STEP 57

Check for hydraulic oil leakage at the remote control


valve.

STEP 55
Check the level of hydraulic oil in the reservoir and
add as required.

STEP 56

BD06F208

Install and close the access panel.

STEP 58

BD06F209

Position the access panel on the ROPS cab or the


ROPS canopy and install and tighten the screw.

BD06F207

Close the right hand window.

Bur 5-4050

Issued 8-06

Printed in U.S.A.

8001-11

8
4
6
7

1
5

5
2

1
8

3
6

4
BC05M092

1. PILOT TANK HOSE


2. PILOT PRESSURE HOSE
3. YELLOW BLACK GREEN

4. ORANGE BLACK GREEN


5. GREEN BLACK GREEN
6. RED BLACK GREEN

7. GREEN WHITE GREEN


8. RED WHITE GREEN

JOYSTICK AND 2 LEVER HOSE COLOR CODING

Bur 5-4050

Issued 8-06

Printed in U.S.A.

8001-12

4
3

4
6

2
7

7
1

7
1

5
BC05M091

1.
2.
3.
4.
5.
6.
7.

PILOT TANK HOSE


PILOT PRESSURE HOSE
RED BLACK GREEN
ORANGE BLACK GREEN
YELLOW BLACK GREEN
GREEN BLACK GREEN
RED WHITE GREEN

3 LEVER HOSE COLOR CODING

Bur 5-4050

1.
2.
3.
4.
5.
6.
7.

PILOT TANK HOSE


PILOT PRESSURE HOSE
RED BLACK GREEN
ORANGE BLACK GREEN
YELLOW BLACK GREEN
GREEN BLACK GREEN
RED WHITE GREEN

JOYSTICK AND 1 LEVER HOSE COLOR CODING

Issued 8-06

Printed in U.S.A.

8001-13

1
5
4

2
1

3
2

3
4

5
BC05M090

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

PILOT TANK HOSE


PILOT PRESSURE HOSE
RED BLACK GREEN
ORANGE BLACK GREEN
YELLOW BLACK GREEN
GREEN BLACK GREEN

2 LEVER HOSE COLOR CODING

Bur 5-4050

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

PILOT TANK HOSE


PILOT PRESSURE HOSE
RED BLACK GREEN
ORANGE BLACK GREEN
YELLOW BLACK GREEN
GREEN BLACK GREEN

JOYSTICK HOSE COLOR CODING

Issued 8-06

Printed in U.S.A.

8001-14

HYDRAULIC PUMP

10
15

4
5
6
4

16

5
8

15
6

13

2
3
14
11
9
12

BC05M095

1.
2.
3.
4.

PUMP MAIN HYDRAULIC


MOUNT BOLTS
DRAIN HOSE
BOLT

Bur 5-4050

5.
6.
7.
8.

SPLIT FLANGE
9. STEERING HIGH PRESSURE
TUBE
10. CLAMPS
HOSE SUCTION
11. STEERING LOAD SENSE HOSE
HOSE CASE DRAIN 12. LOADER LOAD SENSE HOSE

13.
14.
15.
16.

LOADER HIGH PRESSURE


STEERING PRIORITY MANIFOLD
CLAMPS
FITTINGS

Issued 8-06

Printed in U.S.A.

8001-15

Removal
NOTE: When disconnecting hydraulic fittings, plug
hoses and cap fittings to prevent entry of foreign
matter into hydraulic system.

STEP 59
Park the machine on a level surface and lower the
bucket to the floor. Stop the engine and apply the
parking brake.

STEP 69
Connect lifting equipment to hydraulic pump (1). Take
up all slack in lifting equipment. Remove four
mounting bolts (2) and washers securing pump to
transmission. Pull hydraulic pump from transmission
and remove from loader. Remove and discard O-ring
from pump.

Installation
NOTE: Install new O-rings where required.

STEP 60
Place the master disconnect switch in the OFF
position.

STEP 61
Loosen the filler cap on the reservoir to release any
air in the reservoir. Connect a vacuum pump to the
hydraulic reservoir, turn on the pump.

STEP 62
Refer to Section 9007 and remove the ROPS cab or
ROPS canopy.

STEP 63
Remove eight bolts (4) and washers. Remove four
split flanges (5). Disconnect tubes (6) with suction
hoses (7) from hydraulic pump. Remove and discard
O-ring face seals from flange heads of tubes.

STEP 70
Install new O-ring on hydraulic pump flange. Move
pump into position and install in transmission. Install
four washers and bolts (2) to secure pump (1) to
transmission, tighten the bolts. Disconnect lifting
equipment from pump.

STEP 71
Connect pump pressure hoses (9 and 13) to steering
priority manifold (14).

STEP 72
Connect drain hose (3).

STEP 73
Connect load sense hoses (11 and 12).

STEP 74
STEP 64

Install and connect case drain hoses (8).

Loosen clamps (10). Tag and disconnect suction


hoses (7) from hydraulic reservoir and remove from
machine.

STEP 75

STEP 65
Tag and disconnect case drain hoses (8) from fittings
(16); remove hoses (8). Remove and discard O-ring
face seals from fittings.

STEP 66
Tag and disconnect load sense hoses (11 and 12).
Remove and discard O-ring face seals from fittings.

STEP 67
Tag and disconnect drain hose (3). Remove and
discard O-ring face seals from fittings.

STEP 68
Tag and disconnect pump pressure hoses (9 and 13)
from steering priority manifold (14). Remove and
discard O-ring face seals from flange heads of
hoses.
Bur 5-4050

Install suction hoses (7), tighten clamps (10) to 10 to


11 Nm (90 to 100 pound inches).

STEP 76
Install four split flanges (5). Install eight bolts (4) and
washers, tighten bolts (4) to 73 to 90 Nm (53.8 to
66.3 pound feet).

STEP 77
Refer to Section 9007 and install the ROPS cab or
ROPS canopy.

STEP 78
Turn off the vacuum pump and disconnect from the
hydraulic reservoir.

STEP 79
Place the master disconnect switch in the ON
position.

Issued 8-06

Printed in U.S.A.

8001-16

STEP 80

STEP 81

Start the engine and run the engine at low idle for two
minutes.

Stop the engine and check for hydraulic oil leakage at


the hydraulic pump.

NOTE: If any unusual vibration is heard coming from


the pump, stop the machine immediately and check
for obstructions in the pump suction line.

Bur 5-4050

STEP 82
Check the level of the hydraulic oil in the reservoir
and add hydraulic oil as required.

Issued 8-06

Printed in U.S.A.

8001-17

LIFT CYLINDERS
Removal

STEP 87

STEP 83
Park the machine on a level surface and lower the
bucket to the floor. Stop the engine and apply the
parking brake.
IMPORTANT: With the engine NOT running, pump
the brake repeatedly to be sure the brake
accumulators have no hydraulic pressure, put the
ignition switch in the ON position then move the
loader control valve back and forth several times to
release any hydraulic pressure in the pilot control
circuit, turn ignition switch OFF.
BD01D709

STEP 84
Relieve the pressure in the ride control accumulator
with the manual bleeder valve located at the rear of
the front chassis.

Loosen and remove the bolt, washer and spacer that


hold the pivot pin for the yoke.

STEP 88

STEP 85
Loosen the filler cap on the hydraulic reservoir to
release any pressure.

STEP 86

BD01D711

Use a proper lifting device and secure a strap around


the lift cylinder.

STEP 89
BD01D708

Tag and disconnect the hoses on each side of the lift


cylinder. Install plugs in the hoses and caps on the
fittings.

BD01D712

Remove the pivot pin from the yoke end of the lift
cylinder.

Bur 5-4050

Issued 8-06

Printed in U.S.A.

8001-18

Installation

STEP 90

STEP 93
Apply antiseize compound to the bores in the front
frame and the yoke on the piston rod.

STEP 94

BD01D710

Loosen and remove the bolt, washer and spacer that


hold the pivot pin at the closed end of the lift cylinder.

STEP 91
BD01D714

Use a proper lifting device and position the lift


cylinder on the machine.

STEP 95

BD01D713

Remove the pivot pin from the closed end of the lift
cylinder.

STEP 92
Remove the lift cylinder from the machine
BD01D713

Align the closed end of the lift cylinder with the front
frame and install the pivot pin.

Bur 5-4050

Issued 8-06

Printed in U.S.A.

8001-19

STEP 96

STEP 99

BD01D710

Align the pivot pin with the front frame and install the
spacer, washer and bolt. Tighten the bolt.

BD01D712

Install the pivot pin for the yoke. Stop the engine.

STEP 100
STEP 97

BD01D709
BD01D708

Remove the caps and plugs and connect the hoses


to the lift cylinder.

Align the pivot pin with the yoke and install the
spacer, washer and bolt. Tighten the bolt.

STEP 101
STEP 98
If the yoke of the lift cylinder is not aligned with the
loader frame, have another person start and run the
engine at low idle and use the loader control lever to
SLOWLY move the yoke into alignment with the
loader frame.

SLOWLY extend and retract the piston rod three


times to remove any air from the lift cylinders.

STEP 102
Lubricate the pivot pins with molydisulfide grease.

STEP 103
Check the level of hydraulic oil in the reservoir and
add as required. Tighten the filler cap on the
hydraulic reservoir.

Bur 5-4050

Issued 8-06

Printed in U.S.A.

8001-20

BUCKET CYLINDER - Z-BAR LOADER


Removal

STEP 108

STEP 104
Park the machine on a level surface and lower the
bucket to the floor. Stop the engine and apply the
parking brake.

STEP 105
With the engine stopped, move the bucket control
lever to release pressure in the bucket circuit.

STEP 106
BD01D695

Loosen and remove the two bolts that fasten the


mounting bracket to the machine. Remove the
mounting bracket.

STEP 109

BD01D694

Disconnect the proximity switch connector from the


wiring harness connector.

STEP 107
BD01D697

Loosen and remove the two bolts that fasten the


mounting bracket for the proximity switch to the
bucket cylinder. Remove the mounting bracket and
switch.

BD01D696

Loosen and remove the two bolts that fasten the


target bar to the mounting bracket. Remove the
target bar.

Bur 5-4050

Issued 8-06

Printed in U.S.A.

8001-21

STEP 110

STEP 113

BD01D699

BD01D701

Disconnect the hoses from each side of the bucket


cylinder. Install plugs in the hoses and caps on the
fittings.

Remove the pivot pin from the rod end of the bucket
cylinder.

STEP 114
STEP 111

BD01D704
BD01D700

Use acceptable equipment to hold the bucket


cylinder.

STEP 112

Remove the pivot pin from the head end of the bucket
cylinder.
NOTE: It is not necessary to remove the grease line
from the pivot pin unless the pivot pin is to be
replaced.

STEP 115

BD01D698

Loosen and remove the bolt, washer and spacer that


fasten the pivot pin from both ends of the bucket
cylinder.

Bur 5-4050

BD01D706

Raise the bucket cylinder and remove the cylinder


from the machine.
Issued 8-06

Printed in U.S.A.

8001-22

Installation

STEP 120

STEP 116
Apply antisieze compound to the bores in the front
frame and the bores in the loader arm for the bucket
cylinder.

STEP 117

BD01D699

Connect the hoses to each side of the bucket


cylinder.

STEP 121

Use acceptable lifting equipment to lower the bucket


cylinder into position.

If the rod end of the bucket cylinder is not aligned


with the bellcrank, have another person start the
engine and run the engine at low idle and use the
bucket control lever to SLOWLY move the piston rod
eye into alignment with the bellcrank.

STEP 118

STEP 122

BD01D706

Install the pivot pin and stop the engine.

STEP 123

BD01D704

Install the pivot pin to the head end of the bucket


cylinder.
BD01D698

STEP 119
Install the spacer, washer and bolt that fasten the
pivot pin to the front frame. Tighten the bolt.

Install the spacer, washer and bolt that fasten the


pivot pin to the bellcrank. Tighten the bolt.

NOTE: If a new pivot pin is being installed, connect


the grease line to the pivot pin.

Bur 5-4050

Issued 8-06

Printed in U.S.A.

8001-23

STEP 124

STEP 127

BD01D697

BD01D694

Install the two bolts that fasten the mounting bracket


for the switch to the bucket cylinder.

Connect the proximity switch connector to the wiring


harness connector.

STEP 125

STEP 128
See Section 9006 for the adjustment procedure for
adjusting the proximity switch.

STEP 129
Start and run the engine at low idle.

STEP 130
SLOWLY extend and retract the piston rod three
times to remove any air from the bucket cylinder.

STEP 131
Lubricate the pivot pins with molydisulfide grease.
BD01D695

Install the two bolts for the mounting bracket for the
target bar.

STEP 126

STEP 132
Check the level of the hydraulic oil in the reservoir
and add as required. Tighten the filler cap on the
hydraulic reservoir.

BD01D696

Install the two bolts that fasten the target bar to the
mounting bracket.

Bur 5-4050

Issued 8-06

Printed in U.S.A.

8001-24

OIL COOLER
Removal

STEP 138

STEP 133
Park the machine on a level surface and lower the
bucket to the ground. Stop the engine and apply the
parking brake.

STEP 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
cooler.

STEP 136

BD03A154

Disconnect the top hose and install a plug in the hose


and a cap on the fitting.

STEP 139

BD03A120

Have assistant hold side panel in raised position,


remove two mounting screws, remove side panel.

STEP 137
Loosen the filler cap on the hydraulic reservoir to
release the air pressure in the reservoir. Connect a
vacuum pump to the hydraulic reservoir, turn on the
pump.

BD03A179

Loosen and remove the bolt and washer that fasten


the oil cooler to the cooling frame.

STEP 140

BD06H195

Disconnect the hose from the bottom of the oil cooler.


Install a plug in the hose and a cap on the fitting.
Remove the two mounting nuts, remove the oil cooler
from the machine.
Bur 5-4050

Issued 8-06

Printed in U.S.A.

8001-25

Installation

STEP 144

STEP 141

BD03A120

BD06H195

Place the oil cooler in position in the cooling frame.


Connect the lower hose to the oil cooler, install and
tighten the two mounting nuts.

STEP 142

Have assistant hold side panel in raised position,


install and tighten two mounting screws.

STEP 145
Turn off the vacuum pump and disconnect from the
hydraulic reservoir.

STEP 146
Place the master disconnect switch in the ON
position.

STEP 147
Start the engine and run the engine at low idle for two
minutes. Stop the engine and check for hydraulic oil
leakage at the ports on the oil cooler.

STEP 148
Install the shield between the right rear tire and the
oil cooler and tighten the two bolts holding the shield.
BD03A179

Install the bolt and washer that fasten the oil cooler to
the cooling frame

STEP 149
Check the level of the hydraulic oil in the reservoir
and add hydraulic oil as required.

STEP 143

BD03A154

Connect the hose to the top of the oil cooler.

Bur 5-4050

Issued 8-06

Printed in U.S.A.

8001-26

RIDE CONTROL ACCUMULATOR


Removal

STEP 153

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


the ride control accumulator. Install a plug in the hose
and a cap on the fitting.

STEP 151

STEP 154

BD06H198

Relieve the pressure in the ride control accumulator


with the manual bleeder valve located on the top of
the ride control valve. Remove the plug and turn the
valve two turns counter-clockwise.

STEP 152
Loosen the filler cap on the hydraulic reservoir to
release the air pressure in the reservoir. Connect a
vacuum pump to the hydraulic reservoir, turn on the
pump.

Bur 5-4050

BD06H197

Loosen and remove the nuts and washers from the


U-bolt. Remove the U-bolt.

STEP 155
Loosen and remove the two bolts that fasten the
accumulator bracket to the front frame. Remove the
ride control accumulator from the machine.

Issued 8-06

Printed in U.S.A.

8001-27

Installation

STEP 159

STEP 156
Place the ride control accumulator in position on the
front frame.

STEP 157
Install the two bolts that fasten the accumulator
bracket to the front frame. Tighten the bolts.

STEP 158
BD06H196

Remove the caps and plugs and install the hose on


the elbow at the bottom of the r ide control
accumulator.

STEP 160
Turn off and disconnect the vacuum pump from the
hydraulic reservoir.

STEP 161
BD06H197

Install the U-bolt, washers and nuts. Tighten the nuts.

Tighten the accumulator manual bleeder valve


located on the top of the ride control valve to a torque
of 3.5 Nm (31 lb-in). Install the plug and torque to
7 Nm (62 lb-in).

STEP 162
Refer to Section 8002 Testing the Ride Control for
the proper charging of the accumulator to check for
leaks.

STEP 163
Check the level of the hydraulic oil in the reservoir
and add as required. Tighten the filler cap on the
hydraulic reservoir.

Bur 5-4050

Issued 8-06

Printed in U.S.A.

8001-28

RIDE CONTROL VALVE


Removal

STEP 166

STEP 164
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.

Loosen the filler cap on the hydraulic reservoir to


release the air pressure in the reservoir. Connect a
vacuum pump to the hydraulic reservoir, turn on the
pump.

STEP 167
Place the master disconnect switch in the OFF
position.

STEP 168
Disconnect the electrical connector on top of the ride
control valve.

STEP 169

STEP 165

Tag and disconnect the hoses from the ride control


valve. Install a plug in the hoses and caps on fittings.

STEP 170
Loosen and remove the two bolts and washers that
fasten the ride control valve to the frame.

STEP 171
Remove the ride control valve from the machine.

STEP 172
BD06H198

Remove and discard all O-rings.

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.

Bur 5-4050

Issued 8-06

Printed in U.S.A.

8001-29

Installation

STEP 178

STEP 173

Connect the electrical connector to the ride control


valve.

Install the ride control valve in position on the front


frame.

STEP 179

STEP 174

Turn off the vacuum pump and disconnect from the


hydraulic reservoir.

Install the washers and bolts through the frame and


into the ride control valve. Tighten the bolts.

STEP 180

STEP 175

Place the master disconnect switch in the ON


position.

STEP 181
Start and run the engine at low idle for two minutes.

STEP 182
Stop the engine and check for hydraulic oil leakage at
the ride control valve.

STEP 183

BD06H198

Tighten the accumulator manual bleeder valve


located on the top of the ride control valve to a torque
of 3.5 Nm (31 lb-in). Install the plug and torque to
7 Nm (62 lb-in).

Check the level of the hydraulic oil in the reservoir


and add as required. Tighten the filler cap on the
hydraulic reservoir.

STEP 184
Refer to Section 8002 and perform the Ride Control
Test Procedure.

STEP 176
Lubricate and install new O-rings.

STEP 177
Connect the hoses to the ride control valve.

Bur 5-4050

Issued 8-06

Printed in U.S.A.

8001-30

FAN REVERSING VALVE


Removal

STEP 188

STEP 185
Park the machine on a level surface and lower the
bucket to the ground. Stop the engine and apply the
parking brake.
IMPORTANT: With the engine NOT running, pump
the brake repeatedly to be sure the brake
accumulators have no hydraulic pressure, put the
ignition switch in the ON position then move the
loader control valve back and forth several times to
release any hydraulic pressure in the pilot control
circuit, turn ignition switch OFF.

2
1

BD03A174

STEP 186
Loosen the filler cap on the hydraulic reservoir to
release the air pressure in the reservoir. Connect a
vacuum pump to the hydraulic reservoir, turn on the
pump.

Tag and disconnect the fan forward hose (1) from the
fan reversing valve. Install a plug in the hose and a
cap on the fitting. Tag and disconnect the fan reverse
hose (2) from the fan reversing valve. Install a plug in
the hose and a cap on the fitting.

STEP 187

STEP 189

4
BD03A173

BD03A174

Disconnect the electrical connector for the fan


reversing valve.

Tag and disconnect the fan valve return hose (3) from
the fan reversing valve. Install a plug in the hose and
a cap on the fitting. Tag and disconnect the fan valve
supply hose (4) from the fan reversing valve. Install a
plug in the hose and a cap on the fitting.

STEP 190
Loosen and remove the nuts, washers and bolts.

STEP 191
Remove the fan reversing valve from the machine.

STEP 192
Remove and discard all O-rings from the fittings.

Bur 5-4050

Issued 8-06

Printed in U.S.A.

8001-31

Installation

STEP 198

STEP 193
Place the fan reversing valve into position on the
machine.

STEP 194
Lubricate and install new O-rings in the fittings.

STEP 195
Install the bolts, washers and nuts. Tighten the nuts.

STEP 196
BD03A174

Connect the electrical connector for the fan reversing


valve.

STEP 199
Turn off the vacuum pump and disconnect from the
hydraulic reservoir.

STEP 200

Check the level of the hydraulic oil in the reservoir.

4
BD03A173

STEP 201

Connect the fan valve supply hose (4) to the fitting on


the fan reversing valve. Connect the fan valve return
hose (3) to the elbow on the fan reversing valve.

Start the engine and run the engine at low idle for two
minutes.

STEP 197

Stop the engine and check for hydraulic oil leakage at


the fan reversing valve.

STEP 202

STEP 203
Check the level of the hydraulic oil in the reservoir
and add as required. Tighten the filler cap on the
reservoir.

2
1

BD03A174

Connect the fan reverse hose (2) to the fitting on the


fan reversing valve. Connect the fan forward hose (1)
to the fitting on the fan reversing valve.

Bur 5-4050

Issued 8-06

Printed in U.S.A.

8001-32

THERMAL VALVE
Removal

Installation

STEP 204

STEP 208

Park the machine on a level surface and lower the


bucket to the ground. Stop the engine and apply the
parking brake.

Place the thermal valve into position on the machine.

IMPORTANT: With the engine NOT running, pump


the brake repeatedly to be sure the brake
accumulators have no hydraulic pressure, put the
ignition switch in the ON position then move the
loader control valve back and forth several times to
release any hydraulic pressure in the pilot control
circuit, turn ignition switch OFF.

Lubricate and install new O-rings in the fittings.

STEP 205
Loosen the filler cap on the hydraulic reservoir to
release the air pressure in the reservoir. Connect a
vacuum pump to the hydraulic reservoir, turn on the
pump.

STEP 209
STEP 210
Install the bolts, washers and nuts. Tighten the nuts.

STEP 211
Connect the hoses to the thermal valve, remove and
discard tags.

STEP 212
Turn off the vacuum pump and disconnect from the
hydraulic reservoir.

STEP 213

STEP 206

Check the level of the hydraulic oil in the reservoir.

STEP 214
Start the engine and run the engine at low idle for two
minutes.

STEP 215
Stop the engine and check for hydraulic oil leakage at
the thermal valve.

STEP 216
BD06F211

Tag and disconnect the hoses from the thermal valve.


Install a plug in the hose and a cap on the fitting.

Check the level of the hydraulic oil in the reservoir


and add as required. Tighten the filler cap on the
reservoir.

STEP 207
Remove the mounting bolts from the thermal valve,
remove the valve from the machine.

Bur 5-4050

Issued 8-06

Printed in U.S.A.

8002

Section
8002
HYDRAULIC SPECIFICATIONS, TROUBLESHOOTING,
AND PRESSURE CHECKS

CNH America LLC.


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

Bur 5-3270

Copyright 2006 CNH Ameica LLC.


All rights reserved.
Printed in U.S.A.
Issued August, 2006

8002-2

TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Problems in All Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Problem in All Loader Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Problem in the Braking Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Problem in a Single Loader Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Problem in the Steering Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Problem in the Ride Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TESTING AND ADJUSTING THE HIGH PRESSURE
PUMP DIFFERENTIAL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the High Pressure Pump Differential Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TESTING AND ADJUSTING THE LOW PRESSURE
PUMP DIFFERENTIAL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the Low Pressure Pump Differential Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TESTING AND ADJUSTING THE LOADER LIMIT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the Loader Limit Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TESTING AND ADJUSTING THE STEERING LIMIT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the Steering Limit Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TESTING AND ADJUSTING THE LOADER PUMP CUTOFF PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the Loader Pump Cutoff Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TESTING THE HYDAULIC CONTROLLER PILOT SUPPLY PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HIGH PRESSURE PUMP FLOW TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TESTING AND ADJUSTING THE CIRCUIT RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TESTING THE RIDE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HYDRAULIC COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 5-3270

Issued 8-06

3
4
5
5
5
5
6
6
6
7
7
8
9
9
10
11
11
12
13
13
14
15
15
16
17
17
18
20
20
20
21
22

Printed in U.S.A.

8002-3

SPECIFICATIONS
Manufacturer........................................................................................................................................ Bosch-Rexroth
High pressure pump (closest to transmission) .................................................... 120 L/min at 172 bar, at 2000 r/min
(31.6 gpm at 2500 psi at 2000rpm)
Low pressure pump (furthest from transmission) ................................................ 120 L/min at 172 bar, at 2000 r/min
(31.6 gpm at 2500 psi at 2000rpm)
Main relief valve pressure settings .........................................................................248 to 255 bar (3600 to 3700 psi)
Circuit relief valve pressure setting
Auxiliary A and B port.................................................................................................................290 bar (4200 psi)
Bucket A port..............................................................................................................................290 bar (4200 psi)
Bucket B port..............................................................................................................................290 bar (4200 psi)
Pilot accumulator pressure .............................................................................................13 to 15 bar (188 to 218 psi)
Steering relief valve pressure setting ............................................................................................. See Section 5002
Brake accumulator pressure .......................................................................................................... See Section 7002
NOTE: Both pump sections provide flow for both the steering and loader functions.

Bur 5-3270

Issued 8-06

Printed in U.S.A.

8002-4

SPECIAL TOOLS

B877168V

633L95

CAS-1808 FLOWMETER FITTING KIT

CAS-1904 PRESSURE FITTING KIT

B877895M

632L95

CAS-10090 HAND PUMP

CAS-1906 PRESSURE FITTING KIT

B877558M

B785789M

CAS-10280 FLOWMETER

Bur 5-3270

CAS-1804 PRESSURE FITTING KIT

Issued 8-06

Printed in U.S.A.

8002-5

TROUBLESHOOTING PROCEDURE
Visually check the machine for oil leakage and
damaged or missing parts. Repair or replace
any damaged or missing parts.
Check the oil level in the hydraulic reservoir. Is
the oil level correct?.

No

Fill the hydraulic reservoir with the hydraulic oil


specified in Section 1002.

No

See Page 18. Do the flow meter test of the


hydraulic pump.

No

Adjust the limit pressure. See page 11 in this


section.

Yes
Heat the oil in the hydraulic system to
operating temperature. Operate the
machine to find which circuits have
problems.

Problems in All Circuits


Replace the return line hydraulic filter.
See Section 2002. Do the stall test to see if
the engine is good.
See Section 8003 and check for contaminated
oil. Is the oil contaminated?
Yes
See Section 8003 and clean or replace the
oil.

Problem in All Loader Circuits


See Page 11 and check the pressure setting
of the limit pressure in the loader control
valve. Is the pressure setting correct?

Problem in the Braking Circuit


See Section 7002 and check the braking
circuit.

Bur 5-3270

Issued 8-06

Printed in U.S.A.

8002-6

Problem in a Single Loader Circuit


Star t and run the engine at full throttle.
Operate the control for the bad circuit. Does
the cylinder move in both directions?

No

The loader control valve is damaged. See


Section 8005 and repair the loader control
valve

No

See Section 8006 and repair the cylinder.

No

See Section 8005. Disassemble the loader


control valve and che ck for wor n or
damaged parts.

No

Repair the component as necessary.

No

See the Ride Control Test Procedure page


21 in this section.

Yes
Check the cylinder piston packing. Is the
packing good?
Yes
See Page 20. Check and adjust the circuit
relief valves. Then check the operation of
the circuit again. Does the circuit work
correctly?
Yes
The problem is repaired.

Problem in the Steering Circuit


See Section 5002 and check the steering
circuit. Is the steering circuit good?
Yes
See Page 13. Do the Steering Pump Limit
Pressure Test and Adjustment

Problem in the Ride Control


Lift ar ms rapidly and continuously sink
towards the ground.
Yes
Check the manual bleed valve for the ride
control accumulator to be sure that it is
closed.

Bur 5-3270

Issued 8-06

Printed in U.S.A.

8002-7

TESTING AND ADJUSTING THE HIGH PRESSURE


PUMP DIFFERENTIAL PRESSURE
Pressure Check

STEP 3

STEP 1

BD06G180

1
BD00M041

1. ARTICULATION LOCK

Install articulation lock (1).

STEP 2
Make sure that the temperature of the hydraulic oil is
at least 54C to 57C (129F to 135F). The following
is the procedure for heating the hydraulic oil.

To measure the oil temperature with the instrument


cluster:
A. Press the up or down arrow key.
B. Stop at the info screen with the temperatures
that need to be monitored are on.

To heat the hydraulic oil do the following:


A. Start the engine and run at full throttle.
B. Hold the bucket control lever in the
RO L L B AC K p o s i t i o n w h i l e ra i s i n g a n d
lowering the lift arms from ground level to full
height.
C. Continue this procedure until the temperature
of the hydraulic oil is 54 to 57C (129 to
135F).

After heating oil to operating temperature, lower


bucket to the ground, turn off the engine, and relieve
all pressure in the hydraulic system.

BD06F148

1. TEST PORT (LOAD SENSE)


2. TEST PORT (PUMP PRESSURE)

Connect two 69 bar (1000 psi) test gauges, one to


the test port (2) located on the priority valve, and one
on the pump load-sense pressure tap (1 closest to
transmission).
IMPORTANT: Do not steer or operate loader controls
while the gauges are connected, gauges could be
damaged.

STEP 4
Start the engine and run at low idle.

STEP 5
Make sure all of the controls are in the neutral
position and record the readings on the test gauges
(1) and (2).

STEP 6
Subtract the reading of the test port (1) from the
reading of the test port (2).

Bur 5-3270

Issued 8-06

Printed in U.S.A.

8002-8

STEP 7
The difference between the two readings should be
24 to 27 bar (350 to 390 psi).

STEP 8
If this reading is more or less than specified, it will be
necessary to adjust the pump load-sense pressure.

Adjusting the High Pressure Pump


Differential Pressure
STEP 9
The load-sense adjusting screw is directly below the
load-sense pressure tap. Turn the screw clockwise to
increase the load-sense pressure. Turning the screw
counterclockwise will decrease the load-sense
pressure.
NOTE: One turn of the adjustment screw will change
the pressure approximately 16 bar (230 psi).

Bur 5-3270

Issued 8-06

Printed in U.S.A.

8002-9

TESTING AND ADJUSTING THE LOW PRESSURE


PUMP DIFFERENTIAL PRESSURE
Pressure Check

STEP 3

STEP 1

BD06G180

1
2
BD00M041

1. ARTICULATION LOCK

Install articulation lock (1).

STEP 2
Make sure that the temperature of the hydraulic oil is
at least 54C to 57C (129F to 135F). The following
is the procedure for heating the hydraulic oil.

A. Press the up or down arrow key.


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

BD06F148

To measure the oil temperature with the instrument


cluster:

To heat the hydraulic oil do the following:


A. Start the engine and run at full throttle.
B. Hold the bucket control lever in the
RO L L B AC K p o s i t i o n w h i l e ra i s i n g a n d
lowering the lift arms from ground level to full
height.
C. Continue this procedure until the temperature
of the hydraulic oil is 54 to 57C (129 to
135F).

After heating oil to operating temperature, lower


bucket to the ground, turn off the engine, and relieve
all pressure in the hydraulic system.

1. TEST PORT (LOAD SENSE)


2. TEST PORT (PUMP PRESSURE)

Connect two 69 bar (1000 psi) test gauges, one to


the test port (2) located on the priority valve, and one
on the pump load-sense pressure tap (1 furthest
from the transmission).
IMPORTANT: Do not steer of operate loader controls
while the gauges are connected, gauges could be
damaged.

STEP 4
Start the engine and run at low idle.

STEP 5
Make sure all of the controls are in the neutral
position and record the readings on the test gauges
(1) and (2).

STEP 6
Subtract the reading of the test port (1) from the
reading of the test port (2).

Bur 5-3270

Issued 8-06

Printed in U.S.A.

8002-10

STEP 7
The difference between the two readings should be
25 to 28 bar (360 to 400 psi).

STEP 8
If this reading is more or less than specified, it will be
necessary to adjust the pump differential pressure.

Adjusting the Low Pressure Pump


Differential Pressure
STEP 9
The differential adjusting screw is directly below the
load-sense pressure tap. Turn the screw clockwise to
increase the load-sense pressure. Turning the screw
counterclockwise will decrease the differential
pressure.
NOTE: One turn of the adjustment screw will change
the pressure approximately 16 bar (230 psi).

Bur 5-3270

Issued 8-06

Printed in U.S.A.

8002-11

TESTING AND ADJUSTING THE LOADER LIMIT PRESSURE


Pressure Check

STEP 3

STEP 1

Make sure that the temperature of the hydraulic oil is


at least 54C to 57C (129F to 135F). The following
is the procedure for heating the hydraulic oil.

To measure the oil temperature with the instrument


cluster:
A. Press the up or down arrow key.
B. Stop at the info screen with the temperatures
that need to be monitored are on.

To heat the hydraulic oil do the following:


A. Start the engine and run at full throttle.

1
BD00M041

1. ARTICULATION LOCK

B. Hold the bucket control lever in the


RO L L B AC K p o s i t i o n w h i l e r a i s i n g a n d
lowering the lift arms from ground level to full
height.
C. Continue this procedure until the temperature
of the hydraulic oil is 54 to 57C (129 to
135F).

Install articulation lock (1).

STEP 2

After heating oil to operating temperature, lower


bucket to the ground, turn off the engine, and relieve
all pressure in the hydraulic system.

STEP 4

Run the engine at full throttle.

STEP 5
Roll the loader bucket back against the stops.

STEP 6
Record the reading on the test gauge.
BD06F148

1. TEST PORT (LOAD LIMIT)

STEP 7
Reading should be 248 to 255 bar (3600 to 3700 psi).

Connect a 345 bar (5000 psi) test gauge to the test


port (1), located on the priority valve.

STEP 8
If this reading is more or less than specified, it will be
necessary to adjust the pump limit pressure.

Bur 5-3270

Issued 8-06

Printed in U.S.A.

8002-12

Adjusting the Loader Limit


Pressure

STEP 9
The limit adjusting screw is located on the left side of
the loader valve. Tur n the screw clockwise to
increase the limit pressure. Turning the screw
counterclockwise will decrease the limit pressure.
NOTE: One turn of the adjustment screw will change
the pressure approximately 35 bar (500 psi).

BD06H193

Bur 5-3270

Issued 8-06

Printed in U.S.A.

8002-13

TESTING AND ADJUSTING THE STEERING LIMIT PRESSURE


Pressure Check

STEP 3

STEP 1

Make sure that the temperature of the hydraulic oil is


at least 54C to 57C (129F to 135F). The following
is the procedure for heating the hydraulic oil.

To measure the oil temperature with the instrument


cluster:
A. Press the up or down arrow key.
B. Stop at the info screen with the temperatures
that need to be monitored are on.

To heat the hydraulic oil do the following:


A. Start the engine and run at full throttle.

1
BD00M041

1. ARTICULATION LOCK

B. Hold the bucket control lever in the


RO L L B AC K p o s i t i o n w h i l e r a i s i n g a n d
lowering the lift arms from ground level to full
height.
C. Continue this procedure until the temperature
of the hydraulic oil is 54 to 57C (129 to
135F).

Install articulation lock (1).

STEP 2

After heating oil to operating temperature, lower


bucket to the ground, turn off the engine, and relieve
all pressure in the hydraulic system.

STEP 4

Start the engine and run at full throttle.

STEP 5
Steer hard in either direction over relief pressure.

STEP 6
Record the reading on the test gauge.
BD06F148

1. TEST PORT (LOAD LIMIT)

STEP 7
Reading should be 239 to 243 bar (3465 to 3525 psi).

Connect a 345 bar (5000 psi) test gauge to the test


port (1), located on the priority valve.

STEP 8
If this reading is more or less than specified, it will be
necessary to adjust the steering limit pressure.

Bur 5-3270

Issued 8-06

Printed in U.S.A.

8002-14

Adjusting the Steering Limit


Pressure

STEP 9
The steering priority valve is located on the hydraulic
p u m p, t h e a d j u s t i n g va l ve i s l o c a t e d o n t h e
transmission side of the priority valve. Turning the
screw clockwise to increase the limit pressure.
Turning the screw counterclockwise will decrease the
limit pressure.

BD06F147

1. STEERING LIMIT VALVE

Bur 5-3270

Issued 8-06

Printed in U.S.A.

8002-15

TESTING AND ADJUSTING THE LOADER PUMP CUTOFF PRESSURE


Pressure Check

STEP 3

STEP 1

Make sure that the temperature of the hydraulic oil is


at least 54C to 57C (129F to 135F). The following
is the procedure for heating the hydraulic oil.

To measure the oil temperature with the instrument


cluster:
A. Press the up or down arrow key.
B. Stop at the info screen with the temperatures
that need to be monitored are on.

To heat the hydraulic oil do the following:


A. Start the engine and run at full throttle.

1
BD00M041

1. ARTICULATION LOCK

B. Hold the bucket control lever in the


RO L L B AC K p o s i t i o n w h i l e r a i s i n g a n d
lowering the lift arms from ground level to full
height.
C. Continue this procedure until the temperature
of the hydraulic oil is 54 to 57C (129 to
135F).

Install articulation lock (1).

STEP 2

After heating oil to operating temperature, lower


bucket to the ground, turn off the engine, and relieve
all pressure in the hydraulic system.

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

1. TEST PORT (PUMP PRESSURE)

STEP 7
Reading should be 198 to 202 bar (2870 to 2930 psi).

Connect two 345 bar (5000 psi) test gauge to the test
port (1) located on the large hydraulic tube on the
bottom of the pump.

Bur 5-3270

STEP 8
If this reading is more or less than specified, it will be
necessary to adjust the pump cutoff pressure.

Issued 8-06

Printed in U.S.A.

8002-16

Adjusting the Loader Pump Cutoff


Pressure
STEP 9

BD06G179

The unloading adjuster is the longer of the two


adjusters on the loader pump. Tur n the screw
clockwise to increase the cutoff pressure. Turning the
screw counterclockwise will decrease the cutoff
pressure.
NOTE: The adjusting screw is located just above the
steering priority valve on the pump furthest from the
transmission.

Bur 5-3270

Issued 8-06

Printed in U.S.A.

8002-17

TESTING THE HYDAULIC CONTROLLER PILOT SUPPLY PRESSURE


NOTE: This pressure is factory preset and is not
adjustable.

Pressure Check

STEP 6
Open the right side compartment to gain access to
the loader control handle.

STEP 7
STEP 1
Make sure that the temperature of the hydraulic oil is
at least 54C to 57C (129F to 135F). The following
is the procedure for heating the hydraulic oil.

To measure the
instrument cluster:

oil

temperature

with

the

A. Press the up or down arrow key.


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

To heat the hydraulic oil do the following:

Attach a gauge capable of reading 70 bar (1000 psi)


to the test port under loader control handle.

STEP 8
Start and run the machine at low idle, hold the bucket
control lever in the ROLLBACK position to increase
the system pressure.

STEP 9
A pressure reading of 29.5 to 39.5 bar (425 to 575
psi) should be obtained, if pressure is not as
specified do the following steps.

A. Start the engine and run at full throttle.


B. Hold the bucket control lever in the
RO L L B AC K p o s i t i o n w h i l e ra i s i n g a n d
lowering the lift arms from ground level to full
height.
C. Continue this procedure until the temperature
of the hydraulic oil is 54 to 57C (129 to
135F).

STEP 2
Raise lift arms to the top and turn off the engine. Turn
the ignition switch to the RUN position.

STEP 3
Repeatedly put the loader control lever into FLOAT
position and back to neutral.

STEP 4
The system should allow a minimum of 10 actuations
into float and still cause the lift arms to come down.
NOTE: If 10 full actuations cannot be made, an
internal hydraulic leak exists, proceed to next step.

STEP 10
Lower the bucket to the ground and turn off the
engine. Tur n the ignition switch to the RUN
position.

STEP 11
Operate the pilot controls several times until the
gauge pressure suddenly drops to zero. The last
pressure reading before the drop to zero is the
nitrogen charge pressure in the accumulator. If the
pressure is below 13 to 15 bar (188 to 218 psi),
replace the accumulator. If accumulator test is good,
go to next step.

STEP 12
Replace the pilot controls, see section 8001, retest
the system, if test fails go to next step.

STEP 13
Replace the loader control valve, see section 8001,
retest the system.

STEP 5
Start machine and lower the bucket to the ground
and turn off the engine. Turn the ignition switch to the
RUN position, operate the pilots controls a
minimum of 30 strokes to relieve any pressure in the
system.

Bur 5-3270

Issued 8-06

Printed in U.S.A.

8002-18

HIGH PRESSURE PUMP FLOW TEST


NOTE: The pump differential pressure must be set
before attempting any other tests. Refer to page 7 of
this section.

STEP 1
Connect the flow meter (3) by disconnecting the inlet
hose (6) to the valve supply tube (13), installing a cap
(12) on the fitting at the valve supply tube (13). Refer
to illustration on page 19.

STEP 6
Using the temperature gauge on the flow meter,
continue to run the engine at high idle until the
temperature of the hydraulic oil is at least 52C to
60C (125F to 140F).

STEP 7
Run the engine at low idle, fully open the flow meter
valve.

STEP 2

STEP 8

Disconnect the load sense hose (7) and install a cap


(12) the fitting at the loader valve (15).

Open the needle valve (8) and operate the engine at


2000 rpm. At 0 bar (0 psi) the flow should be 250 to
255 L/min (66 to 67.4 gpm).

NOTE: This is the line that returns to the pump


compensator valve.

STEP 9
STEP 3
Connect a T fitting (10) into the loader control valve
inlet hose (6) and to the flow meter inlet hose (11).

Close the flow meter valve slowly and read the flow
at 34.5 bar (500 psi) the flow should be 249 to 255
L/min (65.8 to 66.8 gpm).

STEP 4

STEP 10

Use a union (9) and connect an in line needle valve


(8) to the open port in the T fitting (10), connect the
load sense hose (7) to the needle valve (8).

Close the flow meter valve slowly and read the flow
at 2000 psi @ 2000 rpm. The flow should read 244.5
to 247.5 L/min (64.6 to 65.4 gpm).

STEP 5

STEP 11

Make sure that the flow meter valve and the installed
needle valve are in the open position. Start and run
the engine at high idle, slowly close the flow meter
valve until a pressure reading of 103 bar (1500 psi) is
obtained.

Continue to close the flow meter valve slowly, at


approximately 2900 psi the flow should drop
significantly, this will be the low pressure pump
destroking.

STEP 12
Continue slowly closing the flow meter valve until
3500 psi is reached. The flow should read between
120 to 122 L/min (31.6 and 32.1 gpm).

STEP 13
If any of the pump flow readings are not within
specifications, the pump may be out of calibration
a n d Te c h n i c a l S u p p o r t S e r v i c e s s h o u l d b e
contacted.

Bur 5-3270

Issued 8-06

Printed in U.S.A.

8002-19

3
5
6
11
12

13

7
10
9
12
8

14
15

BS06G117

1. HYDRAULIC RETURN MANIFOLD 6. HOSE M42 ORB


11. FLOW METER INLET HOSE
2. FLOW METER RETURN HOSE
7. LOAD SENSE HOSE M14 ORB
12. CAP
3. FLOW METER
8. NEEDLE VALVE
13. VALVE TUBE SUPPLY
4. PUMPS
9. UNION
14. ELBOW M14 ORB
5. PRIORITY VALVE
10. T FITTING
15. LOADER VALVE
NOTE: IF UNIT IS EQUIPPED WITH AUXILIARY STEERING A TEE FITTING WILL HAVE TO BE USED IN THIS LOCATION

Bur 5-3270

Issued 8-06

Printed in U.S.A.

8002-20

TESTING AND ADJUSTING THE CIRCUIT RELIEF VALVES


Pressure Check

STEP 4

STEP 1

Remove the safety strut and lower the bucket to the


floor. Shut off the engine. Find an easy place to
disconnect the line for the circuit to be tested.

Circuit relief valves are located as shown below.

STEP 5

4
1

Connect the hand pump to the disconnected line that


goes to the loader control valve.

STEP 6
Make sure that the hand pump is full of hydraulic oil
and that the temperature of the oil is approximately
21C (70F).

STEP 7
Operate the handle of the hand pump and read the
highest pressure. Repeat this step several times to
be sure of the reading.

STEP 8
Compare the reading to the specifications on Page 3.

STEP 9
1

If the pressure is not correct, adjust the circuit relief


valve.

1
3

Adjustment

BS03B022

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

CIRCUIT RELIEF VALVES


PUMP LIMIT PRESSURE ADJUSTMENT
BUCKET SPOOL
LIFT SPOOL
AUXILIARY SPOOL
LOADER CONTROL VALVE

STEP 2
Raise the lift arms and install the safety link on the lift
arm cylinder.

STEP 3

STEP 1
Loosen the lock nut. Turn the adjustment screw
clockwise to increase the pressure or
counterclockwise to decrease the pressure.
NOTE: One turn of the adjusting screw will change
the pressure approximately 138 bar (2000 psi).

STEP 2
Check the pressure again. Repeat the adjustment as
necessary.

Loosen and remove the bolts and washers that


fasten the access cover plate for the loader control
valve. Remove the cover plate.

Bur 5-3270

Issued 8-06

Printed in U.S.A.

8002-21

TESTING THE RIDE CONTROL


STEP 1

STEP 6

Move the machine to a clear level surface with


clearance for full lift arm and bucket movement.

Dump the bucket until it hits the dump stops. Hold the
bucket in the dump position for 5 to 10 seconds.

STEP 2
Install the ar ticulation lock, star t the machine,
activate the parking brake.

STEP 3
With the pilot controller in neutral, set the ride control
rocker switch on the right side console to the Always
On position and observe the switch lamp, the lamp
should illuminate.

STEP 4
Set the ride control rocker switch to the Off position
and observe the switch lamp, the lamp should go out.
NOTE: This indicates that the switch is operating
correctly and has power, if the switch does not
illuminate see section 4002 and troubleshoot the
electrical system for the ride control.

STEP 5
Raise the lift arms to the top of their travel and dump
the bucket.

NOTE: This will charge the ride control accumulator.

STEP 7
Lower the lift arms and roll the bucket back to a carry
position. Do not leave the lift arms or the bucket on
their stops, place the pilot control lever in the neutral
position.

STEP 8
Set the ride control rocker switch to the Always On
position. The lift arms should rise 15 to 30 cm (6 to
12 inches) with an empty bucket.
NOTE: Test results will be for a machine with a
empty factory bucket and no attachments.

STEP 9
If there is little or no lift arm raise, the test may have
been done too slowly. The elapsed time between
step 6 and step 8 should not exceed six seconds.
NOTE: If test was done to slowly repeat in the
allotted time.

STEP 10
If test was completed in the allotted time and the lift
arms still do not rise, test the nitrogen charge in the
accumulator, see section 8013.

Bur 5-3270

Issued 8-06

Printed in U.S.A.

8002-22

HYDRAULIC COMPONENT LOCATIONS


5
6

7
9
4

10

2
3

11
15
14
16
19
18
17

12
13

BC00N140

1. REAR BRAKE CYLINDERS


2. BRAKE ACCUMULATOR PRESSURE DIAGNOSTIC
COUPLER
3. BRAKE ACCUMULATORS
4. FRONT AND REAR AXLE BRAKE PRESSURE
DIAGNOSTIC COUPLERS
5. BRAKE LIGHT PRESSURE SWITCH
6. BRAKE WARNING PRESSURE SWITCH
7. BRAKE AND ACCUMULATOR CHARGING VALVE
8. LIFT CYLINDERS
9. BUCKET CYLINDER (TILT CYLINDER)
10. RIDE CONTROL ACCUMULATOR

11. FRONT BRAKE CYLINDERS


12. RIDE CONTROL ACCUMULATOR BLEEDER VALVE AND
RIDE CONTROL VALVE (OPTIONAL)
13. PARKING BRAKE CYLINDER
14. STEERING PRESSURE DIAGNOSTIC COUPLER
15. STEERING PRIORITY VALVE
16. STEERING CYLINDERS
17. AUXILIARY STEERING PUMP AND MOTOR
18. AUXILIARY STEERING PRIORITY VALVE
19. AUXILIARY STEERING PRESSURE SWITCH

NOTE: The hydraulic schematic is located in the rear pocket. All numbers are coordinated with the hydraulic
schematic for reference.

Bur 5-3270

Issued 8-06

Printed in U.S.A.

8002-23

23
24
21
22

26

25

20

30
31

29

28

27

32
33
34

BC00N140

20.
21.
22.
23.
24.
25.
26.
27.

FAN DRIVE MOTOR


HYDRAULIC RESERVOIR BREATHER
HYDRAULIC RESERVOIR
PILOT PRESSURE DIAGNOSTIC COUPLER
PILOT CONTROL VALVE
PILOT PRESSURE ACCUMULATOR
LOADER CONTROL VALVE
PARKING BRAKE ACCUMULATOR

28.
29.
30.
31.
32.
33.
34.

PUMP PRESSURE DIAGNOSTIC COUPLER


LOAD SENSING DIAGNOSTIC COUPLER
IMPLEMENT HYDRAULIC PUMP
HYDRAULIC FILTER
HYDRAULIC COOLER
BRAKE HYDRAULIC PUMP
FAN VALVE

NOTE: The hydraulic schematic is located in the rear pocket. All numbers are coordinated with the hydraulic
schematic for reference.

Bur 5-3270

Issued 8-06

Printed in U.S.A.

8002-24

NOTES

Bur 5-3270

Issued 8-06

Printed in U.S.A.

8003

Section
8003
CLEANING THE HYDRAULIC SYSTEM

CNH America LLC.


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

Bur 7-49641

Copyright 2003 CNH Ameica LLC.


All rights reserved.
Printed in U.S.A.
Issued April, 2003 Revised August, 2006

8003-2

TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TYPES OF CONTAMINATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLEANING THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FLUSHING WATER FROM THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 7-49641

Revised 8-06

3
4
4
5
7

Printed in U.S.A.

8003-3

SPECIAL TOOLS

806128

CAS10508, fitting kit.

806127

CAS101162A, filter unit, portable.

TR98H032

CAS10192, vacuum pump.

Bur 7-49641

Revised 8-06

Printed in U.S.A.

8003-4

GENERAL INFORMATION
Contamination in the hydraulic system is a major
cause of the malfunction of hydraulic components.
Contamination is any foreign material in the hydraulic
oil. Contamination can enter the hydraulic system in
several ways.
1. When you drain the oil or disconnect any line.

1. Cylinder rod seals leak.


2. Control valve spools do not return to neutral.
3. Movement of control valve spools is difficult.
4. Hydraulic oil becomes too hot.

2. When you disassemble a component.

5. Pump gears, housing, and other parts wear


rapidly.

3. From normal wear of the hydraulic components.

6. Relief valves or check valves held open by dirt.

4. From damaged or worn seals.

7. Quick failure of components that have been


repaired.

5. From a damaged component in the hydraulic


system.
All hydraulic systems operate with some
contamination. The design of the components in this
hydraulic system permits efficient operation with a
small amount of contamination. An increase in this
amount of contamination can cause problems in the
hydraulic system. The following list includes some of
these problems.

8. Cycle times are slow; machine does not have


enough power.
If your machine has any of these problems, check the
hydraulic oil for contamination. See types of
contamination below. If you find contamination, use
the Portable Filter to clean the hydraulic system.

TYPES OF CONTAMINATION
There are two types of contamination, microscopic
and visible.
1. Microscopic contamination occurs when very fine
particles of foreign material are in suspension in
the hydraulic oil.
2. These particles are too small to see or feel.
Microscopic contamination can be found by
identification of the following problems or by
t e s t i n g i n a l a b o r a t o r y. E x a m p l e s o f t h e
problems:

3. Visible contamination is foreign material that can


be found by sight, touch, or odor. Visible
contamination can cause a sudden failure of
components. Examples of visible contamination:
A. Particles of metal or dirt in the oil.
B. Air in the oil
C. The oil is dark and thick.
D. The oil has an odor of burned oil.
E. Water in the oil. See page 7.

A. Cylinder rod seal leak.


B. Control valve
NEUTRAL.

spools

do

not

return

to

C. The hydraulic system has a high operating


temperature.

Bur 7-49641

Revised 8-06

Printed in U.S.A.

8003-5

CLEANING THE HYDRAULIC SYSTEM


1. Prepare the portable filter on page 3 by doing the
following steps:
A. Remove all the hydraulic oil from the inlet and
outlet hoses for the portable filter.
B. Remove the filter element from the portable
filter.
C. Remove all hydraulic oil from the portable
filter.
D. Clean the inside of the housing for the filter
element.
2. You must know whether the contamination is
microscopic or visible. See types of
contamination on page 4.
3. If the contamination is microscopic:
A. Check the maintenance schedule for the
machine to learn if the hydraulic oil must be
changed. If needed, change the hydraulic oil.
See Section 1002 for specifications. Change
the hydraulic filter.
B. Do steps 6 through 35.
4. If the contamination is visible:

8. Using the fitting kit shown on page 3, install the


valve in the hole for the drain plug. Make sure
that the valve is closed.
9. Stop the vacuum pump.
10. Connect the inlet hose for the portable filter to
the valve that is installed in the hole for the drain
plug.
11. Disconnect the vacuum pump from the hydraulic
reservoir air breather hose. Remove the filler
cap.
12. Install the outlet hose for the portable filter in the
hydraulic reservoir filler neck.
13. Open the valve that is installed in the hole for the
drain plug.
14. Move the switch for the portable filter to the ON
position. Start and run the engine at 1500 rpm
(r/min).
15. Run the portable filter for 10 minutes.
16. Continue to run the portable filter. Increase the
engine speed to full throttle. Heat the oil to
operating temperature by doing the following
steps:

A. Change the hydraulic oil and hydraulic filter.


See Section 1002 for specifications.

A. Hold the blade control lever in the TILT


position for five seconds.

B. Do steps 5 through 35.

B. Return the blade control lever


NEUTRAL position for five seconds.

5. Check the amount of contamination in the


hydraulic system by doing the following steps:
A. Disassemble one cylinder in two different
circuits. Check for damage to seals, scoring of
the cylinder wall, etc. Repair the cylinders as
necessary.
B. If, in your judgment, the damage to the
cylinders was caused by sever contamination
and is not the result of normal wear, it is
necessary to remove, clean and repair valves,
pump, lines, cylinders, hydraulic reservoir, etc.
in the hydraulic system.
6. Remove the breather from the reservoir and
connect the vacuum pump to the opening. Start
the vacuum pump.
7. Loosen and remove the drain plug from the
reservoir.

Bur 7-49641

in

the

C. Repeat steps A and B until the oil in the


hydraulic system is at operating temperature.
17. Continue to run the engine at full throttle.
Continue to run the portable filter.
18. Operate each hydraulic circuit to completely
extend and retract the cylinders. Continue to
operate each hydraulic circuit two times, one
after the other for 45 minutes.
19. Decrease the engine speed to low idle.
20. Continue to run the portable filter for 10 minutes.
21. Stop the portable filter.
22. Stop the engine.
23. Remove the hose from the hydraulic reservoir.

Revised 8-06

Printed in U.S.A.

8003-6
24. Close the valve that is installed in the hole for the
drain plug.
25. Disconnect the inlet hose for the portable filter
from the valve. Remove the outlet hose from the
reservoir filler neck and replace filler cap.

30. Stop the vacuum pump. Disconnect the vacuum


pump from the opening in the reservoir and
install the breather.
31. Remove the hydraulic filter elements from the
machine.

26. Connect a vacuum pump to the breather hose of


the hydraulic reservoir.

32. Install new hydraulic filter elements on the


machine.

27. Start the vacuum pump.

33. Start the engine. Check for oil leakage around


the new hydraulic filters.

28. Remove the valve from the hole for the drain
plug.
29. Install the drain plug.

Bur 7-49641

34. Stop the engine.


35. Check the oil level in the hydraulic reservoir. Add
o i l a s r e q u i r e d . S e e S e c t i o n 1 0 0 2 fo r
specifications.

Revised 8-06

Printed in U.S.A.

8003-7

FLUSHING WATER FROM THE HYDRAULIC SYSTEM


1. Start and run the engine at 1500 rpm (r/min).
2. Completely retract the cylinders of all
attachments on the machine. Angle the blade to
the right, the right cylinder will be fully retracted
and the left will be fully extended. Stop the
engine.
WARNING: If retracting the cylinder rods
causes the attachments to be raised, block
the attachments in place before proceeding
to the next step!
39-4

13. Slowly move each control lever in both directions


until oil begins to flow from the open line. Hold
the control lever in place until clean oil flows from
the open line.
14. Stop the engine.
15. Connect the system line to the CLOSED end of
each cylinder.
16. Connect a suitable drain line to the OPEN end of
each cylinder and place the other end in an
acceptable container for contaminated oil.
17. Start the engine and run the engine at low idle.

NOTE: Any attachment or part of an attachment that


is raised must be supported with acceptable
equipment to prevent the attachment from falling.

18. Slowly and completely extend all cylinders. As


the piston rod comes in/out of the cylinder, oil will
be pushed out of the OPEN end of the cylinders.

3. Move each control lever in both directions to


release pressure in the hydraulic circuits.

NOTE: Any attachment or part of an attachment that


is raised must be supported with acceptable
equipment to prevent the attachment from falling.

4. Loosen and remove the filler cap from the


reservoir.
5. Drain the hydraulic oil from the reservoir.

19. Support any attachments that will be in the


RAISED position.

A. See Section 1002 for capacity specifications.

20. Stop the engine.

B. Have available acceptable equipment to drain


the hydraulic oil.

21. Disconnect the drain lines and connect the


system lines to the cylinders.

C. Remove the drain plug from the bottom of the


reservoir.

22. Check the oil level in the hydraulic reservoir. Add


o i l a s r e q u i r e d . S e e S e c t i o n 1 0 0 2 fo r
specifications.

6. Remove the hydraulic filter elements from the


machine.

23. Install the filler cap on the reservoir.

7. Install new hydraulic filter elements on the


machine.

24. Remove the hydraulic filter elements from the


machine.

8. Install the drain plug in the bottom of the


reservoir.

25. Install new hydraulic filter elements on the


machine.

9. Fill the hydraulic reservoir with hydraulic fluid.


See Section 1002 for specifications.

26. Start and run the engine at 1500 rpm (r/min),


operate each hydraulic circuit to completely
extend and retract the cylinders.

10. Disconnect the line from the OPEN end and


CLOSED end of each cylinder.
11. Be sure all control levers are in the NEUTRAL
position.

27. Stop the engine and check for leaks. Check the
oil level in the hydraulic reservoir. Add oil as
required. See Section 1002 for specifications.

12. Start and run the engine at low idle.


IMPORTANT: Check the oil level in the hydraulic
reservoir frequently while doing step 13. Have
another person hold a container under the hydraulic
lines while you do step 13.

Bur 7-49641

Revised 8-06

Printed in U.S.A.

8003-8

NOTES

Bur 7-49641

Revised 8-06

Printed in U.S.A.

8004

Section
8004
HYDRAULIC PUMP

CNH America LLC.


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

Bur 5-2970

Copyright 2006 CNH America LLC.


All rights reserved.
Printed in U.S.A.
Issued August, 2006

8004-2

TABLE OF CONTENTS
PUMP SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PREPARING THE EQUIPMENT PUMP FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EQUIPMENT PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 5-2970

Issued 8-06

3
3
4
5
9
11

Printed in U.S.A.

8004-3

PUMP SPECIFICATIONS
Manufacturer................................................................................................................................................... Rexroth
High pressure pump (steering pump next to transmission) ............. 120 L/min at 20 680 kPa, 170 bar, at 2000 r/min
(31.6 U.S. gpm at 2500 psi at 2000rpm)
Low pressure pump (loader pump farthermost from transmission) ... 86 L/min at 20 680 kPa, 170 bar, at 2000 r/min
(22.5 U.S. gpm at 2500 psi at 2000rpm)
Rotation ................................................................................................. Clockwise as seen from the end of the shaft
Special torques
Pump end cover bolts...................................................................................................165 Nm (121.5 pound-feet)
Pump housing plug ........................................................................................................127 Nm (93.5 pound-feet)
Control piston plug ..............................................................................................................90 Nm (66 pound-feet)

PREPARING THE EQUIPMENT PUMP FOR USE


Do the following procedure any time you install a new
or overhauled equipment pump:
1. Start and run the engine at half throttle for three
minutes.
2. With the engine running at half throttle, move the
bucket control lever into roll back position. Hold
the bucket control lever in this position until the
bucket stops moving.

4. Repeat Step 3 for three minutes.


5. Increase the engine speed to full throttle and
repeat Steps 3 and 4.
6. Stop the engine and check for leaks.
7. Replace the hydraulic filter.

3. Hold the bucket control lever in the roll back


position for five seconds. Then put the bucket
control lever in the NEUTRAL position for five
seconds.

Bur 5-2970

Issued 8-06

Printed in U.S.A.

8004-4

EQUIPMENT PUMP
7

6
4

5
4
3

10
1

11
12
13
21

22

23

24

20
19
18
14

17

15

16

30
29
15
26

27

28

25

BC06F550

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Bur 5-2970

SNAP RING
SEAL
MAIN BODY
O-RING
PLUG
CONTROL VALVE
CAP SCREW
PISTON ROD
CONTROL PISTON
SHAFT

11.
12.
13.
14.
15.
16.
17.
18.
19.
20.

TAPERED BEARING
BEARING RACE
SHIM
SPRING
HALF BEARING
SWASH PLATE
PISTONS
RETAINING PLATE
BALL
CYLINDER

21.
22.
23.
24.
25.
26.
27.
28.
29.
30.

PRESSURE PINS
BACKUP PLATE
SPRING
SNAP RING
PORT PLATE
SHIM
TAPERED BEARING
BEARING RACE
DOWEL PIN
END COVER

Issued 8-06

Printed in U.S.A.

8004-5

Disassembly

STEP 3

STEP 1
Remove all dirt, oil, and grease from the exterior of
the equipment pump.

STEP 2

BC06F552

Remove the control valve.

STEP 4

BC06F551

Put alignment marks on the end cover and housing.

BC06F553

Remove the four bolts.

Bur 5-2970

Issued 8-06

Printed in U.S.A.

8004-6

STEP 5

STEP 6

BC06F555

BC06F554

Remove the end cover.


NOTE: Watch for the flow plate, it can be stuck to
either the end cover or pump body.

Bur 5-2970

Use a suitable bearing race puller and pull the


bearing race from the end cover.
NOTE: Do not damage the sealing surfaces.

Issued 8-06

Printed in U.S.A.

8004-7

STEP 7

STEP 9

BC06F558

Remove plug, pull control piston using a suitable tool


as shown.
NOTE: Do not use a magnet to pull the piston.

STEP 10
BC06F556

Remove the bearing and shim.

STEP 8

BC06F559

Remove the piston rod and swash plate. Turn the


swash plate slightly to break it free from the bearings.
BC06F557

Remove the rotary group from the housing in a


horizontal position.

Bur 5-2970

Issued 8-06

Printed in U.S.A.

8004-8

STEP 11

STEP 14

BC06F560

Remove the bearing and spring.

STEP 12
BC06F563

Use a suitable bearing race puller and pull the


bearing race from the housing.

STEP 15

BC06F561

Remove the shaft and bearing.

STEP 13

BC06F564

Remove the shim and plug.

BC06F562

Remove the retaining ring an seal.

Bur 5-2970

Issued 8-06

Printed in U.S.A.

8004-9

Inspection

STEP 19

STEP 16
Clean all parts in cleaning solvent. Be careful not to
remove the alignment mar ks made dur ing
disassembly.

STEP 17

BC06F567

Check the bearing surface.

STEP 20

BC06F565

Check for wear on the splines, seal areas for


grooves, bearing areas for scaring, and key set.

STEP 18

BC06F568

Check that the retaining plate is free of grooves and


that there is no sign of wear.

STEP 21

BC06F566

Check the surface that the pistons contact for


grooves and scaring.

BC06F569

Check the sliding surface for scratches or metal


deposits, check the tightness of the cup on the
piston.
NOTE: If a piston needs to be replaced, all of the
pistons must be replaced.

Bur 5-2970

Issued 8-06

Printed in U.S.A.

8004-10

STEP 22

STEP 24

BC06F570

Check the cylinder bores and splines for damage.

STEP 23

BC06F572

Check cylinder surface for grooves, wear, embedded


particles. Check flow plate for scratches or wear.

STEP 25

BC06F571

Check ball for grooves and wear.

Bur 5-2970

BC06F573

Check mounting surface for the flow plate for


damage.

Issued 8-06

Printed in U.S.A.

8004-11

Assembly

STEP 27

STEP 26

BC06F575

BC06F574

Install the plug in the housing and tighten to 127 Nm


(93.5 pound-feet). Install shim and press in the
bearing race.

Put the shaft and bearing in the housing.

STEP 28

BC06F576

Press in a new race into the end cover.

Bur 5-2970

Issued 8-06

Printed in U.S.A.

8004-12

STEP 29

STEP 31

BC06F579

Install the seal and retaining ring.

STEP 32
BC06F577

Install the end cover, 4 bolts and hand tighten.

STEP 30

BC06F578

A bearing pre load of 0.05 mm (0.002 inch) must be


obtained, add remove shims from bear ing as
required.

BC06F580

Put new bearings in the housing. Install the reaction


spring.

Bur 5-2970

Issued 8-06

Printed in U.S.A.

8004-13

STEP 33

STEP 34

BC06F582

Install the piston into the housing with flat surface


out. Lubricate the O-ring and install the plug, tighten
the plug to 90 Nm (66 pound-feet).

STEP 35

BC06F581

Install the swash plate into the housing, work the


swash plate from side to side to seat it in the
bearings and spring. Install the piston rod.

BC06F583

Use grease to hold the pressure pins into position,


install the spacer, spring and snap ring.

Bur 5-2970

Issued 8-06

Printed in U.S.A.

8004-14

STEP 36

STEP 39

BC06F584

Use a suitable compressor, compress the spring and


install the snap ring.

STEP 37

BC06F585

BC06F587

Place the ball onto the pressure pins, install the


pistons into the retaining plate.

Hold the pistons in the rotating housing using an


O-ring, install the rotating group into the housing,
remove the O-ring.

STEP 38

BC06F586

Lubricate the piston and retaining plate with clean oil,


install the piston into the rotating housing.

Bur 5-2970

Issued 8-06

Printed in U.S.A.

8004-15

STEP 40

STEP 41

BC06F588

Use the shim that was required for the bearing pre
load in step 30. Install the shim and bearing onto the
shaft.

BC06F589

Install a new O-ring on the end cover, place the flow


plate onto the rotating group with aligning notch up.
Place the end cover onto the housing, make sure that
the aligning pin in the end cover aligns with the slot in
the flow plate.

Bur 5-2970

Issued 8-06

Printed in U.S.A.

8004-16

STEP 42

STEP 43

BC06F591

Use new O-rings, install and tighten the control valve.

BC06F590

Instal and tighten the four bolts to 165 Nm


(121.5 pound-feet).

Bur 5-2970

Issued 8-06

Printed in U.S.A.

Section
8005

8005

LOADER CONTROL VALVE

CNH America LLC.


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

Bur 5-2980

Copyright 2006 CNH Ameica LLC.


All rights reserved.
Printed in U.S.A.
Issued August, 2006

8005-2

TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Spool Valve Housing Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Spool Valve Spool Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Spool Mounting Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Spool Mounting Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 and 4 Spool Valve Spool Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISSASEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Relief Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Relief Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 5-2980

Issued 8-06

3
4
5
6
7
8
9
14
14
18
18

Printed in U.S.A.

8005-3

SPECIFICATIONS
Manufacturer................................................................................................................................................... Rexroth
Special Torques
End plate mounting bolts.................................................................................................. 70 Nm (51.5 pound feet)
Pressure relief, flow limit, and pilot pressure reducing valves .................. 20 to 25 Nm (177 to 221 pound inches)
Allen head plugs.............................................................................................................. 240 Nm (177 pound feet)
Allen head locking screw................................................................................................ 100 Nm (73.7 pound feet)
Allen head cover screws (short) .................................................................................. 10.4 Nm (92 pound inches)
Allen head cover screws (long) ........................................................................................ 6 Nm (53 pound inches)
Anticavitation valves ....................................................................................................... 100 Nm (73.7 pound feet)
Combination anticavitation and circuit relief ................................................................. 200 Nm (147.5 pound feet)
Main relief valve pressure settings (XT and Z-Bar) ............................................... 248 to 252 bar (3596 to 3654 psi)
Circuit relief valve pressure setting
Auxiliary A and B port (XT and Z-Bar) .......................................................................................290 bar (4206 psi)
Bucket A port (XT and Z-Bar) ....................................................................................................152 bar (2205 psi)
Bucket B port (XT and Z-Bar) ....................................................................................................290 bar (4206 psi)

Bur 5-2980

Issued 8-06

Printed in U.S.A.

8005-4

1
2
4
3
5
22
6
6

21

20
19

8
18

17

16

10
11

6
15

14
8
12

12

13

BS03C033

1. BOLT
2. WASHER
3. LOCKING SCREWS
4. PLATE
5. REGENERATION
RELIEF VALVE
6. O-RINGS

7. LOAD SENSE SHUTTLE CHECK


8. ANTICAVITATION AND CIRCUIT
RELIEF

13. FLOAT SOLENOID

18. LOAD CHECK

14. PLUG

19. FLOW LIMIT VALVE

10. FLOW COMPENSATOR SPOOL

15. REGENERATION CHECK


VALVE
16. LOCKING SCREW

21. CONE

11. HOUSING

17. SPRING

22. LOCKING SCREW

9. LOAD SENSE BLEED DOWN ORIFICE

20. PRESSURE RELIEF VALVE

12. PLUG
2 SPOOL VALVE HOUSING CONFIGURATION

Bur 5-2980

Issued 8-06

Printed in U.S.A.

8005-5

26

27

25
24
23
28

6
31

29
30

6
6
33
31

34
6
34

24

33 32

24

23
23
35

30

32

29
BC06F593

6.
23.
24.
25.
26.

O-RINGS
SPRING RETAINER
SPRING
SPRING
COVER

27.
28.
29.
30.
31.

BOLT
PISTON
CAP NUT
JAM NUT
PISTON

32.
33.
34.
35.

BOLT
COVER
ADJUSTING ROD
SPOOL

2 SPOOL VALVE SPOOL CONFIGURATION

Bur 5-2980

Issued 8-06

Printed in U.S.A.

8005-6

37

36

37
BS03C036

36. HOUSING

37. ANTICAVITATION AND CIRCUIT RELIEF


3 SPOOL MOUNTING CONFIGURATION

Bur 5-2980

Issued 8-06

Printed in U.S.A.

8005-7

38
39

BS03C035

38. NUT

39. STUD

4 SPOOL MOUNTING CONFIGURATION

Bur 5-2980

Issued 8-06

Printed in U.S.A.

8005-8

31

29

30
33
6

34

23
24
32

23

35

33
31

23
24

6
34

29

32

30

BS03C037

3 AND 4 SPOOL VALVE SPOOL CONFIGURATION


6.
23.
24.
29.
30.

Bur 5-2980

O-RINGS
SPRING RETAINER
SPRING
CAP NUT
JAM NUT

31.
32.
33.
34.
35.

PISTON
BOLT
COVER
ADJUSTING ROD
SPOOL

Issued 8-06

Printed in U.S.A.

8005-9

DISSASEMBLY
STEP 1

STEP 7

Remove valve from machine, see section 8001.

Remove pressure relief valve (20).

STEP 2

STEP 8

Remove bolts (27), cover (26), springs (24 and 25),


and spring retainer (23).

Remove flow limit valve (19).

STEP 9
STEP 3
Remove bolts (32), covers (33), spring (24), and
spring retainer (23).

Remove locking screw (16), spring (17), and cone


(18).

STEP 10
STEP 4

Remove regeneration check valve (15).

Use wooden dowel or brass drift and push spools


(35) from housing (11).

STEP 11

IMPORTANT: Do not force spools from housing, if


spool binds work back and forth until spool comes
out freely.

Remove locking screw (14).

NOTE: Repeat steps 3 and 4 for a 3 and 4 spool


valve configuration.

Remove load sense shuttle check valve (7).

STEP 5

Remove locking screws (12).

Remove anticavitation valves (5, 8, 10, and 13).


NOTE: Repeat step for a 3 and 4 spool anticavitation
valves (37).

STEP 6
Remove locking screw (22) and cone (21).

STEP 12
STEP 13
STEP 14
Remove pilot pressure reducing valve (9).

STEP 15
Remove bolts (1) and washers (2), remove plate (4)
from housing (11).
NOTE: For 4 spool configuration remove nut (38)
from stud (39), remove housings (36) from housing
(11).

Bur 5-2980

Issued 8-06

Printed in U.S.A.

8005-10

STEP 16

STEP 18
2
1
2

BS03C025

BS03C027

Remove and discard O-rings and thrust rings from


pilot pressure reducing valve (9).

Remove and discard O-rings and thrust ring from


locking screw (14).

1. O-RINGS

2. THRUST RINGS

1. O-RINGS

2. THRUST RING

STEP 17
STEP 19

1
2

1
1

BS03C026

1. O-RINGS

2. THRUST RINGS

Remove and discard O-rings and thrust rings from


flow limit valve (19).

Bur 5-2980

BS03C028

1. O-RINGS

2. THRUST RING

3. SPOOL SEAL

Remove and discard O-rings, thrust ring, and spool


seal from anticavitation valve (5).

Issued 8-06

Printed in U.S.A.

8005-11

STEP 20

1
2

1
1
2
2
BS03C029

1. O-RINGS

2. THRUST RINGS

Remove and discard O-rings and thrust rings from pressure relief valve (20).

STEP 21
1
1
2
1
2

1
BS03C030

1. O-RINGS

2. THRUST RINGS

Remove and discard O-rings and thrust rings from anticavitation and pressure relief valves (10).

Bur 5-2980

Issued 8-06

Printed in U.S.A.

8005-12

STEP 22
1

2
1

BS03C031

1. O-RINGS

2. COIL

Remove and discard O-rings and thrust rings from anticavitation valve (13).

Bur 5-2980

Issued 8-06

Printed in U.S.A.

8005-13

STEP 23

1
1

BS03C032

1. O-RINGS

2. THRUST RING

3. SPOOL SEAL

4. LOCK NUT

Remove and discard O-rings and thrust rings from anticavitation and circuit relief valves (8 and 37).

Bur 5-2980

Issued 8-06

Printed in U.S.A.

8005-14

INSPECTION
1. Discard all O-rings, thrust rings, and spool seals.
2. Clean all parts in cleaning solvent.
3. Check the spools and the spool bores for
damage and wear.

4. Check the parts of the pressure relief valve,


anticavitation valves, and the anticavitation and
circuit relief valves. Use new parts as necessary.
Inspect the other parts of the control valve. If any of
the parts are damaged, install new parts.

ASSEMBLY
STEP 1

4
A

See Note

BS03C032

1. O-RINGS

2. THRUST RING

3. SPOOL SEAL

4. LOCK NUT

Install new O-rings and thrust rings on anticavitation and circuit relief valves (8 and 37). Torque relief valve (A) into
anticavitation valve to 200 Nm (147.5 pound feet).
NOTE: Spool seal mounting position is critical, seal must be mounted with lip facing as shown above, pressure is in
direction of arrow.

Bur 5-2980

Issued 8-06

Printed in U.S.A.

8005-15

STEP 2
1

2
1

A
1

BS03C031

1. O-RINGS

2. COIL

Install new O-rings and thrust rings on anticavitation valve (13). Hand tighten coil nut (A).

STEP 3
1
1
2
1
2

BS03C030

1. O-RINGS

2. THRUST RINGS

Install new O-rings and thrust rings on anticavitation and pressure relief valves (10). Torque cap (A) to 100 Nm
(73.7 pound feet).

Bur 5-2980

Issued 8-06

Printed in U.S.A.

8005-16

STEP 4

1
2

1
1
2
2
BS03C029

1. O-RINGS

2. THRUST RINGS

Install new O-rings and thrust rings on pressure relief valve (20).

Bur 5-2980

Issued 8-06

Printed in U.S.A.

8005-17

STEP 5

STEP 8
2

1
1

2
BS03C025

BS03C028

Install new O-rings and thrust rings on pilot pressure


reducing valve (9).

Install new O-rings, thrust ring, and spool seal on


anticavitation valve (5).

STEP 6

STEP 9

1. O-RINGS

2. THRUST RINGS

1. O-RINGS

2. THRUST RING

3. SPOOL SEAL

Install and torque regeneration check valve (15) to


100 Nm (73.7 pound feet).

STEP 10
Install and torque locking screw (14) to 100 Nm
(73.7 pound feet).

2
1

STEP 11

Install and tighten load sense shuttle check valve (7).

STEP 12
BS03C026

1. O-RINGS

2. THRUST RINGS

Install and torque locking screws (12) to 240 Nm


(177 pound feet).

Install new O-rings and thrust rings on flow limit valve


(19).

STEP 13

STEP 7

Install and torque pilot pressure reducing valve (9) to


60 Nm (44 pound feet).

STEP 14
1

Install new O-rings on housing (11). Install plate (4),


bolts (1) and washers (2), onto housing (11). Torque
bolts to 70 Nm (51.5 pound feet).

NOTE: For 4 spool configuration install new O-rings


between housings (36) and housing (11), install nuts
(38) on studs (39). Torque nuts to 70 Nm (51.5 pound
feet).

STEP 15
BS03C027

Install anticavitation valves (5, 10, and 13) and torque


to 100 Nm (73.7 pound feet).

Install new O-rings and thrust ring on locking screw


(14).

NOTE: Repeat step for a 3 and 4 spool anticavitation


valves (37).

1. O-RINGS

Bur 5-2980

2. THRUST RING

Issued 8-06

Printed in U.S.A.

8005-18

STEP 16

Circuit Relief Pressure Test

Install anticavitation valves (8) and torque to 200 Nm


(147.5 pound feet).

STEP 1

STEP 17

Connect the hand pump to the port for anticavitation


and circuit relief valves (21).

Install and torque flow limit valve (19) to 20 to 25 Nm


(177 to 221 pound inches).

STEP 18
Install cone (18), spring (17), locking screw (16).
Torque locking screw to 100 Nm (73.7 pound feet).

STEP 19
Install cone (21) and locking screw (22). Torque
locking screw to 40 Nm (30 pound feet).

NOTE: Repeat steps for machines


configured with a 3 or 4 spool valve.

that

are

STEP 2
Make sure that the hand pump is full of hydraulic oil
and that the temperature of the oil is approximately
21C (70F).

STEP 3

STEP 20

Operate the handle of the hand pump and read the


highest pressure. Repeat this step several times to
be sure of the reading.

Lubricate spools with hydraulic oil and push spools


(35) into housing (11).

STEP 4

IMPORTANT: Do not force spools into housing.

Compare the reading to the specifications on Page 3.

STEP 21

STEP 5

Install spring retainers (23), springs (24), covers (33),


and bolts (32). Torque bolts to 10.4 Nm (92 pound
inches).

If the pressure is not correct, adjust the circuit relief


valve.

NOTE: Repeat steps 18 and 19 for a 3 and 4 spool


valve configuration.

Circuit Relief Adjustment


STEP 1

STEP 22
Install spring retainers (23), spring (24 and 25), cover
(26), and bolts (27). Torque bolts to 6 Nm (53 pound
inches).
NOTE: Prior to installation in the machine, circuit
reliefs can be tested.

Loosen the lock nut. Turn the adjustment screw


clockwise to increase the pressure or
counterclockwise to decrease the pressure.
NOTE: One turn of the adjusting screw will change
the pressure approximately 138 bar (2000 psi).

STEP 2
STEP 23
Install valve in machine, see section 8001.

Check the pressure again. Repeat the adjustment as


necessary.

STEP 24
Check loader limit pressure, see section 8002.

Bur 5-2980

Issued 8-06

Printed in U.S.A.

Section
8006

8006

CYLINDERS

CNH America LLC.


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

Bur 5-3280

Copyright 2006 CNH Ameica LLC.


All rights reserved.
Printed in U.S.A.
Issued August, 2006

8006-2

TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUCKET CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACING THE BUSHINGS FOR THE LIFT CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACING BUSHINGS FOR THE BUCKET CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 5-3280

Issued 8-06

3
3
3
4
4
4
6
7
7
7
9
11
11
11
12
12
12

Printed in U.S.A.

8006-3

SPECIFICATIONS
Approximate weight
Lift Cylinder...........................................................................................................................142.2 kg (313.5 pounds)
Bucket Cylinder........................................................................................................................199.2 kg (439 pounds)

SPECIAL TORQUES
Gland Bolts Bucket Cylinder .......................................................................420 to 500 Nm (310 to 368.8 pound-feet)
Screw in Gland for Lift Cylinders ...................................................................135 to 542 Nm (100 to 400 pound-feet)
Piston Bolt for Lift Cylinders................................................................2830 to 3220 Nm (2087 to 2374.9 pound-feet)
Lock Screw for Lift Cylinders ............................................................................................. 2.3 Nm (20 pound-inches)

SPECIAL TOOLS
Torque Multiplier ......................................................................................................................................... CAS-1039

Bur 5-3280

Issued 8-06

Printed in U.S.A.

8006-4

LIFT CYLINDER
Disassembly

Inspection

1. Clean exterior of cylinder. If hoses were removed


with cylinder, remove hoses from cylinder.

1. Clean all parts in cleaning solvent. Use only lint


free cloths for cleaning and drying.

2. Fasten tube (1) in an acceptable repair stand or


other holding equipment. Do not damage tube
(1).

2. Check to be sure that piston rod (13) is straight.


If piston rod is not straight, replace it with a new
piston rod.

3. Loosen and remove self-tapping screw (12).

3. Shine a light inside tube (1) and check for deep


grooves and other damage. If there is any
damage to tube, replace with a new tube.

4. Use a spanner wrench to loosen and remove


gland (4) from tube (1).
5. Pull piston rod (13) straight out of tube (1) to
prevent damage to tube.
6. Fasten piston rod eye or yoke in a vise and put a
support under piston rod (13) near piston (15).
Put a shop cloth between support and piston rod
to prevent damage to piston rod.
7. Use a torque multiplier, CAS-1039, to loosen and
remove bolt (14) that fastens piston (15) to piston
rod (13).
8. Remove piston (15) from piston rod (13).
9. Remove gland (4) from piston rod (13).
10. Remove and discard seal (16), ring (17), and
wear ring (18) from piston (15).

4. Remove any small scratches on piston rod (13)


or inside tube (1) with emery cloth of medium
grit. Use emery cloth with a rotary motion.
5. Inspect bushings (2) in tube eye. Replace as
required.
6. Inspect gland (4) for rust. Clean and remove rust
as necessary.
7. Inspect gland end of tube (1) for sharp edges
that may cut gland O-ring (11) and remove as
necessary.
8. Inspect piston (15) for damage and wear. If
piston is damaged or worn, replace with a new
piston.

11. Remove and discard O-ring (10), backup ring (9),


O-ring (11), wiper (5), rod seal (6), buffer seal
(7), and bushing (8) from gland (4).

Bur 5-3280

Issued 8-06

Printed in U.S.A.

8006-5

13

5
6
7
4
8
11
9
10
15

12

17
16
18
14
1
3
2

2
3

BC05J002

1.
2.
3.
4.
5.

TUBE
BUSHING
WIPER
GLAND
WIPER

6.
7.
8.
9.
10.

ROD SEAL
BUFFER SEAL
BUSHING
BACKUP RING
O-RING

11.
12.
13.
14.
15.

O-RING
SCREW
ROD
BOLT
PISTON

16. SEAL
17. RING
18. WEAR RING

LIFT CYLINDER
Bur 5-3280

Issued 8-06

Printed in U.S.A.

8006-6

Assembly

17. Install a new ring (17) in the other groove on the


outside of the piston (15).

NOTE: If a new gland is being used, put part number


of cylinder on new gland.

18. Install a new seal (16) on top of ring (17).

1. Install bushing (8) in gland (4).


2. Install rod seal (6) in gland (4). Rod seal is to be
installed so that lips of seal are toward bushing
(8). Rod seal (6) can be difficult to install.
3. Install buffer seal (7) in gland (4). The side of
buffer seal with groove must be toward bushing
(8).
4. Install a new wiper (5) in gland (4). Lips of wiper
must be toward outside end of gland (4).
5. Install a new O-ring (11) in groove on OD of
gland (4).
6. Install a new backup ring (9) in groove on OD of
gland (4). If both sides of backup ring are not flat,
side that is not flat must be toward small end of
gland (4).
7. Install a new O-ring (10) next to backup ring (9)
in groove on outside of gland (4). O-ring must be
toward small end of gland.
8. Fasten piston rod (13) eye or yoke in vise.
9. Remove any marks and sharp edges on chamfer
at end of piston rod (13). Make sure that piston
rod is clean.
10. Lubricate bore of gland (4) and piston rod (13)
with clean oil.
11. Push gland (4) onto piston rod (13). If necessary,
use a soft hammer to drive gland onto piston rod.
12. Put a support below and near end of piston rod
(13). Use a shop cloth between support and the
piston rod to prevent damage to piston rod.
13. Start piston (15) onto piston rod (13).
14. Clean the threads on the end of the piston rod
(13) and the threads of the bolt (14) using Loctite
cleaning solvent. Allow to dry. Apply Loctite 242
to piston rod threads 6.3 mm (1/4 inch) from
open end of piston rod so that there is 13 mm
(1/2 inch) of Loctite 242 on piston rod threads.
DO NOT apply Loctite to first 6.3 mm (1/4 inch)
of piston rod threads.

19. Fasten tube (1) in an acceptable repair stand or


other holding equipment. Be careful to prevent
damage to tube.
20. Lubricate inside of the tube (1) and piston (15)
with clean oil.
21. Push piston (15) straight into tube (1).
22. When the piston (15) is in smooth part of tube
(1), start gland (4) into tube.
23. Lubricate O-rings (10 and 11) on gland (4) with
clean oil.
24. Turn gland (4) into tube (1). Tighten gland to a
torque of 135 to 542 Nm (100 to 400 pound-feet).
25. If the original parts are being assembled:
A. Tighten gland to a torque of 135 to 542 Nm
(100 to 400 pound-feet).
B. Install and tighten self-tapping screw (12) to a
torque of 2.3 Nm (20 inch-pounds).
C. If, after tightening gland, the self-tapping
screw (12) holes are not aligned, a new hole
for self-tapping screw must be drilled. See
Step 26.
26. If a new gland (4) or a new tube (1) are being
assembled:
A. Tighten gland (4) to 135 to 542 Nm (100 to
400 pound-feet).
B. Use a No. 27 drill bit and drill a hole half in
gland (4) and half in tube (1). Drill to a depth of
11 mm (7/16 inch). Do not drill within 13 mm
(1/2 inch) of a hole for gland wrench.
C. Install and tighten self-tapping screw (12) to a
torque of 2.3 Nm (20 inch-pounds).
27. If hoses were removed with cylinder, install new
O-rings, if equipped, on hose fittings. Lubricate
O-rings with clean oil. Install hoses.

15. Install bolt (14) into piston rod (13). Tighten bolt
to a torque of 2830 to 3220 Nm (2087 to 2374.9
pound-feet). A torque multiplier can be used to
help torque the bolt.
16. Install a new wear ring (18) in wide groove on
outside of piston (15).

Bur 5-3280

Issued 8-06

Printed in U.S.A.

8006-7

BUCKET CYLINDERS
Disassembly
1. Clean the outside of the cylinder. If the hoses
were removed with the cylinder, remove the
hoses from the cylinder.
2. Fasten the tube (1) in an acceptable repair stand
or other holding equipment. Do not damage the
tube (1).
3. Loosen and remove the cap screws (2) and
hardened washers (18) from the gland (3) and
the tube (1).
4. Pull the piston rod (4) straight out of the tube (1)
to prevent damage to the tube (1).
5. Fasten the piston rod eye or yoke in a vise and
put a support under the piston rod (4) near the
piston (7). Put a shop cloth between the support
and the piston rod (4) to prevent damage to the
piston rod (4).
6. Remove the retaining ring (10) that fastens the
pin (11) in the piston (7) and piston rod (4).
7. Remove the pin (11) from the piston (7) and the
piston rod (4).
8. Turn the piston (7) off the piston rod (4) and
remove the piston (7).
9. Remove the gland (3) from the piston rod (4).

Inspection
1. Discard the parts that were removed from the
piston and the gland.
2. Clean all parts in cleaning solvent. Use only lint
free cloths for cleaning and drying.
3. Check to be sure that the piston rod is straight. If
the piston rod is not straight, replace it with a
new piston rod.
4. Illuminate the inside of the tube for deep grooves
and other damage. If there is any damage to the
tube, replace it with a new tube.
5. Remove any small scratches on the piston rod or
inside the tube with emery cloth of medium grit.
Use the emery cloth with a rotary motion.
6. Inspect the bushings in the piston rod eye or
yoke and the tube. Replace as required.
7. Inspect the gland for rust and clean and remove
rust as necessary.
8. Inspect the gland end of the tube for sharp edges
that will cut the gland O-ring and remove as
necessary.
9. Inspect the piston for damage and wear. If the
piston is damaged or worn, replace it with a new
piston.

10. Remove the seal (6) from the OD of the piston


(7).
11. Remove the wear ring (5) from the OD of the
piston (7).
12. Remove the backup rings (8) and the O-ring (9)
from the ID of the piston (7).
13. Remove the O-ring (16), backup ring (15), wiper
(12), wide seal (13), narrow seal (14), and
bushing (17) from the gland (3).

Bur 5-3280

Issued 8-06

Printed in U.S.A.

8006-8

19
20
19

4
2
18
3
17

15

12

16
11
7

13
14

8
8

6
1

5
10

19

20
19
BC05M026

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

TUBE
CAP SCREW
GLAND
PISTON ROD
WEAR RING
SEAL

7.
8.
9.
10.
11.

PISTON
BACKUP RING
O-RING
RETAINING RING
PIN

12.
13.
14.
15.
16.

WIPER
WIDE SEAL
NARROW SEAL
BACKUP RING
O-RING

17.
18.
19.
20.

BUSHING
HARDENED WASHER
SEAL
BUSHING

BUCKET CYLINDER

Bur 5-3280

Issued 8-06

Printed in U.S.A.

8006-9

Assembly
NOTE: If a new gland is being used, put the part
number of the cylinder on the new gland.

11. Install a new backup ring (8) in the groove in the


ID of the piston (7). If both sides of the backup
ring (8) are not flat, the side that is not flat must
be toward the O-ring (9).

1. Install the bushing (17) in the gland (3), refer to


illustration on page 8.

12. Install a new O-ring (9) in the groove in the ID of


the piston (7) next to the backup ring (8).

2. Install the wide seal (13) in the gland (3). The


wide seal (13) is to be installed so that the lips of
the wide seal (13) are toward the bushing (17).
The wide seal (13) can be difficult to install.

13. Install the other new backup ring (8) in the


groove in the ID of the piston (7) next to the
O-ring (9). If both sides of the backup ring (8) are
not flat, the side that is not flat must be toward
the O-ring (9).

3. Install a new wiper (12) in the gland (3). The lips


of the wiper (12) must be toward the outside end
of the gland (3).
4. Install the narrow seal (14) in the gland (3). The
side of the narrow seal (14) with the groove must
be toward the bushing (17).
5. Install a new backup ring (15) in the groove on
the outside of the gland (3). If both sides of the
backup ring (15) are not flat, the side that is not
flat must be toward the small end of the gland
(3).
6. Install the O-ring (16) next to the backup ring (15)
in the groove on the outside of the gland (3). The
O-ring (16) must be toward the small end of the
gland (3).

14. Lubricate the ID of the piston (7) with clean oil.


15. Start the piston (7) onto the piston rod (4). Turn
the piston (7) onto the piston rod (4) until the
piston (7) is seated against the shoulder of the
piston rod (4).
16. If none of the holes in the piston (7) align with the
holes in the piston rod (4), turn the piston (7)
counterclockwise until one of the holes in the
piston (7) aligns with one of holes in the piston
rod (4). Do not turn the piston (7) more than 90
degrees.

11

7. Remove any marks and sharp edges on the


chamfer at the end of the piston rod (4). Make
sure that the piston rod (4) is clean.

10

8. Lubricate the bore of the gland (3) and the piston


rod (4) with clean oil.
9. Push the gland (3) onto the piston rod (4). If
necessary, use a soft hammer to drive the gland
(3) onto the piston rod (4).
10. Put a support below and near the end of the
piston rod (4). Use a shop cloth between the
support and the piston rod (4) to prevent damage
to the piston rod (4).

4
GS98J804
PISTON AND PISTON ROD HOLE ALIGNMENT

17. Install the pin (11) in the piston (7) and the piston
rod (4).
18. Install the retaining ring (10) in the pin (11).

Bur 5-3280

Issued 8-06

Printed in U.S.A.

8006-10
19. Install a new wear ring (5) in the wide groove on
the OD of the piston (7).
20. Install a new seal (6) in the groove on the OD of
the piston (7).

27. Tighten the cap screws (2) in the sequence


shown. Torque to 420 to 500 Nm (310 to 368.8
pound-feet).

21. Fasten the tube (1) in an acceptable repair stand


or other holding equipment. Be careful to prevent
damage to the tube (1).
22. Lubricate the inside of the tube (1) and the
outside of the piston (7) with clean oil.
23. Push the piston (7) straight into the tube (1).
24. Lubricate the O-ring (16) on the gland (3) with
clean oil.
25. Push the gland into the tube (1) and align the
holes in the tube (1).
26. Install the cap screws (2) and hardened washers
(18).
BC05M027

TUBE AND GLAND HOLE ALIGNMENT

Bur 5-3280

Issued 8-06

Printed in U.S.A.

8006-11

REPLACING THE BUSHINGS FOR THE LIFT CYLINDERS


Removal
1. Put piston tube (4) in a press.
2. Use an acceptable driver to press wipers (1) and
bushings (2) out of piston tube (4) eye.

3. Clean bore for bushings (2) in tube (4) eye.

Installation
4

1. Use an acceptable driver to press new bushings


(2) into tube (4) eye. Bushings shall be recessed
8 mm (0.315 inch) in tube eye.
2. Use an acceptable driver to install wipers (1) until
flush with tube (4) eye. The lips of wipers must
be toward outside of bore.

2
1
2

BS01C003

1. WIPER
2. BUSHING

3. PISTON ROD YOKE


4. TUBE

BUSHING AND WIPER REMOVAL AND REPLACEMENT


LIFT CYLINDERS

Bur 5-3280

Issued 8-06

Printed in U.S.A.

8006-12

REPLACING BUSHINGS FOR THE BUCKET CYLINDER


Removal

1. Put piston rod eye (3) in a press.


2. Use an acceptable driver to press wipers (1) and
bushing (2) out of piston rod eye (3).
3. Put tube (4) in a press.
4. Use an acceptable driver to press bushings (2)
out of tube (4) eye.

2
1

1
2

5. Clean bore for bushings (2) in piston rod eye (3)


and tube (4) eye.

Installation

4
1
2

1. Use an acceptable driver to press new bushings


(2) into piston rod eye (3) until recessed 8 mm
(0.315 inch).
2. Use an acceptable driver to install wipers (1) until
flush with piston rod eye (3). The lips of the
wipers (1) must be towards outside of bore.

3. Use an acceptable driver to press new bushings


(2) into tube (4) eye until recessed 8 mm (0.315
inch).
4. Use an acceptable driver to install wipers (1) until
flush with tube (4) eye. The lips of wipers (1)
must be towards outside of bore.

1
BS03B201

1. WIPER
2. BUSHING

3. PISTON ROD EYE


4. TUBE

BUSHING AND WIPER REMOVAL AND REPLACEMENT


BUCKET CYLINDERS

Bur 5-3280

Issued 8-06

Printed in U.S.A.

Section
8007

8007

COUPLER SOLENOID LOCKING VALVE

CNH America LLC.


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

Bur 6-42600

Copyright 2003 CNH Ameica LLC.


All rights reserved.
Printed in U.S.A.
Issued April, 2003

8007-2

TABLE OF CONTENTS
coupler solenoid locking valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 6-42600

Issued 4-03

3
3
3
3

Printed in U.S.A.

8007-3

COUPLER SOLENOID LOCKING VALVE


Disassembly

STEP 11
Install solenoid (2) on valve cartridge (3).

STEP 1
Clean exterior of valve.

STEP 12
Install nut (1) to secure solenoid (2).

STEP 2
Remove nut (1) and solenoid (2) from valve cartridge
(3).

STEP 3
Remove valve cartridge (3) from valve housing (7).

STEP 4
Remove and discard all O-rings (4 and 5) and
back-up rings (6).

Cleaning and Inspection


STEP 5

Immerse valve cartridge (3) and valve housing (7) in


cleaning solvent and agitate cleaning solvent. WEAR
EYE PROTECTION WHEN USING COMPRESSED
AIR. Use compressed air to remove foreign matter
from interior of valve cartridge and housing and to
ensure that all passage ways and bores are clear.

4
6

STEP 6

Check valve cartridge for (3) for cracks, breaks,


chipping, or other damage. Replace if any of these
conditions are seen.

6
6
5

STEP 7

Check bores in valve housing (7) for deep scratches,


gouges, and other damage. Replace valve if any of
these conditions are seen.

5
7

STEP 8
Connect an ohmmeter across terminals of solenoid
(2) connector. Replace solenoid (2) and valve
cartridge (3) if ohmmeter indicates short or open
circuit.

Assembly
STEP 9
Install new O-rings (4 and 5) and back-up rings (6) as
shown.

GS98J818

1.
2.
3.
4.

NUT
SOLENOID
VALVE CARTRIDGE
O-RING

5. O-RING
6. BACKUP RING
7. VALVE HOUSING

STEP 10
Lubricate O-rings (4 and 5) using clean oil then install
valve cartridge (3) in valve housing (7).
Bur 6-42600

Issued 4-03

Printed in U.S.A.

8007-4

NOTES

Bur 6-42600

Issued 4-03

Printed in U.S.A.

8013

Section
8013
RIDE CONTROL ACCUMULATOR

CNH America LLC.


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

Bur 5-3000

Copyright 2006 CNH Ameica LLC.


All rights reserved.
Printed in U.S.A.
Issued August, 2006

8013-2

TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACCUMULATOR SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHARGING THE ACCUMULATOR WITH NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 5-3000

Issued 8-06

3
3
3
4
5
5
5
5
7

Printed in U.S.A.

8013-3

SPECIFICATIONS
Ride Control Accumulator Dry Nitrogen Pressure ...................................................................... See chart on page 8
Ride Control Accumulator Fluid Capacity ............................................................................. 3.79 liters (231 cu. inch)
Ride Control Accumulator Maximum Operating Pressure ...........................................................248.4 bar (3600 psi)

ACCUMULATOR SPECIAL TORQUES


Accumulator Gas Charging Valve Cap .................................................................................13.6 Nm (10 pound-feet)
Gas Charging Valve.............................................................................................88 to 102 Nm (65 to 75 pound-feet)
Cap screws for the protection bracket .......................................................... 54 to 61 Nm (480 to 540 pound-inches)
Gland .............................................................................................................163 to 176 Nm (120 to 130 pound-feet)

SPECIAL TOOLS

94L95

CAS10899 NITROGEN ACCUMULATOR CHARGING KIT

Bur 5-3000

B786441M

CAS1456 GLAND WRENCH

Issued 8-06

Printed in U.S.A.

8013-4

DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR

94L95

CAS10899 NITROGEN CHARGING KIT

1. Use the CAS-10899 Nitrogen Charging Kit to


d i s c h a r g e t h e a c c u m u l a t o r, r e fe r t o t h e
illustration above. The tool must be disconnected
from the nitrogen tank.
2. Close valves B, C and D.
3. Adjust the regulator A to the minimum pressure
setting by turning the knob counterclockwise.
4. Turn the T-handle on valve F fully out.
5. Remove the guard and valve assembly cap from
the accumulator.

7. Turn the T-handle inward on valve F to engage


the pin in the valve stem.
8. Open valve D and check the charge pressure on
gauge E.
9. To discharge the accumulator, partially open
valve B. The accumulator charge will bleed down
through the regulator.
10. Once the accumulator is fully discharged,
disconnect valve F from the valve stem.
11. The accumulator can now be disassembled.

6. Connect valve F to the valve stem on the


accumulator.

Bur 5-3000

Issued 8-06

Printed in U.S.A.

8013-5

ACCUMULATOR
Disassembly

Assembly

NOTE: Refer to Section 8001 for the proper


procedure for the removal of the ride control
accumulator.
WA R N I N G : D O N O T a t t e m p t t o
disassemble any accumulator until the
nitrogen charge is properly discharged.
SM386

1. Fasten the body (1) in a vise. Be careful not to


damage the body (1), refer to the illustration on
page 6.
2. Remove the screws (9) and guard (11) from the
body (1).
3. Remove the pressure valve (12) from the
body (1).
4. Remove and discard the O-ring (10) from the
pressure valve (12).
5. Loosen and remove the cap (8) from the body
(1).
6. Loosen and remove the gland (3) from the body
(1).

1. Fasten the body (1) in a vise. Be careful not to


damage the body (1). Refer to the illustration on
page 6.
2. Install a new wear ring (5), O-ring (7) and backup
ring (6) on the piston (4).
3. Lubricate the bore of the body (1) and the piston
(4) with clean oil.
4. Start the piston (4) into the body (1), round
surface first. Then push the piston (4) farther into
the body (1).
NOTE: The piston (4) must be installed squarely and
slowly into the body (1). Once the piston (4) is started
straight into the bore of the body (1), use a hammer
and wood block to gently tap the piston into the
polished area of the bore. Keep force on the piston
(4) while tapping into the bore or damage may occur
to the O-ring.
5. Install and tighten the cap (8) into the body (1).
6. Install new seals (2) on the gland (3).

7. Remove the piston (4) from the body (1).

7. Lubricate the seals (2) with clean oil and start the
gland (3) into the body (1).

8. Remove and discard the wear ring (5), O-ring (7)


and the backup ring (6) from the piston (4).

8. Tighten the gland (3).

9. Remove the seals (2) from the gland (3).

9. Install a new O-ring (10) on the pressure valve


(12).

Inspection
1. Clean body (1), gland (3), cap (8) and piston (4)
in cleaning solvent, refer to the illustration on
page 6.
2. Inspect the piston (4) for cracks, burrs or other
damage.
3. Inspect the bore of the body (1) for scratches or
scoring using a light.

10. Install the pressure valve (12) in the body (1).


11. Install the guard (11), screws (9) in the body (1).
12. Charge the accumulator with dry nitrogen
according to instructions on page 7.
WA R N I N G : U s e o n l y n i t r o g e n w h e n
charging the accumulator. DO NOT use air
or oxygen that will cause an explosion.
SM115A

NOTE: Minor scratches or scoring in the bore of the


body (1) can be removed using crocus cloth.
4. Inspect the pressure valve (12) and replace as
needed.

Bur 5-3000

Issued 8-06

Printed in U.S.A.

8013-6

2
3

10

11

12

BS01B224

1.
2.
3.
4.

BODY
SEALS (2)
GLAND
PISTON

5.
6.
7.
8.

WEAR RING
BACKUP RING
O-RING
CAP

9.
10.
11.
12.

SCREW
O-RING
GUARD
PRESSURE VALVE

RIDE CONTROL ACCUMULATOR ILLUSTRATION

Bur 5-3000

Issued 8-06

Printed in U.S.A.

8013-7

CHARGING THE ACCUMULATOR WITH NITROGEN

GS98N801

1. VALVE C
2. TO NITROGEN TANK
3. VALVE A

4. VALVE B
5. VALVE D
6. TO ACCUMULATOR

NITROGEN CHARGING KIT CAS10899

WARNING: Use only nitrogen when charging the accumulator. Do not use air or oxygen that will cause an
explosion.
M253A

WARNING: Do not drop the accumulator. A charged accumulator contains nitrogen compressed to 31 bar
(450 psi). If the charging valve breaks away from the accumulator, the escaping nitrogen will propel the
accumulator at a dangerous rate of speed.
M406

WARNING: Do not expose the accumulator to temperatures above 49 C (120 F). A charged accumulator
contains nitrogen compressed to 31 bar (450 psi). High heat will cause the safety plug to blow out of the
accumulator and the escaping nitrogen will propel the accumulator at a dangerous rate of speed.
M407

IMPORTANT: The four valves must be in the positions noted in the procedure before connecting the Nitrogen
Accumulator Charging Kit to the machine or nitrogen, refer to the above illustration.
IMPORTANT: To help prevent equipment damage, the low pressure gauge valve C MUST BE SHUT OFF during
high pressure (10 bar/150 psi and above) applications.

Bur 5-3000

Issued 8-06

Printed in U.S.A.

8013-8
1. Close the shutoff valve A by turning it all the way
to the left (counterclockwise), refer to the
illustration on page 7.
2. Open valve B by turning it out all the way to the
left (counterclockwise).
3. Close valve C by turning it all the way to the right
(clockwise).
4. Close the gauge valve D by turning it all the way
to the right (clockwise).
5. Connect the charging hose to the nitrogen supply
tank.
6. SLOWLY turn valve A clockwise while watching
the high pressure gauge. Stop turning valve A
when the needle on the gauge reaches 31 bar
(450 psi).
NOTE: If the needle goes over the needed pressure,
quickly open and close valve D and check the
pressure setting again.
The charging kit is now ready to be installed on the
accumulator.
7. Remove the two cap screws (9) and the
protection bracket (11) from the body (1) on the
accumulator, refer to the illustration on pages 6.
8. Remove the valve cap from the pressure valve
(12) on the accumulator.
9. Back off the needle valve on the accumulator end
of the charging hose by tur ning it
counterclockwise to the maximum amount. This
prevents nitrogen from escaping from the
accumulator when the charging hose is attached
to the accumulator gas charging valve.
10. Install the charging hose fitting onto the
accumulator pressure valve (12).
11. Tighten the needle valve by turning it clockwise.
Slowly open the gauge valve D and observe the
reading on the gauge. This reading is the
nitrogen pressure level inside the accumulator.

Bur 5-3000

12. Open the shutoff valve A on the nitrogen supply


tank. While observing the pressure on the gauge,
slightly open the needle valve on the
accumulator charge hose. By regulating the
needle valve, fill the accumulator to pressure
according to temperature chart below. Close the
needle valve. Close the shutoff valve A on the
nitrogen supply tank.
TEMPERATURE
10 C
50 F
13 C
55 F
16 C
60 F
18 C
65 F
21 C
70 F
24 C
75 F
27 C
80 F
29 C
85 F
32 C
90 F
35 C
95 F
38 C
100 F

CHARGE PRESSURE
1606 KPA
233 PSI
1634 KPA
237 PSI
1669 KPA
242 PSI
1696 KPA
246 PSI
1724 KPA
250 PSI
1751 KPA
254 PSI
1779 KPA
258 PSI
1813 KPA
263 PSI
1841 KPA
267 PSI
1868 KPA
271 PSI
1896 KPA
275 PSI

TEMPERATURE/CHARGE PRESSURE RIDE CONTROL


ACCUMULATOR

13. Close valve B by turning to the right (clockwise).


After a few minutes, check the accumulator for
leakage.
14. Back off the needle valve on the accumulator end
of the charging hose by tur ning it
counterclockwise the maximum amount. This will
p r eve n t n it r o g e n f r o m e s c a p i n g f r o m t h e
accumulator as the hose is removed. Remove
the charging hose from the accumulator pressure
valve (12).
15. Install the valve cap onto the pressure valve (12)
on the accumulator.
16. Install the protection bracket (11) over the
pressure valve (12) and secure it with cap screws
(9).
17. Remove the charging hose from the nitrogen
supply tank.

Issued 8-06

Printed in U.S.A.

8014

Section
8014
RIDE CONTROL VALVE

CNH America LLC.


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

Bur 5-3010

Copyright 2006 CNH Ameica LLC.


All rights reserved.
Printed in U.S.A.
Issued August, 2006

8014-2

TABLE OF CONTENTS
RIDE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dissasembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 5-3010

Issued 8-06

3
3
3
4

Printed in U.S.A.

8014-3

RIDE CONTROL VALVE


9

10

11

13 12

7
15

14

5
4

16

3
2

17

BC05B015.

1.
2.
3.
4.
5.

PLUG
CAP SCREW
BUSHING
SPRING CARRIER
SPRING

6.
7.
8.
9.

SPRING
SPOOL
PLUG
PLUG

10.
11.
12.
13.

Dissasembly

ACCUMULATOR DRAIN SCREW


PLUG
SOLENOID
ORFICE

14.
15.
16.
17.

POPPET
ORFICE
VALVE BLOCK
RELIEF VALVE

STEP 8
Remove the pressure relief valve (17).

STEP 1
Remove ride control valve, refer to section 8001.

STEP 2

Inspection
1. Discard all O-rings.

Remove plugs (1), (8), (9), and (11).

2. Clean all parts in cleaning solvent.

STEP 3

3. Check the spools and the spool bores for


damage and wear.

Remove the solenoid (12).

4. Check the parts of the pressure relief valve.

STEP 4

If any of the parts are damaged, install new parts.

Remove the spool (7) from the valve block (16).

STEP 5
Remove cap screw (2), bushing (3), spring carrier
(4), springs (5 & 6) from spool (7).

STEP 6
Remove orifice (13), poppet (14), and orifice (15).

STEP 7
Remove accumulator drain screw (10).
Bur 5-3010

Issued 8-06

Printed in U.S.A.

8014-4

Assembly

STEP 6

STEP 1
Install new O-rings.

Install springs (5 &6), spring carrier (4), bushing (3),


cap screw (2) onto spool (7) and torque cap screw
(2) to 5.5 Nm (48.5 lb-in).

STEP 2

STEP 7

Install and torque pressure relief valve (17) to 50 Nm


(37 lb-ft).

Install spool (7) into valve block (16).

STEP 3

Install and torque plug (1) to 270 Nm (199 lb-ft).

Install and torque accumulator drain screw (10) to


3.5 Nm (31 lb-in). Install the plug for accumulator
drain screw and torque to 7 Nm (62 lb-in).

STEP 9

STEP 4
Install and torque orifice (15) to 15 Nm (11 lb-ft),
install poppet (14), install and torque orifice (13) to
15 Nm (11 lb-ft).

STEP 8

Install plug (8) and torque to 140 Nm (103 lb-ft), plug


(9) and torque to 30 Nm (22 lb-ft), and plug (11) and
torque to 90 Nm (66 lb-ft).

STEP 10
Install the ride control valve in the machine, see
section 8001.

STEP 5
Install and torque solenoid valve to 12 Nm (106 lb-in).

STEP 11
Test the ride control system, see section 8002.

Bur 5-3010

Issued 8-06

Printed in U.S.A.

SECTION INDEX

MOUNTED EQUIPMENT
Section Title

Section Number

Air Conditioning Troubleshooting and System Checks for Systems with HFC134a Refrigerant . . . . . . . . . . . . .9002
Air Conditioning System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9003
Removal and Installation of Air Conditioning and Heater Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9004
Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9006
Rollover Protective Structure (ROPS) Cab Structural Frame (CSF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9007
Cab Glass Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9010

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

Bur 5-3290

Copyright 2006 CNH Ameica LLC.


All rights reserved.
Printed in U.S.A.
Issued August, 2006

9002

Section
9002
AIR CONDITIONING TROUBLESHOOTING AND SYSTEM
CHECKS FOR SYSTEMS WITH HFC-134A
REFRIGERANT

CNH America LLC.


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

Bur 5-4030

Copyright 2006 CNH Ameica LLC.


All rights reserved.
Printed in U.S.A.
Issued August, 2006

9002-2

TABLE OF CONTENTS
SAFETY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Problem: No Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SYSTEM CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical Compressor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower and Compressor Clutch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cab Temperature Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Visual and Leak Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Evaporator/Heater Core Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Evaporator/Heater Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRESSURE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manifold Gauge Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Test Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRESSURE-TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
QUICK REFERENCE TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A/C RECOVERY AND CHARGING STATION CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROBLEM: NO COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Indication of No Refrigerant or Low Refrigerant Charge: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Indication of Large Quantity of Air in System: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Condenser Malfunctioning - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Expansion Valve Malfunctioning - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigerant Contamination: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HFC-134a Stable Saturation Pressure/ Temperature Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROBLEM: NOT ENOUGH COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air in the System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Not Enough Refrigerant - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Side Restriction - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Expansion Valve Not Operating - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Turning But Not Pumping Properly - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Expansion Valve Stuck Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Condenser Not Operating - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air in the System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROBLEM: INTERMITTENT COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Moisture in the System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROBLEM: NOISE IN SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Too Much Refrigerant in System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TUBE CONNECTIONS TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 5-4030

Issued 8-06

3
5
6
6
8
8
9
10
11
12
12
13
13
13
14
14
15
16
16
17
17
18
18
18
19
19
20
20
21
22
22
23
23
24
24
25
25
26

Printed in U.S.A.

9002-3

SAFETY PROCEDURES
THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT
SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE
THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT
FOLLOWS AND BE ALERT TO THE POSSIBILITY OF
M171B
PERSONAL INJURY OR DEATH.

ATTENTION: Only authorized technicians certified


by an approved training and certification organization
may service or repair motor vehicle or mobile air
conditioning systems. It is mandatory that all
refrigerant must be RECOVERED and RECYCLED
when removed from a system during servicing.
Refrigerant HFC-134a is the most stable, and easiest
to work with of the refrigerants now used in air
conditioner systems. Refrigerant HFC-134a does not
contain any chlorofluorocarbons (CFCs) which are
harmful to the earths ozone layer.
Safety procedures must be followed when working
with Refrigerant HFC-134a to prevent possible
personal injury.
1. Always wear safety goggles when doing any
service work near an air conditioner system.
Liquid refrigerant getting into the eyes can cause
ser ious injur y. Do the following if you get
refrigerant near or in your eyes:
A. Flush your eyes with water for 15 minutes.

3. Keep refrigerant containers in the correct upright


position. Always keep refrigerant containers
away from heat and sunlight. The pressure in a
container will increase with heat.
4. Always reclaim refrigerant from the system, if you
are going to weld or steam clean near the air
conditioner system.
5. Always check the temperature and pressure of
the air conditioner system before reclaiming
refrigerant and when you test the system.
6. Dangerous gas can form when refrigerant comes
in contact with an open flame. Never permit
fumes to be inhaled.
7. Never leak test with compressed air or flame
testers. Tests have indicated that compressed
mixtures of HFC-134a and air can for m a
combustible gas.
8. Always reclaim refrigerant from the system
before removing any air conditioning component.

B. See a physician immediately.


2. A drop of liquid refrigerant on your skin may
cause frostbite. Open the fittings carefully and
slowly when it is necessary to service the air
conditioner system. Your skin must be treated for
frostbite or a physician must be seen if you get
refrigerant on your skin.

Bur 5-4030

Issued 8-06

Printed in U.S.A.

9002-4

299L7C

BELT TENSION TOOL CAS-10808

A22094

REFRIGERANT RECOVERY, RECYCLING AND CHARGING


STATION, OEM-1415

A22090
109L7

ELECTRONIC LEAK DETECTOR OEM-1437


SAFETY GOGGLES CAS-10073-3

Bur 5-4030

Issued 8-06

Printed in U.S.A.

9002-5

OPERATION
The refrigerant circuit of the air conditioning system
contains five major components: compressor,
condenser, receiver-drier, expansion valve and
evaporator. These components are connected by
tubes and hoses and operate as a closed system.
The air conditioner system is charged with HFC-134a
refrigerant.

The refrigerant, still in a high pressure liquid form,


then flows from the receiver-drier to the expansion
valve. The expansion valve then causes a restriction
in flow of refrigerant to the evaporator core. The
evap orator mete rs refr ig erant flow based on
evaporator heat load.
As the refrigerant flows through the evaporator core,
the refrigerant is heated by the air around and flowing
through the evaporator fins. The combination of
increased heat and decreased pressure causes the
air flow through the evaporator fins to become very
cool and the liquid refrigerant to become a low
pressure gas. The cooled air then passes from the
evaporator to the cab for the operators comfort.

The compressor receives the refrigerant as a low


pressure gas. The compressor then compresses the
refrigerant and sends it in the form of a high pressure
gas to the condenser. The air flow through the
c o n d e n s e r t h e n r e m o ve s t h e h e a t f r o m t h e
refrigerant. As the heat is removed the refrigerant
changes to a high pressure liquid.
The high pressure refrigerant liquid then flows from
t h e c o n d e n s e r t o t h e r e c e i v e r - d r i e r. T h e
receiver-drier is a container filled with moisture
removing material, which removes any moisture that
may have entered the air conditioner system in order
to prevent corrosion of the internal components of
the air conditioner system.

The electrical circuit of the air conditioning system


consists of a fan speed control, temperature control,
one (1) relay, a blower motor, blower resistor, A.C.
compressor clutch, A.C. low pressure switch, A.C.
high pressure switch, and A.C. warning light.

3
5
4

208L95

1. EXPANSION VALVE
2. EVAPORATOR

Bur 5-4030

3. COMPRESSOR
4. CONDENSER

5. RECEIVER-DRIER

Issued 8-06

Printed in U.S.A.

9002-6

TROUBLESHOOTING
Perform a visual inspection of the machine. Check
the following and correct as necessary:
1. - Obtain service history if possible.

5. - Are there heavy accumulations of oil, or oily


dust around the fittings, indicating refrigerant
leakage?
6. - Are air ducts undamaged, sealed properly and
in position?

2. - Is compressor drive belt in place and tensioned?


3. - Are grille screens, fan blades, condenser, air filter, and
evaporator unobstructed?

7. - Condensate drain hoses and check valves


present and unobstructed?

4. - Are there any sharp bends or kinks in the


hoses?

Problem: No Cooling
Compressor Runs

No

Mechanical - See Mechanical Compressor


Check Page 8
Electrical - See Blower and Compressor
Clutch Check Page 9

Yes
Internal System Problem
See Pressure Testing, Page 13

Bur 5-4030

Issued 8-06

Printed in U.S.A.

9002-7

Problem:
Not Enough Cooling

Problem:
Erratic Cooling

MECHANICAL
HEATER

See Mechanical Compressor Check Page 8.

Make sure the heater control is OFF and that there is no coolant
flow through the heater core.
ELECTRICAL
See Blower and Compressor Clutch Check - Blower Motor
Check, Blower Switch Check and Compressor Clutch Check
on Page 9.
SEAL
Make sure the sealing material is correctly in place.
INTERNAL SYSTEM PROBLEMS
See Pressure Testing, Page 13.
MECHANICAL
See Mechanical Compressor Check page 8. See Evaporator
Heater Core Check Page 12.

Problem:
System Makes Noise

ELECTRICAL
See Blower and Compressor Clutch Check on Page 9.
MECHANICAL
See Mechanical Compressor Check Page 8.
See Blower Motor Check Page 9.
REFRIGERANT
See Cab Temperature Check Page 10.
ELECTRICAL
See Compressor Clutch Check Page 9.
INTERNAL SYSTEM PROBLEM
See Pressure Testing, Page 13.

INTERNAL SYSTEM PROBLEM


See Pressure Testing, Page 13.

Bur 5-4030

Issued 8-06

Printed in U.S.A.

9002-8

SYSTEM CHECKS
Mechanical Compressor Check
Compressor and Fan Belts

1. Too much belt wear - replace a worn belt,


because a worn belt will cause too much
slippage.

Compressor Mounting Brackets

1. Loose bracket mounting bolts - tighten the


bolts to the correct torque.
2. Bracket has cracks or breaks - replace the
bracket.

Compressor Clutch

1. The compressor belt will slip on the


compressor pulley if there is compressor
seizure. Remove the compressor for
service or replacement.
2. Remove the dust cover and check the air
gap on the compressor clutch. The gap
b e t w e e n t h e f r o n t p l a t e a n d p u l l ey
assembly must be 0.41 to 0.79 mm.
3. Use a socket wrench to slowly rotate the
compressor clockwise. Compressor
rotation should be smooth and not require
much effort.

Pulley and Belt Alignment

1. The
compressor
pulley
and
the
compressor drive pulley must be aligned
within 1.6 mm (1/16 inch) of each other.
Use a straight edge to check pulley
alignment. Adjust the compressor
mounting bracket if needed.

Bur 5-4030

Issued 8-06

Printed in U.S.A.

9002-9

Blower and Compressor Clutch Check


NOTE: Check
supply
voltage
with
compressor lead plugged in and engaged.
Voltage drops will not be apparent without
current flow.
Compressor Clutch

1. If there is electrical system voltage to the


clutch, check for excessive voltage drop in
the ground circuit, then see Section 9004
and replace the compressor.

Low and High Pressure Switches

1. See Section 4002 and check the high and


low pressure switches.

Blower Fuse (10 amp)

1. Check for damaged blower fuse.

Blower Fan Switch

1. Check switch operation. Switch must give


four different blower speeds: OFF, Low,
High, and Purge.
2. Check for loose connections or broken
wires. Repair or replace as necessary.
3. Check resistor board.

Blower Motor

1. Check the wiring to the blower motor.


Make repairs or replace items as
necessary.
2. Check motor ground wire. Make sure
motor ground wire is making good contact
with mounting bracket.

1. With key in ON position, turn switch to


maximum cold. Compressor clutch must
engage.

Temperature Control Switch

Bur 5-4030

NOTE: Blower must be operating, since


electrical power to temperature control switch
is received from blower switch.
2. Turn the blower off. Disconnect the wires
from the temperature control. Using an
ohmmeter, check the continuity between
switch ter minals. If continuity is not
present when switch is on maximum cold,
replace switch.

Issued 8-06

Printed in U.S.A.

9002-10

Cab Temperature Check


Air Louvers

1. Make sure louvers and recirculation vents are fully open


for most efficient air conditioning operation. Defrost
louvers must be closed.
2. Check blower; blower must be running.

ATTENTION: Use caution when feeling hoses. Hoses


become very hot. Check temperature by slowly reaching for
hose and touching briefly several times with finger tips,
increasing the duration with each touch.
Air Conditioning

1. Feel the air conditioning hoses. The high pressure hoses


(small line) must be warmer than the low pressure hose
(large line).
2. If no temperature difference, the system is low on
refrigerant, or compressor is not working correctly.

1. Put a thermometer in the air duct behind the seat and


r u n t h e c o m p r e s s o r fo r f i v e m i n u t e s t o m a k e
temperature stable. Refer to page 12.
2. Duct temperature must be below 25 C (72 F) if the
system is operating at maximum efficiency.
Duct Temperature

Temperature Sensing Probe Check

Bur 5-4030

NOTE: Ambient temperature must be 27 to 43 C (80 to


110 F).
3. If temperature is above 25 C (72 F), system is low on
refr igerant, there is a restr iction in the system,
compressor is not working correctly, or air ducts are not
sealed correctly.

1. Turn the engine OFF, key switch ON, blower switch ON


and temperature control switch turned fully clockwise.
2. Remove the temperature sensing probe from the
evaporator. Refer to Section 9004.
3. Put the end of the temperature sensing probe in a
container with ice and water.
4. When the sensing tube has cooled to the temperature of
the ice and water mixture, the temperature control switch
should interrupt the current flow to the compressor.
Check for current at the control switch terminals as on
previous page. If current is not interrupted then replace
the control switch.

Issued 8-06

Printed in U.S.A.

9002-11

Visual and Leak Check


Compressor Hoses

1. Make sure that all hose connections are


tight.
2. Check hoses for bends or cracks. Replace
all hoses that have damage.

1. Shut off the engine.

Leak Finding Check

WARNING: When refrigerant comes in


contact with an open flame, it can form
dangerous gas. Never breathe these fumes.
2. Use electronic leak detector OEM -1437
to inspect all connections. Use
instructions from manufacturer of leak
finding tool.
NOTE: When checking compressor seal for a
leak, remove the dust cover and rotate the
clutch shaft clockwise.
NOTE: To properly check the expansion valve
for leaks, remove the insulation tape.
3. Repair all leaks and recharge the system.
See Section 9003.

Condenser

Bur 5-4030

1. Make sure the condenser is clean and the


seals are in place. Make sure condenser
fans run when temperature control switch
is ON.

Issued 8-06

Printed in U.S.A.

9002-12

Evaporator/Heater Core Check


Make sure heater valve is closed

Evaporator/Heater Core

Evaporator/Heater Core

1. See Section 9004 for access to the


evaporator/heater core.
2. Inspect the fins on the evaporator/heater
core. All the fins that have bends or
damage must be made straight.
3. Inspect the evaporator/heater core for
r e s t r i c t i o n s. I f t h e c o r e i s d r y, u s e
compressed air or a brush and vacuum
cleaner. If the core is wet or filled with
mud, flush the core with water using a
hose without pressure. Make sure the
water drains freely from the
evaporator/heater core. DO NOT USE
STEAM.
WARNING: Do not steam clean any air
conditioning systems parts while the system is
charged. The heat will cause the refrigerant to
rise to a pressure that could cause the system
to explode.

Evaporator/Heater Core Sealing

1. See Section 9004 for access to the


evaporator/heater core.
2. Make sure seals are in place so blower
will pull air only through the
evaporator/heater core and not around the
evaporator/heater core.

Filters

1. Make sure the filters are clean.

Bur 5-4030

Issued 8-06

Printed in U.S.A.

9002-13

PRESSURE TESTING
Manifold Gauge Set
NOTE: The gauge set is not accurate enough to
optimize an existing charge of HFC-134a. The best
use of the gauge set is to determine whether
undercharge or overcharge exists, and then
evacuate, reclaim and recharge system with the
recommended quantity (charge) of HFC-134a.
The manifold gauge set is the most important tool
used to service the air conditioning system. The
manifold gauge set is used to measure the high and
low pressures of the system, as a tool to troubleshoot
for correct refrigerant charge quantity, system
diagnosis, and operating efficiency. The manifold
gauge set can read both the high (discharge) and low
(suction) sides at the same time, since pressure must
be compared in order to make a diagnosis of system
operation.

During normal operation the low pressure gauge


must always indicate from 10 to 35 psi (0.7 to 2.4
bar) after the system has run 10 to 15 minutes.
HIGH PRESSURE GAUGE - The high pressure
gauge is used to indicate pressures in the high side
of the system. The gauge must indicate from 0 to 400
psi (0 to 27.6 bar) minimum.
During normal operation, the high pressure gauge
will normally indicate from 120 to 310 psi (8.3 to 21.4
bar). See pressure-temperature chart on page 14.

Pressure Test Connection


C o n n e c t t h e m a n ifo l d g a u g e s e t i n t o t h e a i r
conditioning system as shown. Make sure that both
valves in the manifold gauge set are closed.

LOW PRESSURE GAUGE - The low pressure gauge


is a compound gauge. It is best used to judge
eva cuat io n effe ctiven ess. A vac uum rea ding
indicates a system malfunction. For this reason, it is
necessar y to use a compound gauge that will
indicate both pressure and vacuum.

Bur 5-4030

Issued 8-06

Printed in U.S.A.

9002-14

PRESSURE-TEMPERATURE CHART
AIR LOUVER (BEHIND
SEAT)
MAXIMUM TEMP.
TEMPERATURE PRESSURE INDICATION PRESSURE INDICATION
F (C)
psi (bar)
psi (bar)
F (C)
AMBIENT

NORMAL LOW

NORMAL HIGH

80 (27)

9 to 12

145 to 165

(0.62 to 0.83)

(10 to 11.53)

11 to 15

190 to 210

(0.76 to 1.04)

(13.10 to 14.48)

16 to 18

210 to 230

(1.10 to 1.24)

(14.48 to 15.86)

17 to 19

235 to 255

(1.17 to 1.31)

(16.2 to 17.58)

20 to 21

260 to 280

(1.38 to 1.45)

(17.93 to 19.31)

22 to 24

290 to 310

(1.93 to 2.14)

(20 to 21.37)

90 (32)
95 (35)
100 (38)
105 (41)
110 (43)

The pressure-temperature chart is based on the


following conditions:
NOTE: High humidity will cause higher air louver
temperatures and dramatic increase in suction
pressure. The table shown represents readings taken
in low relative humidity. Adjust the chart according to
local conditions.

55 (14)
61 (18)
63 (20)
66 (22)
68 (23)
72 (25)

2. All panels and access doors installed and closed.


3. Cab filters clean and installed.
4. Heater valve at engine closed.
5. Measurements taken 15 minutes after startup.

1. Engine at 1500 RPM, no load, fan speed &


temperature control at max setting, A/C switch
ON, all louvers and doors open

QUICK REFERENCE TROUBLESHOOTING CHART


PROBLEM

LOW PRESSURE
GAUGE

HIGH PRESSURE
GAUGE

SEE
PAGE

NO COOLING

VERY LOW

VERY LOW

16

NO COOLING

HIGH

HIGH

17

NOT ENOUGH COOLING

NORMAL TO HIGH

NORMAL

19

NOT ENOUGH COOLING

LOW

LOW

20

NOT ENOUGH COOLING

HIGH

LOW

22

NOT ENOUGH COOLING

HIGH

HIGH

23

INTERMITTENT COOLING

NORMAL

NORMAL

24

NOISE IN SYSTEM

NORMAL TO HIGH

HIGH

25

Bur 5-4030

Issued 8-06

Printed in U.S.A.

9002-15

A/C RECOVERY AND CHARGING STATION CONNECTIONS


STEP 1

STEP 4

Clean the external surfaces of the compressor and


hoses. Remove the caps from the service ports on
the suction and pressure hoses.

Connect the hose from the high pressure gauge to


the port on the discharge hose.

WARNING: Do not steam clean any air


conditioning system parts while the system is
charged. The heat will cause the refrigerant
to rise to a pressure that could cause the
SM104A
system to explode.

WARNING: Always wear safety goggles


when working with liquid refrigerant. Liquid
r e f ri g er a n t i n y o u r ey e s c o u l d c a u s e
SM105A
blindness.

STEP 5

STEP 2

Make sure the charging station manifold gauge


valves are in the closed position.

Connect the hoses from the test gauges to the


service ports by turning the knurled knobs on the
depressors.

STEP 6

STEP 3
Connect the hose from the low pressure gauge to the
port on the suction hose.

Bur 5-4030

Start the engine and run at 1500 RPM maximum


speed. Operate the air conditioner system at
maximum cooling setting and blower speed for 15
minutes with the cab door open. Observe the test
gauges and check the chart on page 13 against the
gauge readings.

Issued 8-06

Printed in U.S.A.

9002-16

PROBLEM: NO COOLING

VERY LOW

VERY LOW

SEE PRESSURE - TEMPERATURE CHART ON PAGE 14

476L7

Indication of No Refrigerant or Low Refrigerant Charge:


1. Leak test the system, see Page 11. It may
be necessary to add refrigerant. See
Section 9003.
2. Evacuate
and
reclaim
remaining
refrigerant from system. See Section
9003.
3. Repair system leaks as needed. Follow
the given repair procedure.
A. Discharge air from evaporator warm.
B. Compressor does not run, or cycles off
rapidly after start-up. (A/C warning light
in cab should illuminate).

Yes

4. Check level of oil in compressor - possible


for compressor to have an oil loss.
5. Remove air and moisture from the
system. Replace Receiver-Drier. See
Section 9004.
6. Charge system with new refrigerant. See
Section 9003.
7. Continue performance
possible problems.

Bur 5-4030

Issued 8-06

test for other

Printed in U.S.A.

9002-17

HIGH

HIGH

SEE PRESSURE - TEMPERATURE CHART ON PAGE 14

476L7

Indication of Large Quantity of Air in System:


1. Evacuate and reclaim refrigerant from
system. See Section 9003.
2. Replace receiver-drier.
Discharge air from evaporator warm

Yes

3. Remove air and moisture from the


system. See Section 9003.
4. Charge system with new refrigerant. See
Section 9003.

Condenser Malfunctioning - Indications:


1. Check for loose or worn compressor or engine fan
belt and proper condenser fan operation.
2. Check to see that condenser is clean and
unobstructed and that the fins are straight.
3. Check system for too much refrigerant. Evacuate,
reclaim and recharge refrigerant until gauge
pressure is normal. See Section 9003.
A. Liquid line (between evaporator and
condenser) is very hot.
B. Discharge air from evaporator warm.

4. Remove and check condenser for restrictions


caused by oil or reduced heat transfer.
A. Remove refrigerant from the system. See
Section 9003.
B. Use compressed
condenser.

air

to

remove

oil

from

C. Replace receiver-drier.
D. Remove moisture and charge the system. See
section 9003.
5. Continue the performance test for other possible
problems.

Bur 5-4030

Issued 8-06

Printed in U.S.A.

9002-18

Expansion Valve Malfunctioning - Indications:


A. Discharge air from heater/evaporator
warm.
B. Much condensation on suction hose at
compressor.
C. Much condensation
outlet.

on

See Section 9004 and replace the expansion


valve.

evaporator

Refrigerant Contamination:
1. See table below and check stable saturation pressures at
given temperature to determine if contamination exists.
A. Measure pressure from gauge on reclamation unit.
B. Measure temperature from refrigerant in reclamation
tank. If refrigerant has been in reclamation unit for some
time, use ambient temperature. The numbers in the
table represent the boiling point for HFC-134a.

Refrigerant Contamination

C. Pressure readings below range given in chart indicate


contaminated refrigerant.
IMPORTANT: Do not use contaminated refrigerant or mix
with uncontaminated refrigerant. Dispose of in accordance
with all applicable laws and local procedure.

HFC-134a Stable Saturation Pressure/ Temperature Chart


Temperature F ( C)

Pressure PSIG (Bar)

50 (10)
55 (13)
60 (16)
65 (18)
70 (21)
75 (24)
80 (27)
85 (29)
90 (32)
95 (35)
100 (38)
102 (39)
104 (40)
106 (41)
108 (42)
110 (43)
112 (44)
114 (46)
116 (47)
118 (48)
120 (49)

45 (3.1)
51 (3.5)
57 (3.9)
64 (4.4)
71 (4.9)
78 (5.4)
88 (6.1)
95 (6.6)
104 (7.2)
114 (7.9)
124 (8.6)
129 (8.9)
133 (9.2)
138 (9.5)
142 (9.8)
147 (10.1)
152 (10.5)
157 (10.8)
162 (11.2)
167 (11.5)
172 (11.9)

Bur 5-4030

Issued 8-06

Printed in U.S.A.

9002-19

PROBLEM: NOT ENOUGH COOLING

NORMAL TO
SLIGHTLY HIGH

NORMAL

SEE PRESSURE - TEMPERATURE CHART ON PAGE 14

476L7

Air in the System - Indications:


1. Test system for leaks. See page 11. Possible
leak has let air enter; check compressor seal
carefully.
2. Discharge system of refrigerant. See Section
9003.
A. Suction line warm to your hand.

3. Repair system leak as necessary.

B. Discharge air from heater/evaporator


only a little cool.

4. Replace receiver-drier.
5. Check compressor oil level.
6. Remove air and moisture from the system.
See Section 9003.
7. Charge system with new refrigerant. See
Section 9003.

Bur 5-4030

Issued 8-06

Printed in U.S.A.

9002-20

LOW

LO W

SEE PRESSURE - TEMPERATURE CHART ON PAGE 14

476L7

Not Enough Refrigerant - Indications:


1. Leak test system - system has a loss of refrigerant.
NOTE: Normally, the system will lose 1/2 to 1 ounce (14.7
to 29.5 grams) of refrigerant between seasons.
A. If leak is found, go to Step 2.
B. If no leak is found, go to Step 6.
2. Discharge refrigerant from system. See Section 9003.
A. Discharge air from evaporator
cool or warm - not cold.

3. Repair system leaks as needed.


4. Check oil level in compressor - It is possible for
compressor to lose oil.
5. Remove air and moisture from the system. Replace
Receiver-Drier. See Section 9004.
6. Charge system with new refrigerant. See Section
9003.

High Side Restriction - Indications:


A. Discharge air from heater/evaporator
only a little cool.
B. Condensation
receiver-drier.

or

frost

on

C. Liquid line to receiver-drier cool, with


frost or condensation.
NOTE: The frost will form downstream from
or at the point of the restriction

Bur 5-4030

1. Discharge refrigerant from system-restriction in


receiver-drier or liquid line must be removed.
2. Remove and replace part with restriction.
3. Remove air and moisture from the system. See
Section 9003.
4. Charge system with new refrigerant. See Section
9003.

Issued 8-06

Printed in U.S.A.

9002-21

Expansion Valve Not Operating - Indications:


A. Discharge air from evaporator warm
or cool - not cold.
B. Condensation or frost on expansion
valve outlet.
C. Inlet end of expansion valve is
warm.

Bur 5-4030

1. Expansion valve outlet with condensation or frost is


an indication of a restriction in the expansion valve.
Replace expansion valve. See Section 9004.
2. Inlet end of expansion valve is warm (not hot),
indicating expansion valve is not completely open.
If the valve is stuck closed, there will be little or no
flow of refrigerant through the valve. Replace
expansion valve. See Section 9004.

Issued 8-06

Printed in U.S.A.

9002-22

HIGH

LOW

SEE THE PRESSURE - TEMPERATURE CHART ON PAGE 14

476L7

Compressor Turning But Not Pumping Properly - Indications:


1. Discharge refrigerant from system. See Section
9003.
2. Remove the compressor from the machine. See
Section 9004.
3. Remove and replace compressor because there is
indication of internal leak in compressor.
A. System is fully charged.

4. Replace compressor.

B. Cool discharge air from evaporator.

5. Replace receiver-drier if:


A. System has been opened before.
B. Receiver-drier has been used two or more
years. See Section 9004 for receiver-drier
replacement.
6. Charge the system with refrigerant. See Section
9003.

Expansion Valve Stuck Open


Expansion Valve Stuck Open

Bur 5-4030

1. Replace expansion valve. See Section 9004.

Issued 8-06

Printed in U.S.A.

9002-23

HIGH

HIGH

SEE PRESSURE - TEMPERATURE CHART ON PAGE 14

476L7

Condenser Not Operating - Indications:


1. Check for loose or worn compressor belt and
proper condenser fan operation.
2. Check to see that condenser is clean and that
the fins are straight.
3. Check system for too much refrigerant.
A. Remove refrigerant from system until gauge
pressure is below normal. See Section 9003.
A. Liquid line very hot.
B. Discharge air from evaporator warm.

B. Add refrigerant until gauge pressures are


normal. See Section 9003.
C. If there is still a problem, do step 4.
4. Remove and inspect condenser for restrictions
caused by oil or reduced heat transfer.
A. Discharge refrigerant from system. See
Section 9003.
B. Use compressed air to remove oil from
condenser.
C. Replace receiver-drier. See Section 9004.

Air in the System - Indications:


1. Discharge refrigerant from system. See
Section 9003.
2. Replace receiver-drier.
Warm discharge air from evaporator.

3. Remove air and moisture from the


system. See Section 9003.
4. Charge system with new refrigerant. See
Section 9003.

Bur 5-4030

Issued 8-06

Printed in U.S.A.

9002-24

PROBLEM: INTERMITTENT COOLING

NORMAL

NORMAL

SEE PRESSURE - TEMPERATURE CHART ON PAGE 14

476L7

Moisture in the System - Indications:


1. Discharge system of refrigerant. If too
much moisture enters the orifice of the
expansion valve, the freezing of this
moisture can stop refrigerant flow. See
Section 9003.

Cooling is acceptable during cool part of day


but not acceptable during hot part of day.

2. Replace receiver-drier. The moisture


removing material could be full to capacity
with moisture. See Section 9004.
3. Remove air and moisture from the
system. See Section 9003.
NOTE: The time needed to remove a large
amount of moisture will be two to three hours
minimum.
4. Charge system with new refrigerant. See
Section 9003.

Bur 5-4030

Issued 8-06

Printed in U.S.A.

9002-25

PROBLEM: NOISE IN SYSTEM

NORMAL
TO HIGH

HIGH

SEE PRESSURE - TEMPERATURE CHART ON PAGE 14

476L7

Too Much Refrigerant in System - Indications:


A. Cool discharge air from heater/evaporator.
B. Compressor makes noise.

Bur 5-4030

1. Remove refrigerant from system until gauge


readings are below normal. See Section
9003.
2. Add new refrigerant until gauge readings are
normal. See Section 9003.

Issued 8-06

Printed in U.S.A.

9002-26

TUBE CONNECTIONS TORQUE CHART


TUBING SIZE

3/8 inch

1/2 inch

5/8 inch

THREAD SIZE

M10 -1.25

5/8-18

3/4-18
OR
3/4-16

7/8-18
OR
7/8-14

1-14

STEEL TO STEEL

31-36 Nm

31-36 Nm

40-46 Nm

45-52 Nm

45-52 Nm

ALUMINUM TO BRASS

10-14 Nm

10-14 Nm

24-30 Nm

30-37 Nm

45-52 Nm

NOTE: When tightening air conditioning hose or pipe fittings, a second wrench serving as support must be used.
IMPORTANT: Special care is required when tightening the fittings on the compressor, condenser and evaporator
since these connections are easily distorted.

Bur 5-4030

Issued 8-06

Printed in U.S.A.

9003

Section
9003
AIR CONDITIONER SYSTEM SERVICE

CNH America LLC.


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

Bur 5-3030

Copyright 2006 CNH Ameica LLC.


All rights reserved.
Printed in U.S.A.
Issued August, 2006

9003-2

TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRESSURE - TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 5-3030

Issued 8-06

3
3
4
5
7
10

Printed in U.S.A.

9003-3

SPECIFICATIONS
Air conditioning system refrigerant capacity ...................................................................................... 1.7 kg (3.75 lbs)

SPECIAL TOOLS

A22094

REFRIGERANT RECOVERY, RECYCLING AND RECHARGING


STATION OEM-1415

Bur 5-3030

109L7

SAFETY GOGGLES CAS-10073-3

Issued 8-06

Printed in U.S.A.

9003-4

SAFETY PROCEDURES
THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT
SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE
THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT
FOLLOWS AND BE ALERT TO THE POSSIBILITY OF
M171B
PERSONAL INJURY OR DEATH.
ATTENTION: Only authorized technicians certified
by an approved training and certification organization
may service or repair motor vehicle or mobile air
conditioning systems. It is mandatory that all
refrigerant must be RECOVERED and RECYCLED
when removed from a system during servicing.
Refrigerant HFC-134a is the most stable and easiest
to work with of the refrigerants now used in air
conditioning systems. Refrigerant HFC-134a does
not contain chlorofluorocarbons (CFCs) which are
harmful to the Earths ozone layer.
Safety procedures must be followed when working
with refrigerant HFC-134a to prevent possible
personal injury.
1. Always wear safety goggles when doing any
service work near an air conditioner system.
Liquid refrigerant getting into the eyes can cause
ser ious injur y. Do the following if you get
refrigerant near or in your eyes:
A. Flush your eyes with water for 15 minutes.

3. Keep refrigerant containers in the correct upright


position. Always keep refrigerant containers
away from heat and sunlight. The pressure in a
container will increase with heat.
4. Always reclaim refrigerant from the system, if you
are going to weld or steam clean near the air
conditioner system.
5. Always check the temperature and pressure of
the air conditioner system before reclaiming
refrigerant and when you test the system.
6. Dangerous gas can form when refrigerant comes
in contact with an open flame. Never permit
fumes to be inhaled.
7. Never leak test with compressed air or flame
testers. Tests have indicated that compressed
mixtures of HFC-134a and air can for m a
combustible gas.
8. Always reclaim refrigerant from the system
before removing any air conditioning component.

B. See a physician immediately.


2. A drop of liquid refrigerant on your skin may
cause frostbite. Open the fittings carefully and
slowly when it is necessary to service the air
conditioner system. Your skin must be treated for
frostbite or a physician must be seen if you get
refrigerant on your skin.

Bur 5-3030

Issued 8-06

Printed in U.S.A.

9003-5

AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY


Recovered refr igerant passes through an oil
separator and a filter-drier before entering the
refrigerant tank. The moisture indicator will turn
green when dry refrigerant passes over it.

STEP 3

If possible, run the air conditioning system for ten


minutes before starting the recovery process. Turn
the system off before proceeding.

STEP 1

A22114

Open the high and low valves.

STEP 4

BD03A213

Clean the external surfaces of the compressor and


hoses. Remove the caps from the service ports on
the suction and pressure hoses.

STEP 2
A22107

Make certain the refrigerant tank gas and liquid


valves are open.

BD03B001

With the charging station manifold gauge valves in


the closed position, connect the hoses from the test
gauges to the service ports.
Connect the hose from the low pressure gauge to the
port on the suction hose. Turn in valve depressor.
Connect the hose from the high pressure gauge to
the por t on the discharge hose. Tur n in valve
depressor.

Bur 5-3030

Issued 8-06

Printed in U.S.A.

9003-6

STEP 5

STEP 7

A22112

A22110

Connect the main power plug to a 115 volt AC outlet.


Move the main power switch to the ON position and
depress the recovery start switch.

Slowly open the oil drain valve and drain the oil into
the reservoir. When the oil stops draining, close the
oil drain valve completely.

The compressor will shut OFF automatically when


recovery is complete. Wait for 5 minutes and observe
the manifold pressure gauges for a pressure rise. If
pressure rises above 0 psi (0 bar), depress the
hold/cont switch. Then wait for the compressor to
automatically shut OFF.

STEP 8

STEP 6

A22111

Fill the A/C compressor with fresh SP-20 PAG oil


equal to the amount in the reservoir.

STEP 9
A22108

Drain the oil separator of the A/C system oil. Open


the air purge valve long enough to let some of the
compressor discharge pressure back into the
separator.

BD03A213

Remove the hoses from the service ports and install


the caps.

Bur 5-3030

Issued 8-06

Printed in U.S.A.

9003-7

AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING


IMPORTANT: Replace the receiver-drier if one or
more of the following conditions occurs before you
remove the air and moisture from the system.
A. The system has been opened for service
before.
B. Receiver-drier has operated two or more
years.
C. Disassembly of compressor shows small
particles of moisture removing material (gold
or brown particles).

Air and moisture are removed from the system by a


va c u u m p u m p. A v a c u u m p u m p i s t h e o n l y
equipment made to lower the pressure enough to
change the moisture to vapor that can be removed
from the system.
NOTE: Refer to the vacuum pump manufacturers
user manual for additional information.

STEP 11

D. Large system leak (broken hose, break in


line).
E. Too much air or moisture in system.
F. Removal of compressor caused the system to
be open (uncapped) longer than 5 minutes.

STEP 10
A22113

Connect the main power plug to a 115 volt AC outlet.


Move the main power switch to the ON position. If
program and vacuum do not appear at the top of the
display press the vacuum key. Program a minimum of
45 minutes and press the Enter key. The display will
flash once indicating the programmed data has been
accepted.

STEP 12
BD03B001

With the charging station manifold gauge valves in


the closed position, connect the hoses from the test
gauges to the service ports as follows:
1. Connect the hose from the low pressure gauge
to the port on the suction hose.
2. Connect the hose from the high pressure gauge
to the port on the discharge hose.
3. Turn in both thumbscrews to depress the service
valves.
Removal of air and moisture from the system is
necessary after the refrigerant has been removed
after the system has been opened for maintenance.
Air enters the system when the system is opened. Air
has moisture that must be removed to prevent
damage to the system components.

A22115

Press the Charge key. Program and Charge will


appear on the display.

NOTE: The pump on the reclamation unit will not pull


a sufficient vacuum to remove air and moisture.

Bur 5-3030

Issued 8-06

Printed in U.S.A.

9003-8

STEP 13

STEP 16

A22113

A22123

Program 3.5 lbs and press the enter key. The display
will flash once indicating the programmed data has
been accepted.

Press the Vacuum key. Automatic will appear on the


display. Vacuum will appear on the display and after
a slight delay, the vacuum pump will star t. The
display will show the amount of time programmed
and begin a countdown to zero.

STEP 14

When the programmed time has elapsed, an


automatic hold occurs. Check the low pressure
gauge to see that the A/C system maintains a 28 to
29-1/2 inches of mercury (Hg). The low pressure
gauge must not increase faster than one inch of
mercury (Hg) in 10 minutes. A previously charged,
l e a k - f r e e s y s t e m w i l l l e a c h r e f r i g e ra n t f r o m
compressor oil and raise system pressure under
vacuum. If the system will not hold vacuum, a leak
exists that must be corrected before recharging can
begin. See Section 9002 in the manual for a leak
test.
A22114

Fully open the low and high pressure valves.

STEP 17

STEP 15

A22113
A22107

Open the red (vapor) and blue (liquid) valves on the


tank.

Bur 5-3030

Press the charge key to begin refrigerant charging.


Automatic and Charge will appear on the display.
The display shows the programmed amount and
counts down to zero as charging proceeds. When
charging is completed, the display shows CPL.

Issued 8-06

Printed in U.S.A.

9003-9

STEP 18

STEP 21

A22114

BD03B001

Completely close the high and low pressure manifold


valves.

Stop the engine, close any open valves and carefully


remove the manifold gauge hoses.

ATTENTION: Check the OEM equipment manual


before performing Step 19 to avoid damaging the
recovery unit. The pressure reading should be
obtainable with valves closed. Damage may occur if
the machine is started with the valves accidently
open or if either or both valves are opened while the
A/C system is operating.

STEP 22

STEP 19
Start the engine and run at 1500 RPM. Operate the
air conditioner system at maximum cooling setting
and blower speed with the doors and windows open.
NOTE: The compressor will not operate if the
system pressure is too low or too high. The pressure
indicator lamp will illuminate when the relay is
actuated by a low or high pressure and the
compressor clutch will disengage. To restart the
compressor, the air conditioner control or blower
switch must be turned to the OFF position and then
to the ON position.

BD03B213

Install the caps on the service ports on the suction


and discharge hoses.

STEP 20

A22117

Observe the pressure gauge readings to determine


that the correct amount of refrigerant has entered the
system. See chart on Page 9002-9 for temperature
and pressure variations.
Bur 5-3030

Issued 8-06

Printed in U.S.A.

9003-10

PRESSURE - TEMPERATURE CHART


AMBIENT
NORMAL LOW
NORMAL HIGH
TEMPERATURE PRESSURE INDICATION PRESSURE INDICATION
F (C)
psi (bar)
psi (bar)

AIR LOUVER
MAXIMUM TEMP.
F (C)

80 (27)

9 to 12
(0.62 to 0.83)

145 to 165
(10 to 11.5)

55 (14)

90 (32)

11 to 15
(0.76 to 1.04)

190 to 210
(13.1 to 14.5)

61 (18)

95 (35)

16 to 18
(1.10 to 1.24)

210 to 230
(14.5 to 15.8)

63 (20)

100 (38)

17 to 19
(1.17 to 1.31)

235 to 255
(16.2 to 17.6)

66 (22)

105 (41)

20 to 21
(1.38 to 1.45)

260 to 280
(17.9 to 19.3)

68 (23)

110 (43)

22 to 24
(1.93 to 2.14)

290 to 310
(20 to 21.4)

72 (25)

The pressure-temperature chart is based on the


following conditions:
1. Engine operating at 1500 RPM
2. No engine load
3. Fan speed control in maximum position and all
louvers open.

5. Both cab doors open


6. All panels and access doors installed and closed.
7. Cab filters clean and installed.
8. Heater valve at engine closed.
9. Measurements taken 15 minutes after start-up.

4. Cab temperature control set to maximum


cooling.

Bur 5-3030

Issued 8-06

Printed in U.S.A.

REMOVAL AND INSTALLATION OF AIR CONDITIONING


AND HEATER COMPONENTS

CNH America LLC.


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

Bur 5-3040

Copyright 2006 CNH Ameica LLC.


All rights reserved.
Printed in U.S.A.
Issued August, 2006

9004

Section
9004

9004-2

TABLE OF CONTENTS
SAFETY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EXPANSION VALVE, EVAPORATOR/HEATER CORE,
HEATER VALVE, BLOWERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONDENSER AND RECIEVER DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 5-3040

Issued 8-06

3
4
5
5
6
8
9
14
19
19
20

Printed in U.S.A.

9004-3

SAFETY PROCEDURES
THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT
SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE
THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT
FOLLOWS AND BE ALERT TO THE POSSIBILITY OF
M171B
PERSONAL INJURY OR DEATH.
ATTENTION: Only authorized technicians certified
by an approved training and certification organization
may service or repair motor vehicle or mobile air
conditioning systems. It is mandatory that all
refrigerant must be RECOVERED and RECYCLED
when removed from a system during servicing.
Refrigerant HFC-134a is the most stable, and easiest
to work with of the refrigerants now used in air
conditioner systems. Refrigerant HFC-134a does not
contain any chlorofluorocarbons (CFCs) which are
harmful to the earths ozone layer.
Safety procedures must be followed when working
with Refrigerant HFC-134a to prevent possible
personal injury.
1. Always wear safety goggles when doing any
service work near an air conditioner system.
Liquid refrigerant getting into the eyes can cause
ser ious injur y. Do the following if you get
refrigerant near or in your eyes:
A. Flush your eyes with water for 15 minutes.

3. Keep refrigerant containers in the correct upright


position. Always keep refrigerant containers
away from heat and sunlight. The pressure in a
container will increase with heat.
4. Always reclaim refrigerant from the system if you
are going to weld or steam clean near the air
conditioner system.
5. Always check the temperature and pressure of
the air conditioner system before reclaiming
refrigerant and when you test the system.
6. Dangerous gas can form when refrigerant comes
in contact with an open flame. Never permit
fumes to be inhaled.
7. Never leak test with compressed air or flame
testers. Tests have indicated that compressed
mixtures of HFC-134a and air can for m a
combustible gas.
8. Always reclaim refrigerant from the system
before removing any air conditioning component.

B. See a physician immediately.


2. A drop of liquid refrigerant on your skin may
cause frostbite. Open the fittings carefully and
slowly when it is necessary to service the air
conditioner system. Your skin must be treated for
frostbite or a physician must be seen if you get
refrigerant on your skin.

Bur 5-3040

Issued 8-06

Printed in U.S.A.

9004-4

SPECIAL TOOLS

A22094

REFRIGERANT RECOVERY, RECYCLING AND CHARGING


STATION OEM-1415

Bur 5-3040

BS03H012

SAFETY GOGGLES CAS-10073-3

Issued 8-06

Printed in U.S.A.

9004-5

COMPRESSOR
Removal

STEP 4

STEP 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

Remove the fan belt.

STEP 5

BD06F113

BD06F117

Disconnect the low pressure line from the suction


port and the high pressure line from the discharge
p o r t o n t h e c o m p r e s s o r. I m m e d i a t e l y i n s t a l l
protective caps on the open ports and lines.

BD06F114

Loosen and remove the four bolts holding the


protective shield. Remove the shield.

Bur 5-3040

Issued 8-06

Printed in U.S.A.

9004-6

Installation

STEP 6

STEP 9
Place the compressor into position on the machine.

STEP 10

BD06F117

Disconnect the compressor clutch wire from the


engine harness assembly.

STEP 7
BD06F117

Install the three bolts to mount the compressor.

STEP 11

BD06F117

Loosen and remove the three compressor mounting


bolts.

STEP 8
Remove the compressor from the machine.

Bur 5-3040

BD06F117

Connect the compressor clutch wire to the engine


harness assembly.

Issued 8-06

Printed in U.S.A.

9004-7

STEP 12

STEP 13
Carefully remove the protective cap, install a new
O-ring, and connect the low pressure line to the
suction port on the compressor.

STEP 14
Install the belt.

STEP 15
Install the protective shield.

STEP 16
BD06F117

Charge the air conditioning system according to the


instructions in Section 9003.

Slowly remove the protective cap, install a new


O-ring, and connect the high pressure line to the
discharge port on the compressor.
IMPORTANT: Use caution when removing cap as
new compressors have internal pressure when
shipped.

Bur 5-3040

Issued 8-06

Printed in U.S.A.

9004-8

EXPANSION VALVE, EVAPORATOR/HEATER CORE,


HEATER VALVE, BLOWERS
3

7
4

2
1
8
9

10

18
17
12

14

11

13

16
15

BS06G118

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

Bur 5-3040

EVAPORATOR
UPPER BOX PPE
COVER PPE
SOLENOID DRIVER
UPPER BOX
BOLT

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

WASHER
GROMMET
HEATER CORE
HEATER VALVE 24V
THERMOSTAT
LOWER BOX

13.
14.
15.
16.
17.
18.

LOWER BOX PPE


EXPANSION VALVE
BLOWER
RECIRCULATING VAIN
RECIRCULATING MOTOR
RESISTOR BLOWER MOTOR

Issued 8-06

Printed in U.S.A.

9004-9

Removal

STEP 23

STEP 17
Park the machine on a level surface and lower the
bucket to the floor.

STEP 18
If changing any air conditioning components,
discharge the air conditioning system according to
the instructions in Section 9003.

STEP 19
BD06G212

Open the cover on the cooler.

STEP 24

BD02N160

If changing the heater core, put a 37 liter (10 gallon)


container below radiator drain. Remove radiator cap.
Remove cap and drain coolant into container. Install
cap after coolant has drained. Install radiator cap.

BD06G213

Remove the four screws securing the air vent,


remove the vent cover.

STEP 20
Place the master disconnect in the OFF position.

STEP 25

STEP 21
Disconnect the wiring harness from the operators
seat (if equipped with air seat option).

STEP 22

BD06G214

Remove the three screws securing the cooler to the


cab, remove the cooler.

STEP 26
BD06G202

Fold the rubber mat over to gain access to the upper


box mounting bolts.

Remove the four bolts that fasten the operators seat


to the upper box, remove the seat from the machine.
Bur 5-3040

Issued 8-06

Printed in U.S.A.

9004-10

STEP 27

STEP 30

BD06G215

Remove the six bolts securing the upper box.

BD06G217

G o i n g t h r o u g h th e i n s i d e f i l t e r a r e a fe e l th e
recirculating vain to make sure is is in the outside air,
closed, position.

STEP 28

STEP 31

BD06G216

Remove two screws, one on each side of the upper


box, securing the upper box to the lower box.

BD06G218

STEP 29

The above photo shows that the recirculating vain is


not in the outside air closed position.

Place the air selector on the control panel to outside


air.

STEP 32

NOTE: In step 30 and 33 the upper box is shown


removed for clarity only, these steps must be done
prior to removing the upper box.

BD06G240

Use a screw driver and disconnect the linkage.

Bur 5-3040

Issued 8-06

Printed in U.S.A.

9004-11

STEP 33

STEP 36

BD06G219

Close the vain so the upper cover can be removed.

BD06G203

Disconnect the solenoid driver.

STEP 34
Remove the upper box up and rest it against the
console.

STEP 37

NOTE: The wiring harness for the HVAC system


goes through the upper cover, by resting the cover
against the console the wiring harness will not need
to be removed.

STEP 35

BD06G236

Remove the upper PPE from the heater and air


conditioning cores.
NOTE: If testing on the electrical components are
required the solenoid driver can be reconnected
once the upper PPE is removed.

BD06G220

Pull the wiring harness loose from the upper PPE.

Bur 5-3040

Issued 8-06

Printed in U.S.A.

9004-12
NOTE: If replacing the heater control valve, heater
core, air conditioning expansion valve, air
conditioning evaporator core do steps 38 through 47,
if replacing electrical components go to step 48.

STEP 40

STEP 38

BD06G206

Remove the thermostat probe and clamp from the


evaporator core.

STEP 41
BD06G204

Remove the right side cab skirt.

STEP 39

BD06G237

Disconnect the electrical connectors from the


thermostat control.

STEP 42
BD06G205

1. TRANSMISSION FILTER
2. AIR CONDITIONING HOSES
3. HEATER HOSES

Fasten identification tags on the hoses. Disconnect


the hoses for the heater core and evaporator core,
install plugs in the hoses and caps on the fittings.

BD06G236

Disconnect the electrical connectors from the heater


control valve.

Bur 5-3040

Issued 8-06

Printed in U.S.A.

9004-13

STEP 43

STEP 49

Pull the heater core and evaporator core from the


lower box PPE.

STEP 44
Remove the expansion valve from the evaporator
core.

STEP 45
Remove and discard the O-rings from the openings
in the expansion valve.

STEP 46
Remove the screws from the heater core and remove
the control valve.

STEP 47
Remove and discard the O-rings from the heater
control valve.

BD06G208

D i s c o n n e c t t h e e l e c t r i c a l c o n n e c t o r fo r t h e
recirculating vain motor, disconnect the linkage from
the vain. Remove the mounting screws and remove
the motor.

STEP 50

STEP 48
1

3
2
BD06G209
BD06G207

1. RESISTORS
2. RESISTOR CONNECTOR
3. BLOWER MOTOR CONNECTOR

Remove the fans from the lower PPE, disconnect the


electrical connectors. Remove the two mounting
screws for the resistor, remove the resistor.

Bur 5-3040

1. FAN SPEED AND A/C SWITCH


2. INSIDE/OUTSIDE AIR SELECTOR SWITCH
3. THERMOSTAT

R e m ove t h e sw i t c h p a n e l f r o m t h e c o n s o l e.
Disconnect the electrical connectors and remove
switches as required.

Issued 8-06

Printed in U.S.A.

9004-14

Installation

STEP 53

STEP 51
1

1
2

3
3
2

BD06G207

BD06G209

1. FAN SPEED SWITCH


2. INSIDE/OUTSIDE AIR SELECTOR SWITCH
3. THERMOSTAT

Re place switches and connect the electr ical


connectors as required. Install the switch panel in the
console.

1. RESISTORS
2. RESISTOR CONNECTOR
3. BLOWER MOTOR CONNECTOR

Install the resistor, install the two mounting screws


and tighten. Install the fans in the lower PPE, connect
the electrical connectors.

STEP 54
Install new O-rings on the heater control valve.

STEP 52
STEP 55
Install the control valve, install and tighten the screws
to the heater core.

STEP 56
Install new O-rings on the openings of the expansion
valve.

STEP 57
Install the heater core and evaporator core into the
lower box PPE.
BD06G208

STEP 58

Install the motor and install the mounting screws and


tighten. Connect the electrical connector for the
recirculating vain motor, connect the linkage to the
vain.

BD06G236

Connect the electrical connectors to the heater


control valve.

Bur 5-3040

Issued 8-06

Printed in U.S.A.

9004-15

STEP 59

STEP 61
3

BD06G237

Connect the electrical connectors to the thermostat


control.

STEP 60

BD06G205

1. TRANSMISSION FILTER
2. AIR CONDITIONING HOSES
3. HEATER HOSES

Remove the plugs from the hoses and the caps from
the fittings. Install new O-rings in the evaporator
fittings, connect the heater and evaporator hoses.
Remove and discard identification tags that were
used during disassemble.

STEP 62

BD06G206

Install the thermostat probe coil and clamp to the


evaporator core cold tube.

BD06G204

Install the right side cab skirt.

STEP 63

BD06G238

Install the upper PPE on the heater and air


conditioning cores.
Bur 5-3040

Issued 8-06

Printed in U.S.A.

9004-16

STEP 64

STEP 67

BD06G210.
BD06G203

Connect the solenoid driver.

Make sure that the recirculating vain is in the closed


position.
IMPORTANT: This photo shows it in the open
position and the upper box will not go back into
position without damaging the recirculating vain.

STEP 65

STEP 68

BD06G239

Push the wiring harness into the preformed notches


in the upper PPE.

BD06G241

STEP 66

Set the upper box into position on the heater and


evaporator cores.

Place the air selector on the control panel to outside


air.

STEP 69

BD06G216

Install two screws, one on each side of the upper box


securing the upper box to the lower box.

Bur 5-3040

Issued 8-06

Printed in U.S.A.

9004-17

STEP 70

STEP 74

BD06G242

BD06G214

Install the insolation panel in the center of the upper


box.

Install and tighten the three screws securing the


cooler to the cab.

STEP 71

STEP 75

BD06G215

BD06G213

Install and tighten the six bolts securing the upper


box.

Install the vent cover, install and tighten the four


screws securing the air vent.

STEP 72

STEP 76

BD06G243

Install the right rear floor mat into the cab, if machine
is equipped with air ride seat make sure to pull the
wiring up above the mat for the seat.

BD06G202

Install and torque the four bolts to 73 to 87 Nm (55 to


65 pound-feet).

STEP 73
Install the remainder of the floor mat.

Bur 5-3040

Issued 8-06

Printed in U.S.A.

9004-18

STEP 77

STEP 79

Connect the wiring connector to the operators seat


(if equipped with air seat option).

Charge the air conditioning system according to the


instructions in Section 9003.

STEP 78
Fill engine coolant system with a solution of 50%
Ethylene Glycol and 50% water. Install the radiator
cap. Fill the coolant reservoir up to the FULL mark on
the reservoir.

Bur 5-3040

Issued 8-06

Printed in U.S.A.

9004-19

CONDENSER AND RECIEVER DRIER


Removal

STEP 85

STEP 80
Park the machine on a level surface and lower the
bucket to the ground.

STEP 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

Fa s t e n i d e n t i f i c a t i o n t a g s o n t h e h o s e s a n d
disconnect the hoses from the condenser.

STEP 83

STEP 86

Install plugs in the hoses and caps on the fittings.

STEP 87

BD01D142

1. COVER

2. CONDENSER

Open the cover (1) to gain access to the condenser


(2).

STEP 84
BS03A109

Loosen the bolts that fasten the condenser to the


bracket, pivot the condenser and remove the bolts
and condenser.

BD03A109

The condenser is connected to a bracket which


pivots on the cooling frame. Pivot the condenser to
gain access to the hoses.

Bur 5-3040

Issued 8-06

Printed in U.S.A.

9004-20

Installation

STEP 88

STEP 91
Put the condenser in position on the bracket.

STEP 92

BD06G211

Fa s t e n i d e n t i f i c a t i o n t a g s o n t h e h o s e s a n d
disconnect the hoses from the receiver drier.

STEP 89
Install plugs in the hoses and caps on the fittings.

STEP 90
Disconnect the trinary switch, remove the mounting
bolt, remove the receiver drier and bracket.

BS03A109

Install the bolts that fasten the condenser to the


bracket, pivot the condenser down and tighten the
bolts.

STEP 93

BS03A107

Pivot the condenser to gain access to the hoses.

STEP 94
Remove the plugs from the hoses and the caps from
the fittings. Install new O-rings and connect the
hoses to the fittings. Remove and discard
identification tags that were used during
disassemble.

STEP 95
Pivot the condenser down and close the cover.

STEP 96
Mount the receiver drier and bracket, install and
tighten the mounting bolt.

Bur 5-3040

Issued 8-06

Printed in U.S.A.

9004-21

STEP 97

STEP 98
Charge the air conditioning system according to the
instructions in Section 9003.

STEP 99
Place the master disconnect switch in the ON
position.

BD06G211

Remove plugs from the hoses and caps from the


fittings, install new O-rings and connect the hoses to
the fittings, connect the trinary switch. Remove and
discard identification tags that were used during
disassemble.

Bur 5-3040

Issued 8-06

Printed in U.S.A.

9004-22

NOTES

Bur 5-3040

Issued 8-06

Printed in U.S.A.

Section
9006

9006

LOADER

CNH America LLC.


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

Bur 5-3300

Copyright 2006 CNH Ameica LLC.


All rights reserved.
Printed in U.S.A.
Issued August, 2006

9006-2

TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUCKET TEETH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement of the Tooth Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement of the Bucket Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement of the Bucket Corner Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RETURN TO DIG ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE LOADER FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE LOADER FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 5-3300

Issued 8-06

3
3
3
3
3
4
5
7
9

Printed in U.S.A.

9006-3

SPECIFICATIONS
Special Torques
Bolts for the Bucket Teeth ........................................................................1315 to 1480 Nm (970 to 1090 pound-feet)

BUCKET TEETH
Replacement of the Tooth Points
3

1. Use a hammer and punch to drive the retaining


pin (1) for the tooth point (2) out of the tooth
shank (3), refer to the illustration on this page.

2. Remove the tooth point (2).


3. Install a new tooth point (2) on the tooth shank
(3).
4. Install the retaining pin (1) into the tooth point (2)
and tooth shank (3). Make sure the shoulder on
the retaining pin is toward the cutting edge. Use
a hammer to hit the retaining pin (1) until the
retaining pin (1) is even with the outside of the
tooth shank (3).

7
3
2

10

Replacement of the Bucket Teeth


1. Loosen and remove the nuts (4), hardened
washers (5), and bolts (6) from the bucket teeth.

9
7

NOTE: If wear of the bolt or nut makes removal


difficult, the bolt or nut can be cut off.
2. Remove the tooth.

B0740A88J

3. Install the new tooth on the bucket cutting edge


(7).
4. Use new nuts (4), hardened washers (5), and
bolts (6) for the tooth being installed.
5. Tighten the nuts (4) to 1315 to 1480 Nm (970 to
1090 pound-feet).

1.
2.
3.
4.
5.

RETAINING RING
TOOTH POINT
TOOTH SHANK
NUT
HARDENED WASHER

6.
7.
8.
9.
10.

BOLT
CUTTING EDGE
PLOW BOLT
NUT
CORNER TOOTH

BUCKET TEETH ILLUSTRATION

Replacement of the Bucket Corner


Teeth
1. Loosen and remove the nuts (9) and bolts (8)
from the bucket corner teeth (10).
NOTE: If wear of the bolt or nut makes removal
difficult, the bolt or nut can be cut off.
2. Remove the corner tooth (10).
3. Install the new corner tooth (10) on the bucket
cutting edge (7).
4. Use new nuts (9) and bolts (8) for the corner
tooth being installed.
5. Tighten the nuts (9) to 1315 to 1480 Nm (970 to
1090 pound-feet).
Bur 5-3300

Issued 8-06

Printed in U.S.A.

9006-4

RETURN TO DIG ADJUSTMENT

2
6
1

3
4

BS01C083

1. TARGET MOUNTING BRACKET


2. BUCKET CYLINDER

3. TARGET BAR
4. PROXIMITY SWITCH MOUNTING BRACKET

5. PROXIMITY SWITCH
6. PROXIMITY SWITCH GUARD

RETURN TO DIG ADJUSTMENT ILLUSTRATION

IMPORTANT: Before adjusting the return-to-dig,


make sure that the target bar on the bucket linkage is
not damaged. Slowly roll back and dump the bucket
and make sure that the target bar stays the same
distance from the switch. The switch mounting
bracket protects the switch. Make sure the target bar
cannot touch the switch when the bucket is dumped.
1. Park the machine on a level surface. Raise the lift
arms until they are approximately horizontal and
dump the bucket. Lower the bucket until the
bucket edge is on the ground.
2. Apply the parking brake and stop the engine.
3. Loosen the bolts holding the target mounting
bracket (1) to the tilt cylinder eye. Align the target
mounting bracket (1) parallel to the tilt cylinder
(2). Tighten the bolts, refer to the illustration on
this page.
4. Loosen the bolts holding the proximity switch
mounting bracket (4) to the tilt cylinder (2).
Position the proximity switch (5) parallel to the
target bar (3) and tighten the bolts.
5. Adjust the proximity switch (5) out towards the
target bar (3), until an air gap of 3.2 to 5.0 mm
(1/8 to 3/16 inch) is obtained. Torque the jam nut
to 6 to 7.5 Nm (4.5 to 5.5 pound-feet).
NOTE: The proximity switch (5) must not protrude
past the proximity switch guard (6).
6. Start the engine, position the bucket to the
correct digging angle and stop the engine.

7. Loosen the bolts holding the target bar (3) to the


target mounting bracket (1). Slide the target bar
(3) towards the proximity switch (5) until the face
of the proximity switch (5) is completely covered.
8. Align the target bar (3) parallel to the tilt cylinder
(2) and tighten the bolts.
9. Turn the ignition switch to the ON position. Do
NOT start the engine.
10. Place the bucket control lever in the ROLLBACK
position.
11. Loosen the bolts holding the target bar (3) to the
target mounting bracket (1).
12. Slide the target bar (3) slowly away from the
proximity switch (5), until the control lever returns
to the center position. Tighten the bolts holding
the target bar (3).
13. Check to make sure that the 3.2 to 5.0 mm (1/8
to 3/16 inch) gap is still maintained.
14. Start the engine.
15. Place the detent switch in the ON position and
place the return to travel/float detent switch to the
TRAVEL position.
16. Raise the lift arms approximately horizontal, and
put the bucket in the fully dumped position.
17. Place the loader control lever in the ROLLBACK
position, and verify that the electromagnet holds
it in that position until the end of the target bar (3)
passes in front of the proximity switch (5).
18. Lower the lift arms and verify that the bucket is at
the correct digging angle.

Bur 5-3300

Issued 8-06

Printed in U.S.A.

9006-5

HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT

5
6

3
2
1

BS01C081

1. TARGET MOUNTING PLATE


2. HEIGHT CONTROL TARGET

3. PROXIMITY SWITCH
4. LIFT ARM

5. RETURN TO TRAVEL TARGET


6. FRONT CHASSIS (TOP LEFT HAND SIDE)

HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT ILLUSTRATION

1. Park the machine on a level surface.


2. Start the engine and apply the parking brake.
3. Lower the lift arms and place the bucket flat on
the ground.
4. Stop the engine.

6. Adjust the proximity switch (3) out towards the


return to travel target (5) until an air gap of 3.2 to
5.0 mm (1/8 to 3/16 inch) is obtained.
7. Lock the proximity switch (3) in this position with
the jam nut. Torque the jam nut to 6 to 7.5 Nm
(4.5 to 5.5 pound-feet).

NOTE: To avoid damage to the proximity switch (3),


it must be adjusted back to clear everything on the lift
arm as it passes. Refer to the illustration on this
page.
WARNING: Raised equipment on the machine
without an operator can cause injury or death.
Before you leave the operators compar tment,
always suppor t or lower the equipment
(backhoe, blade, boom, bucket, etc.) to the
ground and stop the engine.
CSM105

5. Position the return to travel target (5) opposite


the proximity switch (3) and tighten it to the target
mounting plate (1).
Bur 5-3300

Issued 8-06

Printed in U.S.A.

9006-6

2
A

3
B

BS01C082

1. HEIGHT CONTROL TARGET

2. RETURN TO TRAVEL TARGET

MACHINE

APPROXIMATE
RESULTING RETURN TO
TRAVEL HINGE PIN
HEIGHT

821E

56 mm (2.2 inches)

414 mm (16.3 inches)

3. TARGET MOUNTING PLATE

APPROXIMATE
RESULTING HEIGHT
CONTROL HINGE PIN
HEIGHT

42 mm (1.6 inches)

3302 mm (130 inches)

HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT ILLUSTRATION

8. Refer to the table and the illustration on this


page. Position the height control target (1) on the
target mounting plate (3) using the table above.
NOTE: The higher the height control target (1) is
positioned in its slot in the target mounting plate (3),
the lower the lift arms will stop as they are raised.
9. Tighten the height control target (1).
10. Position the return to travel target (2) using the
table above.
NOTE: The higher the return to travel target (2) is
positioned in its slot in the target mounting plate (3),
the lower the lift arms will stop as they are lowered.
11. Check to make sure the proximity switch (3) and
all of the mounting bolts are tight. Refer to the
illustration on page 5.

14. Place the loader control lever in the raise position


and verify that the electromagnet holds it in that
position until the height control target (2) passes
in front of the proximity switch (3). Refer to the
illustration on page 5.
15. With the lift arms still raised, place the loader
control lever in the lower position and verify that
the electromagnet holds it in that position until
the return to travel target (5) passes in front of
the proximity switch (3). Refer to the illustration
on page 5.
16. Repeat steps 8 through 15 until the desired
heights are reached.
17. Lower the bucket to the ground and stop the
engine.

12. Start the engine.


13. Place the detent switch in the ON position, and
set the return to travel/float detent switch to the
return to travel position.

Bur 5-3300

Issued 8-06

Printed in U.S.A.

9006-7

REMOVING THE LOADER FRAME


1. Park the machine on a level surface and apply
the parking brake. Roll the bucket all the way
forward and lower the bucket to the floor. Stop
the engine.
2. Loosen the filler plug in the reservoir to release
the air in the reservoir.
3. Fasten a chain hoist to the cross member (1) of
the loader frame (2), refer to the illustration on
page 8.

17. Loosen and remove the bolt (19), flat washer


(20) and spacer (21) that fasten the pivot pin (9
or 10) to the front frame.
18. Raise the loader frame slightly. Use an
acceptable driver and drive the pivot pin (9 or 10)
out of the front frame. Do not lose the washers
(18) and wipers (22) between the front frame and
the loader frame (2).

4. Loosen and remove the bolt (12), flat washer


(13), and spacer (14) that fasten the pivot pin (3)
to the piston rod yoke of the right lift cylinder (4).
5. Use an acceptable driver and drive the pivot pin
(3) out of the piston rod yoke of the right lift
cylinder (4). Do not remove the driver.
6. Repeat Steps 4 and 5 for the left lift cylinder (6).
7. Start the engine. Roll the bucket back and lower
the bucket so that the bucket is flat on the floor
and fasten the chain hoist to a lift cylinder (4 or
6).
8. Raise the lift cylinder (4 or 6) slightly and remove
the driver.

BD01G009

19. Remove the proximity switch cover. Left-hand


side of the machine only.

9. Repeat steps 7 and 8 for the other lift cylinder (4


or 6).
10. Connect the chain hoist to the bucket cylinder
(8).
11. Loosen and remove the bolt (15), flat washer
(16), and spacer (17) that fasten the pivot pin (7)
for the piston rod eye of the bucket cylinder (8) to
the bell crank (11).

1
2

12. Use an acceptable driver and drive the pivot pin


(7) out of the piston rod eye of the bucket cylinder
(8).
BD01G010

13. Raise the bucket cylinder (8) and use a chain or


other acceptable holding equipment to hold the
bucket cylinder (8) in place.
14. If the machine is equipped with auxiliary
hydraulics, disconnect the two hoses from the
tubes at the bracket on the right side of the
loader frame (2). Install caps on the hoses and
plugs in the tube fittings.
15. If the machine is equipped with front lamps,
loosen and remove the cap screws and lock
washers that fasten the lamp brackets to the front
frame. Put the lamp brackets on the fenders.

1. ELECTRICAL CONNECTION

2. PROXIMITY SWITCH

20. Disconnect the electrical connector (1), remove


the lock nut from the proximity switch (2) and
remove the proximity sw itch (2) fr om the
machine. Left-hand side of the machine only.
21. Repeat Steps 17 and 18 for the other pivot pin (9
or 10).
22. Raise the loader frame (2) out of the front frame.
Carefully move the machine out of the loader
frame (2).

16. Connect the chain hoist to the loader frame (2).

Bur 5-3300

Issued 8-06

Printed in U.S.A.

9006-8

10

19

18

22

20 18

8
16
6

15

17

2
11

1
21

5
4

14
5

12
3
13
23

BS01G022

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

CROSS MEMBER
LOADER FRAME
PIVOT PIN
LIFT CYLINDER
PIVOT PIN
LIFT CYLINDER

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

PIVOT PIN
BUCKET CYLINDER
PIVOT PIN
PIVOT PIN
BELL CRANK
BOLT

13.
14.
15.
16.
17.
18.

WASHER
SPACER
BOLT
WASHER
SPACER
WASHER

19.
20.
21.
22.
23.

BOLT
WASHER
SPACER
WIPER
DUMP LINK

LOADER FRAME ILLUSTRATION

Bur 5-3300

Issued 8-06

Printed in U.S.A.

9006-9

INSTALLING THE LOADER FRAME


1. Apply antiseize compound to the inner bores and
outer bores for the pivot pins of the front frame,
refer to the illustration on page 8.
2. Move the machine into alignment with the loader
frame (2).
3. Lower the loader frame (2) into alignment with
the front frame.
4. Apply antiseize compound to the pivot pins (9
and 10) that fasten the loader frame (2) to the
front frame.
5. Start the pivot pins (9 and 10) into the front
frame. Install the washers (18) and new wipers
(22) between the loader frame (2) and the front
frame.
6. Install the pivot pins (9 and 10) all the way.
7. Install the bolt (19), washer (20) and spacer (21)
that fasten the pivot pins (9 and 10). Tighten the
bolt.
8. Install the proximity switch and cover. Left-hand
side of the machine only.
9. Disconnect the chain hoist from the loader frame
(2).
10. If the machine is equipped with front lamps, hold
the front lamps in place and install the cap
screws and lock washers that fasten the front
lamps to the front frame. Tighten the cap screws.
11. If the machine is equipped with auxiliary
hydraulics, remove the plugs from the tube
fittings and the caps from the hoses. Connect the
hoses to the tubes.
12. Connect the chain hoist to the bucket cylinder (8)
and lower the bucket cylinder (8).
13. Start the engine and run the engine at low idle.
14. Have another person help you at this time. Move
the bucket control lever as required to align the
piston rod eye of the bucket cylinder (8) with the
bell crank (11). Stop the engine.
IMPORTANT: D o n o t u s e yo u r f i n g e r s t o
check the alignment of the cylinder rod.
Personal injury can be the result.
48-88

15. Install the pivot pin (7) in the bell crank (11) and
the piston rod eye of the bucket cylinder (8).
16. Install the bolt (15), washer (16), and spacer (17)
that fasten the pivot pin (7). Tighten the bolt.

Bur 5-3300

17. Disconnect the chain hoist from the bucket


cylinder (8).
18. Fasten the chain hoist to one of the lift cylinders
(4 or 6).
19. Raise the piston rod yoke of the lift cylinder (4 or
6) so the piston rod yoke is aligned with the
loader frame (2).
20. Install a driver in the piston rod yoke and the
loader frame (2).
21. Repeat Steps 18, 19, and 20 for the other lift
cylinder (4 or 6).
22. Disconnect the chain hoist from the lift cylinder (4
or 6).
23. Start the engine. Raise the loader frame and roll
the bucket all the way forward. Lower the bucket
to the floor. Stop the engine.
24. Fasten the chain hoist to the cross member (1) of
the loader frame (2).
25. Start the engine and run the engine at low idle.
26. Have another person help you at this time. Move
the lift control lever as required to align the piston
rod yoke of one of the lift cylinders (4 or 6) with
the loader frame (2).
IMPORTANT: D o n o t u s e yo u r f i n g e r s t o
check the alignment of the cylinder rod.
Personal injury can be the result.
48-88

27. Remove the driver and install the pivot pin (3).
28. Install the bolt (12), washer (13), and spacer(14)
that fasten the pivot pin (3). Tighten the bolt.
29. Repeat Steps 26, 27, and 28 for the other lift
cylinder (4 or 6). Stop the engine.
30. Lubricate the pivot pins with molydisulfide
grease.
31. Disconnect the chain hoist from the cross
member (1) of the loader frame (2).
32. Tighten the filler plug in the reservoir.
33. If the machine is equipped with auxiliary
hydraulics, start the engine and run the engine at
low idle.
34. Slowly extend and retract the clam cylinders four
times to remove air from the auxiliary circuit.
35. Stop the engine, check the level of the oil in the
reservoir, and check for leaks. Add oil to the
reservoir as required.
Issued 8-06

Printed in U.S.A.

9006-10

NOTES

Bur 5-3300

Issued 8-06

Printed in U.S.A.

Section
9007

9007

ROLLOVER PROTECTIVE STRUCTURE (ROPS)


CAB STRUCTURAL FRAME (CSF)

CNH America LLC.


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

Bur 5-4070

Copyright 2006 CNH Ameica LLC.


All rights reserved.
Printed in U.S.A.
Issued August, 2006

9007-2

TABLE OF CONTENTS
ROLLOVER PROTECTIVE STRUCTURE (ROPS)
CAB STRUCTURAL FRAME (CSF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE AND INSPECTION OF THE (CSF) CAB OR (ROPS) CANOPY . . . . . . . . . . . . . . . . . . . . . . . .
CSF CAB AND ROPS CANOPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 5-4070

Issued 8-06

3
3
4
4
9

Printed in U.S.A.

9007-3

ROLLOVER PROTECTIVE STRUCTURE (ROPS)


CAB STRUCTURAL FRAME (CSF)
Attention

The Rollover Protective Structure (ROPS) or Cab


S t r u c t u r a l Fr a m e ( C S F ) i s a s p e c i a l s a fe t y
component of your machine.

After an accident, fire or rollover, the following MUST


be performed before returning the machine to field or
job site operation:

The ROPS or CSF structure MUST be replaced.

The ROPS or CSF mounting or suspension,


operator seat and suspension, seat belts and
mounting components and wiring within the
operators protective system MUST be carefully
inspected for damage.

All damaged parts MUST be replaced.

DO NOT attach any device to the ROPS or CSF for


pulling purposes.
The ROPS or CSF is a certified structural support
and any damage, fire, corrosion or modification will
weaken the structure and reduce your protection. If
this occurs, the ROPS or CSF MUST be replaced so
that it will provide the same protection as a new
ROPS or CSF.

DO NOT WELD, ATTEMPT TO STRAIGHTEN OR


REPAIR THE ROPS OR CAB STRUCTURAL
FRAME.

MAINTENANCE AND INSPECTION OF THE (CSF) CAB OR (ROPS) CANOPY


After every 500 hours of operation or every six
months, whichever comes first, do the following:
1. Check the torque on the CSF cab or ROPS
canopy mounting bolts; torque should be 773 to
854 Nm (570 to 630 lb-ft). If necessary, tighten
the bolts to the correct torque.
2. Check that seat belt mounting hardware is tight
and seat belt is not cut or frayed. Check the
torque on operators seat mounting bolts; torque
should be 73 to 87 Nm (54 to 64 lb-ft). If
necessary, tighten the bolts to the correct torque.
Replace parts that are worn or damaged.
WARNING: Grade 8 hardware is used to
mount and anchor the ROPS. Parts used for
replacement must be those shown in the
47-27A
parts catalog.

Bur 5-4070

WARNING: Do not install attachments that


will make the total weight of the machine
more than the weight shown in the maximum
gross vehicle weight section of the ROPS
47-26
serial number plate.
WARNING: Do not change the ROPS in any
way. Changes made to the ROPS which are
not authorized, such as welding, drilling or
cutting will make the ROPS weaker and
decrease your protection. Replace the
ROPS if it becomes damaged in any way.
DO NOT TRY TO MAKE REPAIRS TO THE
47-25
ROPS.

Issued 8-06

Printed in U.S.A.

9007-4

CSF CAB AND ROPS CANOPY


Removal

STEP 5

NOTE: Procedures and photos in following steps


cover in detail removal and installation of CSF
structure. Removal and installation of ROPS is
similar to removal and installation of CSF structure.

STEP 1
Park machine on a level surface and lower bucket to
floor. Stop engine. Actuate brake pedal several times
to discharge brake accumulators. Put key switch in
ON position and move loader control lever back and
forth at least 30 times to release any pressure from
hydraulic circuit. Put key switch in OFF position.

BD06G191

Remove skirting under each side and front of cab.

STEP 2

STEP 6

BD01F143

Put articulation lock in LOCKED position.

BD06G186

Remove the ducts from the machine.

STEP 3

STEP 7

Put battery disconnect switch in OFF position.

STEP 4

BD06G189

BD01F184

At RH rear, bottom of cab, disconnect ground strap


from rear chassis.

If machine is equipped with a heater, put a 40 liters


(10 Gallons) container below radiator drain. Remove
cap and drain coolant into container. Install cap after
coolant has drained.

Bur 5-4070

Issued 8-06

Printed in U.S.A.

9007-5

STEP 8

STEP 11

BD06G194

BD06G192

If machine is equipped with windshield washers,


identify, tag, and disconnect front and rear windshield
washer nozzle hoses from supply hoses.

Identify, tag, and disconnect hoses from steering


control valve. Plug hoses and cap steering control
valve fittings to prevent entry of foreign matter into
hydraulic system.

STEP 9
STEP 12
2

BD06G205

1. TRANSMISSION FILTER
2. AIR CONDITIONING HOSES
3. HEATER HOSES

BD06F207

Unlatch and open the window on the right hand side.

If machine is equipped with a heater disconnect


heater hoses (3), if machine is equipped with air
conditioning discharge the air conditioning system,
see section 9003, and disconnect the air conditioning
hoses (2), cap and plug lines and fittings.

STEP 13

STEP 10

BD06F208

Open and remove the access panel.

BD06G193

Disconnect throttle connector and the air duct.


Bur 5-4070

Issued 8-06

Printed in U.S.A.

9007-6

STEP 14

STEP 19

BD06F209

Remove the front access panel.

BD06G187

Disconnect the electrical connectors, push


connectors out of the bottom of the cab with the
rubber gromment

STEP 15

STEP 20

BD06F210

Disconnect the electrical connectors for the remote


control valve.

BD06G188

STEP 16

Raise floor mat up and away from brake pedal to gain


access to mounting hardware.

Loosen the filler cap on the reservoir to release any


air in the reservoir. Connect a vacuum pump to the
hydraulic reservoir, turn on the pump.

STEP 21

STEP 17
Put identification tags on each hose and disconnect
one at a time from the remote control valve. Install
plugs in the hoses and caps on the fittings to prevent
entry of foreign matter into hydraulic system.

STEP 18
Push the hoses out of the bottom of the cab with the
rubber gromment.
BD06G185

Remove hardware securing brake valve to cab floor.


Let brake valve rest on the frame.

Bur 5-4070

Issued 8-06

Printed in U.S.A.

9007-7

STEP 22

STEP 25
Slowly raise cab from rear chassis. Check that all tie
straps and clamps have been removed and all hoses,
tubes, and wires are disconnected and free. Check
that brake valve with hoses attached are free and
clear of cab. Remove the ROPS or CSF from the
machine. Lower ROPS or CSF onto wooden blocks
to prevent damaging cab or canopy.

BD06G184

Install lifting eyes in threaded holes at top of the cab.

STEP 23
Connect lifting equipment to cab at lifting eyes. Take
up all slack in lifting equipment.

STEP 24
Remove nuts, bolts, and washers securing cab to
rear chassis.

Bur 5-4070

Issued 8-06

Printed in U.S.A.

9007-8

1
2

1
2

4
4
5
5
6
6
BC06G031

1. NUT
2. WASHER
3. RUBBER MOUNT

Bur 5-4070

4. RUBBER MOUNT
5. WASHER
6. BOLT

Issued 8-06

Printed in U.S.A.

9007-9

Installation

STEP 32

STEP 26
Check rubber mounts (3 an 4) for deterioration, tears,
defor mation, or other damage; replace rubber
mounts as necessary.

STEP 27

BD06G188

Position floor mat.

STEP 33

BD01D388

Position cab over rear chassis then put wood blocks


under brake valve. Slowly lower cab onto rear
chassis making sure that brake valve is positioned so
that brake pedal enters into cab. Remove wood
blocks as cab is lowered onto brake valve.

STEP 28
Install washers, bolts, and nuts to secure cab to rear
chassis. Tighten bolts to a torque of 773 to 854 Nm
(570 to 630 pound feet)

STEP 29

BD06G192

Remove plugs from hoses and caps from fittings.


Connect hoses to steering control valve following
tags installed during removal. Remove and discard
tags.

Disconnect lifting equipment from cab.

STEP 34

STEP 30
Remove lifting eyes.

STEP 31

BD06G193

Connect throttle connector and mount air duct.

BD06G185

Align mounting holes in brake valve with associated


holes in cab or canopy floor. Install hardware to
secure brake valve to floor.
Bur 5-4070

Issued 8-06

Printed in U.S.A.

9007-10

STEP 35

STEP 38
3

BD06G186

BD06G205

1. TRANSMISSION FILTER
2. AIR CONDITIONING HOSES
3. HEATER HOSES

Install the ducts on the machine.

STEP 36

If machine is equipped with a heater, remove plugs


from hoses and caps from fittings, connect heater
hoses (3), if machine is equipped with air
conditioning, remove plugs from hoses and caps
from fittings, connect air conditioning hoses (2),
charge the air conditioning system, see section 9003.

STEP 39
Remove plugs from hoses and caps from fittings.
Connect hoses to joystick and two-lever controller
and install in hose mounting grommet halves as
shown on pages 11, 12, and 13.
BD06G189

At RH rear, bottom of cab, connect ground strap to


rear chassis.

STEP 37

BD06G194

If machine is equipped with windshield washers,


connect front and rear windshield washer nozzle
hoses following tags installed during removal.
Remove and discard tags.

Bur 5-4070

Issued 8-06

Printed in U.S.A.

9007-11

8
4
6
7

1
5

5
2

1
8

3
6

4
BC05M092

1. PILOT TANK HOSE


2. PILOT PRESSURE HOSE
3. YELLOW BLACK GREEN

4. ORANGE BLACK GREEN


5. GREEN BLACK GREEN
6. RED BLACK GREEN

7. GREEN WHITE GREEN


8. RED WHITE GREEN

JOYSTICK AND 2 LEVER HOSE COLOR CODING

Bur 5-4070

Issued 8-06

Printed in U.S.A.

9007-12

4
3

4
6

2
7

7
1

7
1

5
BC05M091

1.
2.
3.
4.
5.
6.
7.

PILOT TANK HOSE


PILOT PRESSURE HOSE
RED BLACK GREEN
ORANGE BLACK GREEN
YELLOW BLACK GREEN
GREEN BLACK GREEN
RED WHITE GREEN

3 LEVER HOSE COLOR CODING

Bur 5-4070

1.
2.
3.
4.
5.
6.
7.

PILOT TANK HOSE


PILOT PRESSURE HOSE
RED BLACK GREEN
ORANGE BLACK GREEN
YELLOW BLACK GREEN
GREEN BLACK GREEN
RED WHITE GREEN

JOYSTICK AND 1 LEVER HOSE COLOR CODING

Issued 8-06

Printed in U.S.A.

9007-13

1
5
4

2
1

3
2

3
4

5
BC05M090

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

PILOT TANK HOSE


PILOT PRESSURE HOSE
RED BLACK GREEN
ORANGE BLACK GREEN
YELLOW BLACK GREEN
GREEN BLACK GREEN

2 LEVER HOSE COLOR CODING

Bur 5-4070

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

PILOT TANK HOSE


PILOT PRESSURE HOSE
RED BLACK GREEN
ORANGE BLACK GREEN
YELLOW BLACK GREEN
GREEN BLACK GREEN

JOYSTICK HOSE COLOR CODING

Issued 8-06

Printed in U.S.A.

9007-14

STEP 40

STEP 43

BD06F210

Connect the electrical connectors for the remote


control valve.

BD06F208

Install and close the access panel.

STEP 44
STEP 41

BD06F209

Place the access panel into position, install and


tighten the screw.

STEP 42

BD06F207

Close the right hand window.

STEP 45

BD06G187

Connect wiring harness connectors.

Bur 5-4070

BD06G191

Install skirting under each side and front of cab.

Issued 8-06

Printed in U.S.A.

9007-15

STEP 46

STEP 49
Start engine and run engine at low idle. Run engine
at operating temperature for approximately five
minutes to completely mix Ethylene Glycol and
water. When coolant is at operating temperature,
stop engine. When engine has cooled, check coolant
level at reservoir.
WARNING: Hot coolant can spray out if radiator cap
is removed. To remove radiator cap: let system cool,
turn to first notch, then wait until all pressure is
released. Scalding can result from fast removal of
radiator cap.
BD01F184

If machine is equipped with a heater and coolant was


drained, check that coolant drain cap is tight.

STEP 50
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.

Bur 5-4070

Issued 8-06

Printed in U.S.A.

9007-16

NOTES

Bur 5-4070

Issued 8-06

Printed in U.S.A.

Section
9010

CNH America LLC.


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

Bur 6-42710

Copyright 2003 CNH Ameica LLC.


All rights reserved.
Printed in U.S.A.
Issued April, 2003

9010

CAB GLASS INSTALLATION

9010-2

TABLE OF CONTENTS
PREPARATION FOR GLASS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GLASS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SILICONE SEALANT APPLICATION - FRONT WINDOWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Bur 6-42710

Issued 4-03

Printed in U.S.A.

9010-3

PREPARATION FOR GLASS REPLACEMENT


1. Remove all of the damaged glass section and
the silicone sealant from the window frame
2. Remove all the adhesive from the window frame.
3. The window frame recesses must be free of oil
and dust. Clean the frame with rubbing alcohol
with a clean rag. Do not reuse the rag.

5. Clean the new glass section. Apply a 25 mm (1


inch) wide band of glass primer (349-110) to the
black ceramic painted edges of the window.
6. When replacing a front window section, a
silicone forming tool is needed, refer to Figure 2.
Use the template and instructions provided to
make the tool.

4. Apply a 25 mm (1 inch) wide band of metal


primer (349-108) to the window recesses.

GLASS INSTALLATION
NOTE: Once the adhesive is applied, the glass must
be installed within 5 minutes. If the glass is not
installed within the 5 minute period, the adhesive
must be removed and applied again.
1. Apply a 10 mm (3/8 inch) diameter bead of
adhesive (345-135) to the pr imed surface
approximately 12 mm (1/2 inch) from edge.
2. The adhesive may be applied either to the
primed glass or to the primed metal frame. DO
NOT apply the adhesive to both the glass and
the frame.

3. For front glass installations install a glass spacer


12 mm (1/2 inch) from each corner on bottom
edge of each glass section, refer to Figure 3.
4. Install the glass. The glass edges must not
contact the metal frame at any point.
5. For front glass installations position the glass to
maintain a uniform 3 mm (1/8 inch) gap between
front and front side glass sections.

NOTE: When replacing two or more sections of the


front glass apply extra adhesive in corners, refer to
Figure 3.

SILICONE SEALANT APPLICATION - FRONT WINDOWS


1. Clean the edges of the front center and front side
windows. Use glass cleaning primer.
2. Apply masking tape to the inside edge of each
glass section next to the gap.
3. Apply the polyester tape on top of the masking
tape across the inside side gap. Do not push the
tape into the gap.
4. Apply masking tape to the outside edge of each
glass section. Align the edge of the tape with
edge of glass on both sections.
5. The tape must be smooth to get the best result
when using the silicone forming tool.

Bur 6-42710

6. Fill the joint with the clear silicone sealant


(114328A1), refer to Figure 1. The silicone must
completely penetrate and fill the gap between the
glass sections. The sealant must extend at least
1.5 mm (1/16 inch) above the outside surface of
the glass section for the length of the gap. Be
sure the sealant fills against the adhesive at each
end of the joint.
7. Remove the polyester tape from the inside joint.
8. Remove the extra silicone from the outside joint
by carefully sliding the forming tool down the
length of the joint. The tool must remain in
contact with the glass sections during this
process. Refer to Figure 2 for for ming tool
template.

Issued 4-03

Printed in U.S.A.

9010-4

9. Remove all the silicone from the forming tool


immediately after use.

10. Remove the outside tape from the glass


sections.
11. Remove the extra silicone sealant from the inside
joint by carefully sliding the forming tool down the
length of the joint.
12. Remove all the silicone from the forming tool
immediately after use.

13. Remove the inside joint masking tape.

4
498L93

1. FRONT RH SIDE GLASS


2. FRONT CENTER GLASS

3. SILICONE BEFORE
SMOOTHING
4. SILICONE AFTER
SMOOTHING

FIGURE 1. SILICONE APPLICATION

NOTE: Make the forming tool from 10 mm (3/8 inch)


plexiglass, or wood. Sand all radius and edges
smooth.

14. If two or more glass sections are being replaced,


use the procedure on the second joint.
15. Apply the gray silicone sealant above the front
center, front side or rear windows for additional
leak protection.
16. Apply the gray silicone sealant (345-174) down
approximately 50 mm (2 inches) from the top on
each front side window replaced, refer to Figure
3.
17. Apply the gray silicone sealant (345-174) down
approximately 50 mm (2 inches) from the top
edge of the rear glass, if replaced.

6 MM
(1/2 INCH) R

120

120

4 MM
(3/16 INCH) R
496L93

FIGURE 2. SILICONE FORMING TOOL TEMPLATE


Bur 6-42710

Issued 4-03

Printed in U.S.A.

9010-5

2
1
3
4

6
2

497L93

1. SIDE GLASS ADHESIVE


2. CENTER GLASS ADHESIVE

4. RIGHT HAND SIDE GLASS SPACER LOCATIONS


5. APPLY GRAY SILICONE SEALANT DOWN 50 MM (2 INCHES)
FROM TOP OF FRONT SIDE GLASS
3. APPLY EXTRA ADHESIVE HERE WHEN REPLACING BOTH 6. APPLY GRAY SILICONE SEALANT ALONG BOTTOM EDGE OF
CENTER AND SIDE PANELS
CENTER GLASS
FIGURE 3 SILICONE APPLICATION

NOTE: After completting the installation, DO NOT slam the cab door. The increased air pressure may break the
seal on newly installed glass. DO NOT operate the machine for a period of 12 hours, allowing the adhesive and
silicone to properly set.
Bur 6-42710

Issued 4-03

Printed in U.S.A.

9010-6

NOTES

Bur 6-42710

Issued 4-03

Printed in U.S.A.

Vended Schematic
5-3310

CNH AMERICA LLC


700 STATE STREET
RACINE, WI 53404 U.S.A.

English
Part Number 84299244
Printed in U.S.A. Rac
2009 CNH America LLC. All Rights Reserved.
Case is a registered trademark of CNH America

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