New Holland Guardian™ SP.295F/SP.300F/SP.345F/SP.400F Tier 4B (final) Sprayer Service Repair Manual by www.heydownloads.com

SERVICE MANUAL Guardian™ SP.295F / Guardian™ SP.300F Guardian™ SP.345F / Guardian™ SP.400F Tier 4B (final) Sprayer PIN YFYM00001 and above

Part number 47691240 1st edition English February 2015 Printed in U.S.A. © 2015 CNH Industrial America LLC. All Rights Reserved. New Holland is a trademark registered in the United States and many other countries, owned by or licensed to CNH Industrial N.V., its subsidiaries or affiliates.

SERVICE MANUAL SP.295F SP.300F SP.345F SP.400F

47691240 24/02/2015 EN

Contents INTRODUCTION Engine....................................................................................... 10 [10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 [10.114] Pump drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 [10.216] Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 [10.206] Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 [10.202] Air cleaners and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 [10.500] Selective Catalytic Reduction (SCR) exhaust treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7 [10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8

Front axle system ....................................................................... 25 [25.100] Powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1

Hydrostatic drive......................................................................... 29 [29.218] Pump and motor components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.1

Brakes and controls .................................................................... 33 [33.202] Hydraulic service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1

Hydraulic systems....................................................................... 35 [35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 [35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2 [35.220] Auxiliary hydraulic pump and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3 [35.752] Hydraulic fan drive cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4 [35.610] Machine leveling control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5

Pneumatic system ...................................................................... 36 [36.100] Pneumatic system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36.1 [36.908] Pneumatic suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36.2

Steering..................................................................................... 41 47691240 24/02/2015

[41.101] Steering control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1 [41.216] Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2

Wheels ...................................................................................... 44 [44.511] Front wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.1 [44.520] Rear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.2

Cab climate control ..................................................................... 50 [50.100] Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.1 [50.104] Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.2 [50.200] Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.3

Electrical systems ....................................................................... 55 [55.000] Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 [55.015] Engine control system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 [55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 [55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 [55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6 [55.640] Electronic modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7 [55.050] Heating, Ventilation, and Air-Conditioning (HVAC) control system. . . . . . . . . . . . . . . . . 55.8 [55.047] Steering control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.9

Spraying .................................................................................... 78 [78.110] Chemical spraying. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.1 [78.111] Spraying pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.2 [78.120] Foam marking system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.3

Platform, cab, bodywork, and decals ............................................. 90 [90.151] Cab interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1 [90.120] Mechanically-adjusted operator seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2 [90.100] Engine hood and panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.3

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[90.116] Fenders and guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.4

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INTRODUCTION

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Contents INTRODUCTION Foreword - Important notice regarding equipment servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Personal safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Safety rules - Ecology and the environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Basic instructions - Shop and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Torque - Minimum tightening torques for normal assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Torque - Standard torque data for hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Maintenance chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Hydraulic contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Product identification - Sprayer model and serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Product identification - Machine orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

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INTRODUCTION

Foreword - Important notice regarding equipment servicing All repair and maintenance work listed in this manual must be carried out only by qualified dealership personnel, strictly complying with the instructions given, and using, whenever possible, the special tools. Anyone who performs repair and maintenance operations without complying with the procedures provided herein shall be responsible for any subsequent damages. The manufacturer and all the organizations of its distribution chain, including - without limitation - national, regional, or local dealers, reject any responsibility for damages caused by parts and/or components not approved by the manufacturer, including those used for the servicing or repair of the product manufactured or marketed by the manufacturer. In any case, no warranty is given or attributed on the product manufactured or marketed by the manufacturer in case of damages caused by parts and/or components not approved by the manufacturer. The manufacturer reserves the right to make improvements in design and changes in specifications at any time without notice and without incurring any obligation to install them on units previously sold. Specifications, descriptions, and illustrative material herein are as accurate as known at time of publication but are subject to change without notice. In case of questions, refer to your NEW HOLLAND Sales and Service Networks.

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Safety rules Personal safety This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible death or injury.

Throughout this manual you will find the signal words DANGER, WARNING, and CAUTION followed by special instructions. These precautions are intended for the personal safety of you and those working with you. Read and understand all the safety messages in this manual before you operate or service the machine.

DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury. WARNING indicates a hazardous situation that, if not avoided, could result in death or serious injury. CAUTION indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.

FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION MESSAGES COULD RESULT IN DEATH OR SERIOUS INJURY. Machine safety NOTICE: Notice indicates a situation that, if not avoided, could result in machine or property damage. Throughout this manual you will find the signal word Notice followed by special instructions to prevent machine or property damage. The word Notice is used to address practices not related to personal safety.

Information NOTE: Note indicates additional information that clarifies steps, procedures, or other information in this manual. Throughout this manual you will find the word Note followed by additional information about a step, procedure, or other information in the manual. The word Note is not intended to address personal safety or property damage.

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INTRODUCTION

Personal safety General safety rules Use caution when operating the machine on slopes. Raised equipment, full tanks and other loads will change the center of gravity of the machine. The machine can tip or roll over when near ditches and embankments or uneven surfaces. Never permit anyone other than the operator to ride on the machine. Never operate the machine under the influence of alcohol, drugs, or while otherwise impaired. Pay attention to overhead power lines and hanging obstacles. High voltage lines may require significant clearance for safety. Hydraulic oil or diesel fuel leaking under pressure can penetrate the skin, causing serious injury or infection. • DO NOT use your hand to check for leaks. Use a piece of cardboard or paper. • Stop engine, remove key and relieve the pressure before connecting or disconnecting fluid lines. • Make sure all components are in good condition and tighten all connections before starting the engine or pressurizing the system. • If hydraulic fluid or diesel fuel penetrates the skin, seek medical attention immediately. • Continuous long term contact with hydraulic fluid may cause skin cancer. Avoid long term contact and wash the skin promptly with soap and water. Keep clear of moving parts. Loose clothing, jewelry, watches, long hair, and other loose or hanging items can become entangled in moving parts. Wear protective equipment when appropriate. DO NOT attempt to remove material from any part of the machine while it is being operated or components are in motion. Make sure all guards and shields are in good condition and properly installed before operating the machine. Never operate the machine with shields removed. Always close access doors or panels before operating the machine. Dirty or slippery steps, ladders, walkways, and platforms can cause falls. Make sure these surfaces remain clean and clear of debris. A person or pet within the operating area of a machine can be struck or crushed by the machine or its equipment. DO NOT allow anyone to enter the work area. Raised equipment and/or loads can fall unexpectedly and crush persons underneath. Never allow anyone to enter the area underneath raised equipment during operation. Never operate engine in enclosed spaces as harmful exhaust gases may build up. Before starting the machine, be sure that all controls are in neutral or park lock position. Start the engine only from the operator’s seat. If the safety start switch is bypassed, the engine can start with the transmission in gear. Do not connect or short across terminals on the starter solenoid. Attach jumper cables as described in the manual. Starting in gear may cause death or serious injury. Always keep windows, mirrors, all lighting, and Slow Moving Vehicle (SMV) emblem clean to provide the best possible visibility while operating the machine. Operate controls only when seated in the operator’s seat, except for those controls expressly intended for use from other locations.

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Before leaving the machine: 1. Park machine on a firm level surface. 2. Put all controls in neutral or park lock position. 3. Engage park brake. Use wheel chocks if required. 4. Lower all hydraulic equipment â&#x20AC;&#x201D; Implements, header, etc. 5. Turn off engine and remove key. When, due to exceptional circumstances, you would decide to keep the engine running after leaving the operatorâ&#x20AC;&#x2122;s station, then the following precautions must be followed: 1. Bring the engine to low idle speed. 2. Disengage all drive systems. 3.

WARNING Some components may continue to run down after disengaging drive systems. Make sure all drive systems are fully disengaged. Failure to comply could result in death or serious injury. W0113A

Shift the transmission into neutral. 4. Apply the parking brake.

General maintenance safety Keep area used for servicing the machine clean and dry. Clean up spilled fluids. Service machine on a firm level surface. Install guards and shields after servicing the machine. Close all access doors and install all panels after servicing the machine. Do not attempt to clean, lubricate, clear obstructions or make adjustments to the machine while it is in motion or while the engine is running. Always make sure working area is clear of tools, parts, other persons and pets before you start operating the machine. Unsupported hydraulic cylinders can lose pressure and drop the equipment causing a crushing hazard. Do not leave equipment in a raised position while parked or during service, unless securely supported. Incorrect towing procedures can cause accidents. Contact your dealer if towing is required. Stop the engine, remove key and relieve pressure before disconnecting or connecting fluid lines. Stop the engine and remove key before disconnecting or connecting electrical connections. Scalding can result from incorrect removal of coolant caps. Cooling system operates under pressure. Hot coolant can spray out if a cap is removed while the system is hot. Allow system to cool before removing cap. When removing a cap turn it slowly to allow pressure to escape before completely removing the cap. Replace damaged or worn tubes, hoses, electrical wiring, etc. Engine, transmission, exhaust components, and hydraulic lines may become hot during operation. Take care when servicing such components. Allow surfaces to cool before handling or disconnecting hot components. Wear protective equipment when appropriate. When welding, remove all electrical monitors from unit to prevent damage. Always disconnect the battery before welding on the machine. Always wash your hands after handling battery components.

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INTRODUCTION

Wheels and tires Make sure tires are correctly inflated. Do not exceed recommended load or pressure. Tires are heavy. Handling tires without proper equipment could cause death or serious injury. Always have a qualified tire technician service the tires and wheels. If a tire has lost all pressure, take the tire and wheel to a tire shop or your dealer for service. Explosive separation of the tire can cause serious injury. DO NOT weld to a wheel or rim especially if a tire is installed. Inflated tires can generate a gas mixture with the air that can be ignited by high temperatures from welding procedures performed on the wheel or rim. Removing the air or loosening the tire on the rim (breaking the bead) will NOT eliminate the hazard. This condition can exist whether tires are inflated or deflated.

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INTRODUCTION

Driving on public roads and general transportation safety Comply with local laws and regulations. Use appropriate lighting to meet local regulations. Make sure SMV emblem is visible. Lift implements and attachments high enough above ground to prevent accidental contact with road. When transporting equipment or machine on a transport trailer, make sure it is properly secured. Be sure the SMV on the equipment or machine is covered while being transported on a trailer. Be aware of overhead structures or power lines and make sure the machine and/or attachments can pass safely under. Travel speed should be such that complete control and machine stability is maintained at all times. Slow down and signal before turning. Pull over to allow faster traffic to pass. Follow correct towing procedure for equipment with or without brakes.

Fire and explosion prevention Fuel or oil leaked or spilled on hot surfaces or electrical components can cause a fire. Crop materials, trash, debris, bird nests, or flammable material can ignite on hot surfaces. Always have a fire extinguisher on or near the machine. Make sure the fire extinguisher(s) is maintained and serviced according to the manufacturerâ&#x20AC;&#x2122;s instructions. At least once each day and at the end of the day remove all trash and debris from the machine especially around hot components such as engine, transmission, exhaust, battery, etc. More frequent cleaning of your machine may be necessary depending on the operating environment and conditions. At least once each day, remove debris accumulation around moving components such as bearings, pulleys, belts, gears, cleaning fan, etc. More frequent cleaning of your machine may be necessary depending on the operating environment and conditions. Inspect the electrical system for loose connections or frayed insulation. Repair or replace loose or damaged parts. Do not store oily rags or other flammable material on the machine. Do not weld or flame cut any items that contain flammable material. Clean items thoroughly with non-flammable solvents before welding or flame-cutting. Do not expose the machine to flames, burning brush, or explosives. Promptly investigate any unusual smells or odors that may occur during operation of the machine.

General battery safety Always wear eye protection when working with batteries. Do not create sparks or have open flame near battery. Ventilate when charging or using in an enclosed area. Disconnect negative (-) first and reconnect negative (-) last. When welding on the machine, disconnect both terminals of the battery. 47691240 24/02/2015

INTRODUCTION

Do not weld, grind, or smoke near a battery. When using auxiliary batteries or connecting jumper cables to start the engine, use the procedure shown in the operatorâ&#x20AC;&#x2122;s manual. Do not short across terminals. Follow manufacturerâ&#x20AC;&#x2122;s instructions when storing and handling batteries. Battery post, terminals, and related accessories contain lead and lead compounds. Wash hands after handling. This is a California Proposition 65 warning. Battery acid causes burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes, or clothing. Antidote (external): Flush with water. Antidote (eyes): flush with water for 15 minutes and seek medical attention immediately. Antidote (internal): Drink large quantities of water or milk. Do not induce vomiting. Seek medical attention immediately. Keep out of reach of children and other unauthorized persons.

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INTRODUCTION

Instructional seat safety Passengers are not permitted to ride on the machine. The instructional seat is to be used only when training a new operator or when a service technician is diagnosing a problem. When required for the purposes of training or diagnostics, only one person may accompany the operator and that person must be seated in the instructional seat. When the instructional seat is occupied, the following precautions must be followed: • Machine should be driven only at slow speeds and over level ground. • Avoid driving on highways or public roads. • Avoid quick starts or stops. • Avoid sharp turns. • Always wear correctly adjusted seat belts. • Keep door closed at all times.

Operator presence system Your machine is equipped with an operator presence system to prevent the use of some features while the operator is not in the operator’s seat. The operator presence system should never be disconnected or bypassed. If the system is inoperable, the system must be repaired.

Reflectors and warning lights Flashing amber warning lights must be used when operating on public roads.

Seat belts Seat belts must be worn at all times. Seat belt inspection and maintenance: • Keep seat belts in good condition. • Keep sharp edges and items than can cause damage away from the belts. • Periodically check belts, buckles, retractors, tethers, slack take-up system, and mounting bolts for damage and wear. • Replace all parts that have damage or wear. • Replace belts that have cuts that can make the belt weak. • Check that bolts are tight on the seat bracket or mounting. • If belt is attached to seat, make sure seat or seat brackets are mounted securely. • Keep seat belts clean and dry. • Clean belts only with soap solution and warm water. • Do not use bleach or dye on the belts because this can make the belts weak.

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Air-conditioning system The air-conditioning system is under high pressure. Do not disconnect any lines. The release of high pressure can cause serious injury. The air-conditioning system contains gases that are harmful to the environment when released into the atmosphere. Do not attempt to service or repair the system. Service, repair, or recharging must be performed only by a trained service technician.

Personal Protective Equipment (PPE) Wear Personal Protective Equipment (PPE) such as hard hat, eye protection, heavy gloves, hearing protection, protective clothing, etc.

Do Not Operate tag Before you start servicing the machine, attach a ‘Do Not Operate’ warning tag to the machine in an area that will be visible.

Hazardous chemicals If you are exposed to or come in contact with hazardous chemicals you can be seriously injured. The fluids, lubricants, paints, adhesives, coolant, etc. required for the function of your machine can be hazardous. They may be attractive and harmful to domestic animals as well as humans. Material Safety Data Sheets (MSDS) provide information about the chemical substances within a product, safe handling and storage procedures, first aid measures and procedures to be taken in the event of a spill or accidental release. MSDS are available from your dealer. Before you service your machine check the MSDS for each lubricant, fluid, etc. used in this machine. This information indicates the associated risks and will help you service the machine safely. Follow the information in the MSDS, on manufacturer containers, as well as the information in this manual when servicing the machine. Dispose of all fluids, filters, and containers in an environmentally safe manner according to local laws and regulations. Check with local environmental and recycling centers or your dealer for correct disposal information. Store fluids and filters in accordance with local laws and regulations. Use only appropriate containers for the storage of chemicals or petrochemical substances. Keep out of reach or children or other unauthorized persons. Additional precautions are required for applied chemicals. Obtain complete information from the manufacturer or distributor of the chemicals before using them.

Utility safety Make sure the machine has sufficient clearance to pass in all directions. Pay special attention to overhead power lines and hanging obstacles. High voltage lines may require significant clearance for safety. Contact local authorities or utilities to obtain safe clearance distances from high voltage power lines. Retract raised or extended components, if necessary. Remove or lower radio antennas or other accessories. Should a contact between the machine and an electric power source occur, the following precautions must be taken: • Stop the machine movement immediately. • Apply the park brake, stop the engine, and remove the key. • Check if you can safely leave the cab or your actual position without contact with electrical wires. If not, stay in your position and call for help. If you can leave your position without touching lines, jump clear of the machine to make sure you do not make contact with the ground and the machine at the same time. • Do not permit anyone to touch the machine until power has been shut off to the power lines.

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INTRODUCTION

Electrical storm safety Do not operate machine during an electrical storm. If you are on the ground during an electrical storm, stay away from machinery and equipment. Seek shelter in a permanent, protected structure. If an electrical storm should strike during operation, remain in the cab. Do not leave the cab or operator’s platform. Do not make contact with the ground or objects outside the machine.

Mounting and dismounting Mount and dismount the machine only at designated locations that have handholds, steps, or ladders. Do not jump off the machine. Make sure steps, ladders, and platforms remain clean and clear of debris and foreign substances. Injury may result from slippery surfaces. Face the machine when mounting and dismounting. Maintain a three-point contact with steps, ladders, and handholds. Never mount or dismount from a moving machine. Do not use the steering wheel or other controls or accessories as handholds when entering or exiting the cab or operator’s platform.

Working at heights When the normal use and maintenance of the machine requires working at heights: • Correctly use installed steps, ladders, and railings. • Never use ladders, steps, or railings while the machine is moving. • Do not stand on surfaces which are not designated as steps or platforms. Do not use the machine as a lift, ladder, or platform for working at heights.

Spraying • Be sure to clean and flush all residual chemicals from the sprayer before changing to another type of chemical. On some models, it may be necessary to remove the end caps from the spray bars to thoroughly flush the boom plumbing. In some cases a decontamination solution is recommended by the chemical manufacturer. • Always follow chemical manufacturers safety instructions when mixing and applying herbicides and chemicals to prevent serious harm to people or the environment. • Observe all Federal and State EPA regulations and all Local, State and Federal codes and/or laws regarding licensing, handling, storage, transportation, application and waste disposal of herbicides or other chemicals. • Do not pump at pressures higher than the maximum recommended pressure. • Secure the discharge lines before starting the pump. An insecure line may whip causing personal injury and/or property damage. • Check hoses for wear or worn condition before each use. Make certain that all connections are tightly secured. • Periodically inspect the product pump and the system components. Perform routine maintenance as required. • Do not use these pumps for pumping water or other liquids for human or animal consumption.

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INTRODUCTION

Roll over and tip over • Travel speed should be such that complete control and machine stability is maintained at all times. Where possible, avoid operating near ditches, embankments and holes. Reduce speed when turning, crossing slopes, and on rough, slick, or muddy surfaces. • Do not operate the unit on terrain outside its grade and stability limits. Operating the sprayer outside its limits may result in a roll over or tip over. Observe the guidelines in this manual when going down steep hills with load. • Operating the unit on steep grades may result in a machine overturn. It is the operator’s responsibility to make a judgment if weather, road or ground conditions permit safe operation on a hillside, ramp, ditch or rough ground. • Use caution when operating the machine on slopes. Raised equipment, full tanks and other loads can change the center of gravity of the machine. The machine can tip or roll over when near ditches and embankments or uneven surfaces. • Do not operate the unit near or on the soft shoulders of canals, brooks, other waterways or banks which are undermined by rodents. The unit may sink sideways and roll over. • Do not operate the unit on poorly constructed or underrated ramps. The ramps may collapse and cause the sprayer to roll over. Always check the condition and rating of ramps before use. • Do not operate the unit without using the seat restraint. • Do not operate the unit beyond its limits of dynamic stability. High speed, abrupt maneuvers or fast and sharp cornering increase the risk of roll over.

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INTRODUCTION

Safety rules - Ecology and the environment Soil, air, and water quality is important for all industries and life in general. When legislation does not yet rule the treatment of some of the substances that advanced technology requires, sound judgment should govern the use and disposal of products of a chemical and petrochemical nature. Familiarize yourself with the relative legislation applicable to your country, and make sure that you understand this legislation. Where no legislation exists, obtain information from suppliers of oils, filters, batteries, fuels, anti-freeze, cleaning agents, etc., with regard to the effect of these substances on man and nature and how to safely store, use, and dispose of these substances.

Helpful hints • Avoid the use of cans or other inappropriate pressurized fuel delivery systems to fill tanks. Such delivery systems may cause considerable spillage. • In general, avoid skin contact with all fuels, oils, acids, solvents, etc. Most of these products contain substances that may be harmful to your health. • Modern oils contain additives. Do not burn contaminated fuels and or waste oils in ordinary heating systems. • Avoid spillage when you drain fluids such as used engine coolant mixtures, engine oil, hydraulic fluid, brake fluid, etc. Do not mix drained brake fluids or fuels with lubricants. Store all drained fluids safely until you can dispose of the fluids in a proper way that complies with all local legislation and available resources. • Do not allow coolant mixtures to get into the soil. Collect and dispose of coolant mixtures properly. • The air-conditioning system contains gases that should not be released into the atmosphere. Consult an air-conditioning specialist or use a special extractor to recharge the system properly. • Repair any leaks or defects in the engine cooling system or hydraulic system immediately. • Do not increase the pressure in a pressurized circuit as this may lead to a component failure. • Protect hoses during welding. Penetrating weld splatter may burn a hole or weaken hoses, allowing the loss of oils, coolant, etc.

Battery recycling Batteries and electric accumulators contain several substances that can have a harmful effect on the environment if the batteries are not properly recycled after use. Improper disposal of batteries can contaminate the soil, groundwater, and waterways. NEW HOLLAND strongly recommends that you return all used batteries to a NEW HOLLAND dealer, who will dispose of the used batteries or recycle the used batteries properly. In some countries, this is a legal requirement.

Mandatory battery recycling NOTE: The following requirements are mandatory in Brazil. Batteries are made of lead plates and a sulfuric acid solution. Because batteries contain heavy metals such as lead, CONAMA Resolution 401/2008 requires you to return all used batteries to the battery dealer when you replace any batteries. Do not dispose of batteries in your household garbage. Points of sale are obliged to: • Accept the return of your used batteries • Store the returned batteries in a suitable location • Send the returned batteries to the battery manufacturer for recycling

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INTRODUCTION

Basic instructions - Shop and assembly Shimming For each adjustment operation, select adjusting shims and measure the adjusting shims individually using a micrometer, then add up the recorded values. Do not rely on measuring the entire shimming set, which may be incorrect, or the rated value shown on each shim.

Rotating shaft seals For correct rotating shaft seal installation, proceed as follows: 1. Before assembly, allow the seal to soak in the oil it will be sealing for at least thirty minutes. 2. Thoroughly clean the shaft and check that the working surface on the shaft is not damaged. 3. Position the sealing lip facing the fluid. NOTE: With hydrodynamic lips, take into consideration the shaft rotation direction and position the grooves so that they will move the fluid towards the inner side of the seal. 4. Coat the sealing lip with a thin layer of lubricant (use oil rather than grease). Fill the gap between the sealing lip and the dust lip on double lip seals with grease. 5. Insert the seal in its seat and press down using a flat punch or seal installation tool. Do not tap the seal with a hammer or mallet. 6. While you insert the seal, check that the seal is perpendicular to the seat. When the seal settles, make sure that the seal makes contact with the thrust element, if required. 7. To prevent damage to the seal lip on the shaft, position a protective guard during installation operations.

O-ring seals Lubricate the O-ring seals before you insert them in the seats. This will prevent the O-ring seals from overturning and twisting, which would jeopardize sealing efficiency.

Sealing compounds Apply a sealing compound on the mating surfaces when specified by the procedure. Before you apply the sealing compound, prepare the surfaces as directed by the product container.

Spare parts Only use CNH Original Parts or NEW HOLLAND Original Parts. Only genuine spare parts guarantee the same quality, duration, and safety as original parts, as they are the same parts that are assembled during standard production. Only CNH Original Parts or NEW HOLLAND Original Parts can offer this guarantee. When ordering spare parts, always provide the following information: â&#x20AC;˘ Machine model (commercial name) and Product Identification Number (PIN) â&#x20AC;˘ Part number of the ordered part, which can be found in the parts catalog

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INTRODUCTION

Protecting the electronic and/or electrical systems during charging and welding To avoid damage to the electronic and/or electrical systems, always observe the following practices: 1. Never make or break any of the charging circuit connections when the engine is running, including the battery connections. 2. Never short any of the charging components to ground. 3. Always disconnect the ground cable from the battery before arc welding on the machine or on any machine attachment. • Position the welder ground clamp as close to the welding area as possible. • If you weld in close proximity to a computer module, then you should remove the module from the machine. • Never allow welding cables to lie on, near, or across any electrical wiring or electronic component while you weld. 4. Always disconnect the negative cable from the battery when charging the battery in the machine with a battery charger. NOTICE: If you must weld on the unit, you must disconnect the battery ground cable from the machine battery. The electronic monitoring system and charging system will be damaged if this is not done. 5. Remove the battery ground cable. Reconnect the cable when you complete welding.

WARNING Battery acid causes burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing. Antidote (external): Flush with water. Antidote (eyes): flush with water for 15 minutes and seek medical attention immediately. Antidote (internal): Drink large quantities of water or milk. Do not induce vomiting. Seek medical attention immediately. Failure to comply could result in death or serious injury. W0111A

Special tools The special tools that NEW HOLLAND suggests and illustrate in this manual have been specifically researched and designed for use with NEW HOLLAND machines. The special tools are essential for reliable repair operations. The special tools are accurately built and rigorously tested to offer efficient and long-lasting operation. By using these tools, repair personnel will benefit from: • Operating in optimal technical conditions • Obtaining the best results • Saving time and effort • Working in safe conditions

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INTRODUCTION

Torque - Minimum tightening torques for normal assembly Decimal hardware Grade 5 bolts, nuts and studs Size

lb in/lb ft 108 - 132 lb in 204 - 252 lb in 420 - 504 lb in 54 - 64 lb ft 80 - 96 lb ft 110 - 132 lb ft 150 - 180 lb ft 270 - 324 lb ft 400 - 480 lb ft 580 - 696 lb ft 800 - 880 lb ft 1120 - 1240 lb ft 1460 - 1680 lb ft 1940 - 2200 lb ft

lb in/lb ft 144 - 180 lb in 288 - 348 lb in 540 - 648 lb in 70 - 84 lb ft 110 - 132 lb ft 160 - 192 lb ft 220 - 264 lb ft 380 - 456 lb ft 600 - 720 lb ft 900 - 1080 lb ft 1280 - 1440 lb ft 1820 - 2000 lb ft 2380 - 2720 lb ft 3160 - 3560 lb ft

lb in/lb ft 24 - 36 lb in 60 - 72 lb in 96 - 108 lb in 228 - 276 lb in 456 - 540 lb in 66 - 79 lb ft 106 - 127 lb ft 160 - 200 lb ft 320 - 380 lb ft 500 - 600 lb ft 920 - 1100 lb ft 1600 - 1950 lb ft

12 - 15 Nm 23 - 28 Nm 48 - 57 Nm 73 - 87 Nm 109 - 130 Nm 149 - 179 Nm 203 - 244 Nm 366 - 439 Nm 542 - 651 Nm 787 - 944 Nm 1085 - 1193 Nm 1519 - 1681 Nm 1980 - 2278 Nm 2631 - 2983 Nm

1/4 in 5/16 in 3/8 in 7/16 in 1/2 in 9/16 in 5/8 in 3/4 in 7/8 in 1 in 1-1/8 in 1-1/4 in 1-3/8 in 1-1/2 in Grade 8 bolts, nuts and studs Size

16 - 20 Nm 33 - 39 Nm 61 - 73 Nm 95 - 114 Nm 149 - 179 Nm 217 - 260 Nm 298 - 358 Nm 515 - 618 Nm 814 - 976 Nm 1220 - 1465 Nm 1736 - 1953 Nm 2468 - 2712 Nm 3227 - 3688 Nm 4285 - 4827 Nm

1/4 in 5/16 in 3/8 in 7/16 in 1/2 in 9/16 in 5/8 in 3/4 in 7/8 in 1 in 1-1/8 in 1-1/4 in 1-3/8 in 1-1/2 in

NOTE: Use thick nuts with Grade 8 bolts.

Metric hardware Grade 8.8 bolts, nuts and studs Size 4 mm 5 mm 6 mm 8 mm 10 mm 12 mm 14 mm 16 mm 20 mm 24 mm 30 mm 36 mm

3 - 4 Nm 7 - 8 Nm 11 - 12 Nm 26 - 31 Nm 52 - 61 Nm 90 - 107 Nm 144 - 172 Nm 217 - 271 Nm 434 - 515 Nm 675 - 815 Nm 1250 - 1500 Nm 2175 - 2600 Nm

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Grade 10.9 bolts, nuts and studs Nm

Size 4 mm 5 mm 6 mm 8 mm 10 mm 12 mm 14 mm 16 mm 20 mm 24 mm 30 mm 36 mm

4 - 5 Nm 9 - 11 Nm 15 - 18 Nm 37 - 43 Nm 73 - 87 Nm 125 - 150 Nm 200 - 245 Nm 310 - 380 Nm 610 - 730 Nm 1050 - 1275 Nm 2000 - 2400 Nm 3500 - 4200 Nm

lb in/lb ft 36 - 48 lb in 84 - 96 lb in 132 - 156 lb in 324 - 384 lb in 54 - 64 lb ft 93 - 112 lb ft 149 - 179 lb ft 230 - 280 lb ft 450 - 540 lb ft 780 - 940 lb ft 1470 - 1770 lb ft 2580 - 3090 lb ft

Grade 12.9 bolts, nuts and studs Nm Size lb in/lb ft Typically the torque values specified for grade 10.9 hardware can be used satisfactorily on grade 12.9 hardware.

Steel hydraulic fittings 37Â° flare fitting Thread size

Tube outside diameter/Hose inside diameter mm inch 6.4 mm 1/4 in 7.9 mm 5/16 in 9.5 mm 3/8 in 12.7 mm 1/2 in 15.9 mm 5/6 in 19.0 mm 3/4 in 22.2 mm 7/8 in 25.4 mm 1 in 31.8 mm 1-1/4 in 38.1 mm 1-1/2 in

7/16-20 in 1/2-20 in 9/16-18 in 3/4-16 in 7/8-14 in 1-1/16-12 in 1-3/16-12 in 1-5/16-12 in 1-5/8-12 in 1-7/8-12 in

8 - 16 Nm 11 - 22 Nm 14 - 34 Nm 20 - 57 Nm 34 - 79 Nm 54 - 108 Nm 81 - 135 Nm 102 - 158 Nm 169 - 223 Nm 285 - 338 Nm

lb in/lb ft

72 - 144 lb in 96 - 192 lb in 120 - 300 lb in 180 - 504 lb in 300 - 696 lb in 40 - 80 lb ft 60 - 100 lb ft 75 - 117 lb ft 125 - 165 lb ft 210 - 250 lb ft

Straight threads with O-ring Thread size

7/16-20 in 1/2-20 in 9/16-18 in 3/4-16 in 7/8-14 in 1-1/16-12 in 1-3/16-12 in 1-5/16-12 in 1-5/8-12 in 1-7/8-12 in

16 - 26 Nm 22 - 34 Nm 34 - 54 Nm 57 - 91 Nm 79 - 124 Nm 108 - 174 Nm 136 - 216 Nm 159 - 253 Nm 224 - 357 Nm 339 - 542 Nm

lb in/lb ft

144 - 228 lb in 192 - 300 lb in 300 - 480 lb in 540 - 804 lb in 58 - 92 lb ft 80 - 128 lb ft 100 - 160 lb ft 117 - 187 lb ft 165 - 264 lb ft 250 - 400 lb ft

Split flange mounting bolts Nm

Size 5/16-18 in 3/8-16 in 7/16-14 in 1/2-13 in

20 27 47 74

27 Nm 34 Nm 61 Nm 88 Nm 47691240 24/02/2015

lb in/lb ft 180 - 240 lb in 240 - 300 lb in 420 - 540 lb in 55 - 65 lb ft

INTRODUCTION

Size 190 - 203 Nm

5/8-11 in

Nominal SAE dash size -4

lb in/lb ft 140 - 150 lb ft

O-ring face seal end Tube outside diameter Thread size Nm mm in 6.4 mm

1/4 in

-6

9.5 mm

3/8 in

-8

12.7 mm

1/2 in

-10

15.9 mm

5/8 in

-12

19.0 mm

3/4 in

-14

22.2 mm

7/8 in

-16

25.41 mm

1.0 in

-20

31.8 mm

1-1/4 in

-24

38.1 mm

1-1/2 in

lb in/lb ft

14 - 16 Nm 120 - 144 lb in 11/16-16 in 24 - 27 Nm 216 - 240 lb in 13/16-16 in 43 - 54 Nm 384 - 480 lb in 1-14 in 62 - 76 Nm 552 - 672 lb in 90 65 - 80 lb ft 1-3/ 110 Nm 16-12 in 90 65 - 80 lb ft 1-3/ 110 Nm 16-12 in 125 92 - 105 lb 1-7/ 140 Nm ft 16-12 in 170 125 - 140 lb 1-11/ 190 Nm ft 16-12 in 2-12 in 200 150 - 180 lb 254 Nm ft 9/16-18 in

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O-ring boss end fitting or lock nut Thread size Nm lb in/lb ft

7/16-20 in 9/16-18 in 3/4-16 in 7/8-14 in 1-1/ 16-12 in 1-13/ 16-12 in 1-5/ 16-12 in 1`-5/ 6-12 in 1-7/8-12 in

23 - 27 Nm 204 - 240 lb in 34 - 41 Nm 300 - 360 lb in 61 - 68 Nm 540 - 600 lb in 81 - 88 Nm 60 - 65 lb ft 115 122 Nm 129 136 Nm 156 169 Nm 201 217 Nm 258 271 Nm

85 - 90 lb ft 95 - 100 lb ft 115 - 125 lb ft 150 - 160 lb ft 190 - 200 lb ft

INTRODUCTION

Torque - Standard torque data for hydraulics Installation of adjustable fittings in straight thread O-ring bosses 1. Lubricate the O-ring by coating it with a light oil or petroleum. Install the O-ring in the groove adjacent to the metal backup washer which is assembled at the extreme end of the groove (4). 2. Install the fitting into the SAE straight thread boss until the metal backup washer contacts the face of the boss (5). NOTE: Do not over tighten and distort the metal backup washer.

23085659

3. Position the fitting by turning out (counterclockwise) up to a maximum of one turn. Holding the pad of the fitting with a wrench, tighten the locknut and washer against the face of the boss (6).

Standard torque data for hydraulic tubes and fittings Tube nuts for 37° flared fittings

Size

Tubing OD

Thread size

Torque

O-ring boss plugs adjustable fitting locknuts, swivel JIC37° seats Torque

4 5 6 8 10 12 14 16 20 24 32

6.4 mm (1/4 in) 7.9 mm (5/16 in) 9.5 mm (3/8 in) 12.7 mm (1/2 in) 15.9 mm (5/8 in) 19.1 mm (3/4 in) 22.2 mm (7/8 in) 25.4 mm (1 in) 31.8 mm (1-1/4 in) 38.1 mm (1-1/2 in) 50.8 mm (2 in)

7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 1-1/16-12 1-3/16-12 1-5/16-12 1-5/8-12 1-7/8-12 2-1/2-12

12 - 16 N·m (9 - 12 lb ft) 16 - 20 N·m (12 - 15 lb ft) 29 - 33 N·m (21 - 24 lb ft) 47 - 54 N·m (35 - 40 lb ft) 72 - 79 N·m (53 - 58 lb ft) 104 - 111 N·m (77 - 82 lb ft) 122 - 136 N·m (90 - 100 lb ft) 149 - 163 N·m (110 - 120 lb ft) 190 - 204 N·m (140 - 150 lb ft) 217 - 237 N·m (160 - 175 lb ft) 305 - 325 N·m (225 - 240 lb ft)

8 - 14 N·m (6 - 10 lb ft) 14 - 20 N·m (10 - 15 lb ft) 20 - 27 N·m (15 - 20 lb ft) 34 - 41 N·m (25 - 30 lb ft) 47 - 54 N·m (35 - 40 lb ft) 81 - 95 N·m (60 - 70 lb ft) 95 - 109 N·m (70 - 80 lb ft) 108 - 122 N·m (80 - 90 lb ft) 129 - 158 N·m (95 - 115 lb ft) 163 - 190 N·m (120 - 140 lb ft) 339 - 407 N·m (250 - 300 lb ft)

These torques are not recommended for tubes of 12.7 mm (1/2 in) OD and larger with wall thickness of 0.889 mm (0.035 in) or less. The torque is specified for 0.889 mm (0.035 in) wall tubes on each application individually. Before installing and torquing 37 ° flared fittings, clean the face of the flare and threads with a clean solvent or Loctite cleaner and apply hydraulic sealant LOCTITE® 569™ to the 37 ° flare and the threads. Install fitting and torque to specified torque, loosen fitting and retorque to specifications.

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INTRODUCTION

Pipe thread fitting torque Before installing and tightening pipe fittings, clean the threads with a clean solvent or Loctite cleaner and apply sealant LOCTITE® 567™ PST PIPE SEALANT for all fittings including stainless steel or LOCTITE® 565™ PST for most metal fittings. For high filtration/zero contamination systems use LOCTITE® 545™.

Torque (maximum) 13 N·m (10 lb ft) 16 N·m (12 lb ft) 22 N·m (16 lb ft) 41 N·m (30 lb ft) 54 N·m (40 lb ft)

Thread size 1/8-27 1/4-18 3/8-18 1/2-14 3/4-14

Installation of ORFS (O-Ring Flat Seal fittings) When installing ORFS fittings thoroughly clean both flat surfaces of the fittings (1) and lubricate the O-ring (2) with light oil. Make sure both surfaces are aligned properly. Torque the fitting to specified torque listed throughout the repair manual. NOTICE: If the fitting surfaces are not properly cleaned, the O-ring will not seal properly. If the fitting surfaces are not properly aligned, the fittings may be damaged and will not seal properly. NOTICE: Always use genuine factory replacement oils and filters to ensure proper lubrication and filtration of engine and hydraulic system oils. The use of proper oils, grease, and keeping the hydraulic system clean will extend machine and component life.

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50011183

INTRODUCTION

Maintenance chart Tighten Cleaning Grease Check Drain fluid Maintenance action

Lubricate Replace Change fluid Adjust Test Page no.

At warning message display Fuel filter Engine coolant level First 10 hours Tire lug nuts Every 10 hours or daily Engine air filter (Note 1) Engine oil level Engine coolant level Hydraulic oil level Air tank Boom Strainers King pins Fuel filter Suspension system Steering cylinder balljoints Trash and debris Hydraulic components Every 50 hours Tire lug nuts Foam heads and in-line filter Suspension valve linkage pivots Leg widening axle slide pads Cooling package Every 100 hours Tire inflation Every 250 hours Engine air filter Air compressor Charge air cooler Radiator hoses Hydro filters Walkway railing lock Brake circuit filter Every 400 hours Secondary fuel filter Hydraulic oil filters Hydraulic reservoir breather Every 500 hours Engine oil and filter Primary fuel filter Coolant PH level Once a year Cab charcoal pressurization filter (Note 2) Cab recirculation filter Every 750 hours Engine air intake system

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INTRODUCTION

Tighten Cleaning Grease Check Drain fluid Maintenance action

Lubricate Replace Change fluid Adjust Test Page no.

Engine speeds Every 1000 hours Hydraulic oil Belt tensioner Every two years Engine coolant Cooling system thermostats Every 1500 hours Fuel injector nozzles Engine breather filter Every 4500 hours Diesel Exhaust Fluid (DEF)/AdBlueÂŽ supply module filter Every 5000 hours Engine valve clearance Engine brake assembly As required Cooling package Flow meter Flow meter cable Chassis suspension Boom breakaway tension Steering toe in Boom cylinder speed

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INTRODUCTION

Hydraulic contamination 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: • When you drain the oil or disconnect any line • When you disassemble a component • From normal wear of the hydraulic components • From damaged seals or worn seals • 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: • Cylinder rod seals that leak • Control valve spools that do not return to neutral • Movement of control valve spools is difficult • Hydraulic oil that becomes too hot • Pump gears, housing, and other parts that wear rapidly • Relief valves or check valves held open by dirt • Quick failure of components that have been repaired • Slow cycle times are slow. The machine does not have enough power. If your machine has any of these problems, check the hydraulic oil for contamination. There are two types of contamination: microscopic and visible. Microscopic contamination occurs when very fine particles of foreign material are suspended in the hydraulic oil. These particles are too small to see or feel. Microscopic contamination can be found by identification of the following problems or by testing in a laboratory. Examples of problems caused by microscopic contamination: • Cylinder rod seals that leak • Control valve spools that do not return to neutral • The hydraulic system has a high operating temperature 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 problems caused by visible contamination: • Particles of metal or dirt in the oil • Air in the oil • Dark or thick oil • Oil with an odor of burned oil • Water in the oil If you find contamination, use a portable filter to clean the hydraulic system.

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INTRODUCTION

Capacities Engine Oil type

NEW HOLLAND AMBRA UNITEK MASTERGOLD SBL CJ-4 Refer to your Cummins manual

Capacity Cooling system Coolant type

NEW HOLLAND AMBRA AGRIFLU 50-50 water and ethylene glycol mix Approximately 38 l (10 US gal) (does not include the heater core or cab plumbing).

Coolant capacity Hydraulic system Oil type Tank capacity Air conditioning system Refrigerant type

NEW HOLLAND AMBRA HYDROSYSTEM 68 Approximately 132 l (35 US gal) CNH REFRIGERANT HFC-134A

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General specification Engine Fuel capacity and type Diesel Exhaust Fluid (DEF) Capacity Cooling package Engine/transmission Transmission Hydro pump displacement Final drives Parking brake Service brake Steering Standard front wheel Optional 4 wheel steer HYDRALINK™ Suspension Crop clearance Wheel width adjustment Air system Auxiliary hydraulic circuit Product tank options Poly or Stainless steel Poly or Stainless steel Product pump standard Product pump optional Rinse tank standard Boom options Boom lines Cab Height Width (transport) Length (boom unfolded) Wheel base Boom travel Weight (approximate)

Model SP.295F Cummins QSB Tier 4 Final 300 Hp — power bulge to 310 Hp 568 l (150 US gal) Ultra low sulfur diesel 56.8 L (15.0 US gal) Stacked side by side single pass design, hydraulically driven fan Located in rear - ISO mounted Torq-Trac® hydrostatic drive system with Twin Sauer-Danfoss heavy duty pumps 75 cc each Poclain® - MW 14 (front) and Poclain® - MS 18 (rear) 4 wheel 4 wheel internal wet disc Hydrostatic with two steering cylinders, no tie rods, 4.1 m (13.5 ft) turning radius 4.1 m (13.5 ft) turn radius in 4 wheel steer, 5.3 m (17.5 ft) turn radius in 2 wheel steer Full suspension travel of 51 cm (20 in) . 4-wheel independent with integrated hydraulic leveling/shock absorbers, auto leveling for each wheel leg. 183 cm (72 in) 305 - 406 cm (120 - 160 in), hydraulic adjust, wheels move in/out equally on both sides. Operator remains centered. Direct engine driven, water cooled air compressor and air storage tank. 117 l/min (31 US gpm) - Optional 193 l/min (51 US gpm) closed center 3785 L (1000 US gal) 4542 L (1200 US gal) Hypro 9306C - 795 l/min @ 5.5 bar ( 210 US gpm @ 80 psi) Hypro 9307C high capacity - 1173 l/min @ 5.5 bar ( 310 US gpm @ 80 psi) 568 l (150 US gal), Poly 60 ft, 75 ft/60 ft, 80 ft/60 ft, 90 ft/60 ft, 100 ft/60 ft, 120 ft/ 70 ft, 27 m/ 18 m, 30 m/ 18 m, 32 m/ 18 m, 36 m/ 22 m Standard 2.54 cm (1 in) stainless steel — Optional 3.81 cm (1.5 in) stainless steel SprayView Cab or Premium SprayView Cab 401 cm (158 in) 368 cm (145 in) 859 cm (338 in) 389 cm (153 in) Lowered 56 cm (22 in) — Raised 300 cm (118 in) 12927 kg (28500 lb)

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INTRODUCTION

Engine Fuel capacity and type Diesel Exhaust Fluid (DEF) Capacity Cooling package Engine/transmission Transmission Hydro pump displacement Final drives Parking brake Service brake Steering Standard front wheel Optional 4 wheel steer HYDRALINK™ Suspension Crop clearance Wheel width adjustment Air system Auxiliary hydraulic circuit Product tank options Stainless steel Stainless steel Stainless steel Product pump standard Product pump optional Rinse tank standard Boom options Boom lines Cab Height Width (transport) Length (boom unfolded) Wheel base Boom travel Weight (approximate)

Model SP.300F Cummins QSB Tier 4 Final 300 Hp — power bulge to 310 Hp 568 l (150 US gal) Ultra low sulfur diesel 56.8 L (15.0 US gal) Stacked side by side single pass design, hydraulically driven fan Located in rear - ISO mounted Torq-Trac® hydrostatic drive system with Twin Sauer-Danfoss heavy duty pumps 100 cc each Poclain® - MS 18 (front and rear) 4 wheel 4 wheel internal wet disc Hydrostatic with two steering cylinders, no tie rods, 4.6 m (15.0 ft) turning radius 4.6 m (15.0 ft) turn radius in 4 wheel steer, 6.4 m (21.0 ft) turn radius in 2 wheel steer Full suspension travel of 51 cm (20 in) . 4-wheel independent with integrated hydraulic leveling/shock absorbers, auto leveling for each wheel leg. 183 cm (72 in) 305 - 406 cm (120 - 160 in), hydraulic adjust, wheels move in/out equally on both sides. Operator remains centered. Direct engine driven, water cooled air compressor and air storage tank. 117 l/min (31 US gpm) - Optional 193 l/min (51 US gpm) closed center 4542 L (1200 US gal) 5300 L (1400 US gal) 6057 L (1600 US gal) Hypro 9306C - 795 l/min @ 5.5 bar ( 210 US gpm @ 80 psi) Hypro 9307C high capacity - 1173 l/min @ 5.5 bar ( 310 US gpm @ 80 psi) 568 l (150 US gal), Poly 60 ft, 75 ft/60 ft, 80 ft/60 ft, 90 ft/60 ft, 100 ft/60 ft, 120 ft/ 70 ft, 27 m/ 18 m, 30 m/ 18 m, 32 m/ 18 m, 36 m/ 22 m Standard 2.54 cm (1 in) stainless steel — Optional 3.81 cm (1.5 in) stainless steel SprayView Cab or Premium SprayView Cab 401 cm (158 in) 368 cm (145 in) 922 cm (363 in) 450 cm (177 in) Lowered 56 cm (22 in) — Raised 300 cm (118 in) 14016 kg (30900 lb)

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INTRODUCTION

Model SP.345F Cummins QSL Tier 4 Final 320 Hp — power bulge to 345 Hp 568 l (150 US gal) Ultra low sulfur diesel 56.8 L (15.0 US gal) Stacked side by side single pass design, hydraulically driven fan Located in rear - ISO mounted Torq-Trac® hydrostatic drive system with Twin Sauer-Danfoss heavy duty pumps 130 cc each Poclain® - MS 18 4 wheel 4 wheel internal wet disc Hydrostatic with two steering cylinders, no tie rods, 4.6 m (15.0 ft) turning radius 4.6 m (15.0 ft) turn radius in 4 wheel steer, 6.4 m (21.0 ft) turn radius in 2 wheel steer Full suspension travel of 51 cm (20 in) . 4-wheel independent with integrated hydraulic leveling/shock absorbers, auto leveling for each wheel leg. 183 cm (72 in) 305 - 406 cm (120 - 160 in), hydraulic adjust, wheels move in/out equally on both sides. Operator remains centered. Direct engine driven, water cooled air compressor and air storage tank. 98.4 L/min (26.0 US gpm) - Optional 166.6 L/min (44.0 US gpm) closed center 4542 L (1200 US gal) 5300 L (1400 US gal) 6057 L (1600 US gal) Hypro 9306C - 795 l/min @ 5.5 bar ( 210 US gpm @ 80 psi) Hypro 9307C high capacity - 1173 l/min @ 5.5 bar ( 310 US gpm @ 80 psi) 568 l (150 US gal), Poly 80 ft/ 60 ft, 90 ft/ 60 ft, 100 ft/ 60 ft, 120 ft/ 70 ft, 27 m/ 18 m, 30 m/ 18 m, 32 m/ 18 m, 36 m/ 22 m Standard 2.54 cm (1 in) stainless steel — Optional 3.81 cm (1.5 in) stainless steel SprayView Cab or Premium SprayView Cab 401 cm (158 in) 368 cm (145 in) 922 cm (363 in) 450 cm (177 in) Lowered 56 cm (22 in) — Raised 300 cm (118 in) 14969 kg (33000 lb)

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INTRODUCTION

Model SP.400F Cummins QSL Tier 4 Final 380 Hp — power bulge to 400 Hp 568 l (150 US gal) Ultra low sulfur diesel 56.8 L (15.0 US gal) Stacked side by side single pass design, hydraulically driven fan Located in rear - ISO mounted Torq-Trac® hydrostatic drive system with Twin Sauer-Danfoss heavy duty pumps 130 cc each Poclain® - MW 24 4 wheel 4 wheel internal wet disc Hydrostatic with two steering cylinders, no tie rods, 4.6 m (15.0 ft) turning radius 4.6 m (15.0 ft) turn radius in 4 wheel steer, 6.4 m (21.0 ft) turn radius in 2 wheel steer Full suspension travel of 51 cm (20 in) . 4-wheel independent with integrated hydraulic leveling/shock absorbers, auto leveling for each wheel leg. 183 cm (72 in) 305 - 406 cm (120 - 160 in), hydraulic adjust, wheels move in/out equally on both sides. Operator remains centered. Direct engine driven, water cooled air compressor and air storage tank. 98.4 L/min (26.0 US gpm) - Optional 166.6 L/min (44.0 US gpm) closed center 4542 L (1200 US gal) 5300 L (1400 US gal) 6057 L (1600 US gal) Hypro 9306C - 795 l/min @ 5.5 bar ( 210 US gpm @ 80 psi) Hypro 9307C high capacity - 1173 l/min @ 5.5 bar ( 310 US gpm @ 80 psi) 568 l (150 US gal), Poly 80 ft/ 60 ft, 90 ft/ 60 ft, 100 ft/ 60 ft, 120 ft/ 70 ft, 27 m/ 18 m, 30 m/ 18 m, 32 m/ 18 m, 36 m/ 22 m Standard 2.54 cm (1 in) stainless steel — Optional 3.81 cm (1.5 in) stainless steel SprayView Cab or Premium SprayView Cab 401 cm (158 in) 368 cm (145 in) 922 cm (363 in) 450 cm (177 in) Lowered 56 cm (22 in) — Raised 300 cm (118 in) 15386 kg (33920 lb)

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INTRODUCTION

Product identification - Sprayer model and serial number The machine serial number is located on the front side frame cross tube below the cab and above the fill snorkel latch bar. The machine serial number can also be displayed on the chassis monitor. NOTE: Located on front frame just below cab.

RAIL12SP01219AA

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INTRODUCTION

Product identification - Machine orientation

RAIL14SP00996FA

1. Right hand side

2. Front of unit

3. Left hand side

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INTRODUCTION

RAIL14SP00997FA

1. Right hand side

3. Left hand side

4. Rear of unit

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SERVICE MANUAL Engine SP.295F SP.300F SP.345F SP.400F

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Contents Engine - 10

[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 [10.114] Pump drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 [10.216] Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 [10.206] Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 [10.202] Air cleaners and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 [10.500] Selective Catalytic Reduction (SCR) exhaust treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7 [10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8

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Engine - 10 Engine and crankcase - 001

SP.295F SP.300F SP.345F SP.400F

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Contents Engine - 10 Engine and crankcase - 001

SERVICE Engine Replace - Engine oil and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Engine support and mounts Remove - Engine mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Install - Engine mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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Engine - Engine and crankcase

Engine - Replace - Engine oil and filter Refer to the Cummins Operation and Maintenance Manual for all engine maintenance procedures and maintenance schedules not covered in this manual. Change the engine oil and filter as described in the Cummins Operation and Maintenance Manual.

RAIL14SP00872AA

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Engine - Engine and crankcase

Engine - Remove 1. Two different types of engine are used on Guardian sprayers. The sprayer model numbers SP.295F and the SP.300F use the Cummins QSB engine (1). The sprayer model numbers SP.345F and SP.400F use the Cummins QSL engine (2). 2. Move the vehicle to a hard level surface 3. Turn the ignition key to the OFF position. Remove the key from the ignition. 4. Allow the engine to cool before proceeding. 5. Access the battery disconnect switch located at the left rear of the vehicle. Turn the switch to the OFF position.

6. Drain the hydraulic reservoir. Refer to Reservoir, cooler, and filters - Remove (35.300) 7. Drain the engine coolant from the cooling package. Refer to Engine cooling system - Remove (10.400) 8. Remove the engine enclosure panels. Refer to Engine hood and panels - Remove (90.100) 9. Disconnect and remove the deaeration tank, which is attached to the SCR mounting enclosure. 10. Remove the SCR system and the mounting enclosure. Refer to Selective Catalytic Reduction (SCR) muffler and catalyst - Remove (10.500) 11. Remove the air cleaner and the mounting frame. Refer to Air cleaners and lines - Remove (10.202) 12. Remove the Auxiliary pump from the hydrostatic tandem pump assembly. Refer to Auxiliary hydraulic pump - Remove (35.220) 13. Remove the hydrostatic tandem pump assembly from the engine. Refer to Pump - Remove (29.218) for QSB engines. Refer to Pump - Remove (29.218) for QSL engines. 14. Disconnect the fuel line attached to the engine. Plug the fuel line and mark the connection point for reattachment. 15. Disconnect any lines connected to the SCR system from the engine. Plug the lines and mark the connection points for reattachment. 47691240 24/02/2015

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RAIL15SP00248FA

RAIL15SP00249FA

Engine - Engine and crankcase

16. Disconnect any hydraulic oil lines attached to the engine. This will include the line connected to the cooling fan motor. Plug the lines and mark the connection points for reattachment. 17. Disconnect any engine coolant lines attached to the engine. Plug the lines and mark the connection points for reattachment. 18. Disconnect any air intake lines attached to the engine. This will include air line attached to the turbocharger, and lines attached to the pneumatic system. Plug the lines and mark the connection points for reattachment. 19. Remove the air conditioner compressor from the engine by removing the mounting bolts. Do not evacuate the air conditioning system. Move the air conditioner compressor, with lines attached, to the side. 20. Disconnect all electrical connections to the engine. This will include ground wires, ECM harness, sensor connections, and system power wires. Tag and mark the wires and connectors for reattachment. 21. Verify that all attachments and connections to the engine have been removed. 22. Attach a suitable lifting device to the engine lift points. Support the engine. 23. Access the engine mounting bolts located on the underside of the engine. Two mounting bolts are located at the right hand side to the engine, and one mounting bolt is located at the left side of the engine. 24. Loosen the bolts but do not remove completely. 25. Lift the engine slightly and verify full support of the engine with the lifting device. 26. Remove the engine mounting bolts from the engine. Lift the engine from its mounting points.

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Engine - Engine and crankcase

Engine - Install 1. Two different types of engine are used on Guardian sprayers. The sprayer model numbers SP.295F and the SP.300F use the Cummins QSB engine (1). The sprayer model numbers SP.345F and SP.400F use the Cummins QSL engine (2).

2. Attach the engine to a suitable lifting device. Lift the engine onto the vehicle and position the engine at its mounting point on the vehicle frame. 3. Insert the engine mounting blots with flat washers through the engine mounts and into the engine mounting holes. Do not fully tighten the mounting bolts. 4. Ensure that the engine is fully positioned and secure on the engine mounts. Tighten the bolts securely. 5. Remove the lifting device from the engine. 6. Connect all electrical connections to the engine. This will include ground wires, ECM harness, sensor connections, and system power wires. 7. Attach the air conditioner compressor and belt to the engine using the mounting bolts. Position the compressor and ensure belt tightness. Tighten the bolt securely. 8. Connect all air intake lines to the engine. This will include air line attached to the turbocharger, and lines attached to the pneumatic system. Tighten all clamps securely. 9. Connect all engine coolant lines to the engine. Tighten all clamps securely. 10. Connect all hydraulic oil lines attached to the engine. This will include the line connected to the cooling fan motor. Tighten all clamps securely. 11. Connect any lines connected to the SCR system to the engine. Tighten all clamps securely. 47691240 24/02/2015

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RAIL15SP00248FA

RAIL15SP00249FA

Engine - Engine and crankcase

12. Connect the fuel line attached to the engine. Tighten all clamps securely. 13. Attach the hydrostatic tandem pump assembly to the engine. Refer to Pump - Install (29.218) for QSB engines. Refer to Pump - Install (29.218) for QSL engines. 14. Attach the auxiliary pump to the hydrostatic tandem pump assembly. Refer to Auxiliary hydraulic pump - Install (35.220) 15. Install the air cleaner and the mounting frame. Refer to Air cleaners and lines - Install (10.202) 16. Install the SCR system and the mounting enclosure. Refer to Selective Catalytic Reduction (SCR) muffler and catalyst - Install (10.500) 17. Attach the deaeration tank to the SCR mounting enclosure. Connect any coolant lines to the engine. 18. Attach the engine enclosure panels to the engine enclosure frame. Refer to Engine hood and panels Install (90.100) 19. Fill the cooling system with proper coolant to the proper level. 20. Fill the hydraulic reservoir with proper hydraulic oil and to the proper level. 21. Inspect and ensure that all connections to the engine are made and secure. 22. Turn the battery disconnect switch to the ON position. 23. Ensure that the fuel tank, and that the Diesel Exhaust Fluid (DEF) tank are filled to the proper levels 24. Start the vehicle engine and inspect for any leaks or lose connections. Ensure proper operation of the engine and all connected components.

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Engine - Engine and crankcase

Engine support and mounts - Remove - Engine mounts Prior operation: Remove compartment engine panels and doors. Refer to Engine hood and panels - Remove (90.100) NOTE: The applicable end of engine should be lifted slightly to remove/install some hardware in the following procedures. 1. Secure engine to suitable lifting device. Lift engine slightly to enable removal of the front engine mounts as follows. 2. There are three mounting points for the engine.

RAIL14SP01913AA

RAIL14SP01914AA

WARNING Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply could result in death or serious injury. W0398A

Remove hex bolts, washers, and nuts (1) attaching the motor mount (2) to the frame. 4. Remove the nut and washer (3) attaching the motor mount (4) to the frame. 5. Remove the motor mount from the frame by removing the hex bolt and snubbing washers (5). 6. Secure engine to suitable lifting device. Lift engine slightly to enable removal of the rear engine mounts as follows. NOTE: There are two rear engine mounts, both configured the same. 47691240 24/02/2015

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Engine - Engine and crankcase

7. Remove nuts and washers (1), and the hex bolts and washers (2) attaching the motor mount (3) to the frame. Remove the motor mounts from the vehicle.

RAIL14SP01915AA

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Engine - Engine and crankcase

Engine support and mounts - Install - Engine mounts 1. Secure engine to suitable lifting device. Lift engine slightly to enable installation of the rear engine mounts. NOTE: There are two rear engine mounts, both configured the same. 2. Install the motor mounts (1) onto the frame at the engine mounting points. 3. Lower the engine into place and install the hex bolts with snubbing washers (2) through the engine mounting holes and then through the motor mounts. 4. Secure the motor mounts and the engine in place using the nuts and washers (3). Tighten securely.

RAIL14SP01915AA

RAIL14SP01914AA

5. Install the front motor mount (1) in to place on the vehicle. 6. Attach the motor mount to the vehicle frame using the two hex bolts, washers, and nuts (2). Tighten securely. 7. Secure the front end of the engine to the motor mount by installing the hex bolt and snubber washers (3) through the motor mount and then through the engine mounting hole. Secure the motor mount in place using the washer and nut (4). Tighten securely.

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Index Engine - 10 Engine and crankcase - 001 Engine - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Engine - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Engine - Replace - Engine oil and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine support and mounts - Install - Engine mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Engine support and mounts - Remove - Engine mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Engine - 10 Pump drives - 114

SP.295F SP.300F SP.345F SP.400F

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Contents Engine - 10 Pump drives - 114

SERVICE Hydraulic pump drive coupler Remove - Hydrostatic pump drive coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install - Hydrostatic pump drive coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Engine - Pump drives

Hydraulic pump drive coupler - Remove - Hydrostatic pump drive coupler Prior operation: Remove the right hand engine compartment enclosure and panels. Refer to Engine hood and panels - Remove (90.100) Prior operation: Apply a vacuum to the hydraulic fluid tank. Refer to Oil reservoir - Service instruction - Tank vacuum procedure (35.300) Prior operation: Remove the Auxiliary pump assembly. Refer to Auxiliary hydraulic pump - Remove (35.220) 1. Park the vehicle on a flat, level surface. Release the parking brake and lower the suspension completely. 2. Apply the parking brake and swing the right side boom outward, or raise the boom up and out of the saddle. 3. Shut off the engine, remove the ignition key, and allow the engine and hydraulic oil to cool. 4. Tag and mark all hydrostatic pump hydraulic hoses. Record the hose connections and hose routing to aid in reinstallation of the hoses. 5. Remove all hydraulic hoses, and disconnect any electrical connections from hydrostatic tandem pump set. 6. Cap and plug the lines and fittings. Use plastic covers to cover lower ports on hydrostatic pump units. 7. Disconnect the cable connection to the ball joint (1) of the turnbuckle assembly. 8. Disconnect pump turnbuckle (2) from the pump set by removing the nuts (2). Lift the turnbuckle assembly from the pump set.

RAIL14SP01911AA

9. Attach a suitable lifting device to the hydrostatic tandem pump set (2), ensuring strap routing will evenly balance the assembly, once lifted. Remove slack from strapping, but do not lift assembly at this time.

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Engine - Pump drives

10. Remove four hex bolts and flat washers (1) securing hydrostatic tandem pump set to flywheel housing mounting plate (2). 11. Remove the hydrostatic tandem pump set from flywheel housing mounting plate.

RAIL14SP01910AA

RAIL13SP03449AA

RAIL13SP01139FA

12. Use a jack or suitable lifting device and a block, and position block under engine at flywheel end (13). Do not lift engine at this time.

13. Remove two bolts (7) from flywheel housing mounting plate (6). Retain hardware for reassembly. 14. Remove twelve (8) hex bolts that secure flywheel housing mounting plate (6) to engine flywheel housing. Retain hardware. 15. Using a suitable lifting device, lift engine high enough for mounting plate (6) to clear frame. 16. Remove flywheel housing mounting plate (6). Retain plate. 17. Remove eight hex socket head capscrews (9) and lockwashers (10) that secure the hydrostat coupler (11) to flywheel and remove coupler. Retain hardware. Discard coupler.

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Engine - Pump drives

Hydraulic pump drive coupler - Install - Hydrostatic pump drive coupler 1. Clean Loctite residue from threads or threaded holes on retained hardware and components. 2. Apply red LOCTITEÂŽ 273 to threads of capscrews and install new hydrostat coupler (11) to flywheel with eight hex socket head capscrews (9) and lockwashers (10). Tighten the capscrews securely. 3. Secure flywheel housing mounting plate (6) to engine flywheel housing with twelve (8) hex bolts. Tighten the bolts securely. 4. Lower engine down until mounting plate rests on frame.

RAIL13SP01139FA

5. Secure flywheel housing mounting plate (6) with two bolts (7). Tighten the bolts securely. 6. Reposition hoses and wiring onto guide plate (12) at bell housing and secure. 7. Using lifting device, position hydrostatic tandem pump set/auxiliary hydraulic pump assembly (2) onto flywheel housing mounting plate (6). NOTE: The splines of the hydrostatic tandem pump set and the splines on the coupler are difficult to align. It may be necessary to turn the engine crank by hand with a breaker bar and socket on the damper end of the engine to assist in alignment of splines. 8. Secure hydrostatic tandem pump set/auxiliary hydraulic pump assembly (2) to flywheel housing mounting plate (6) by installing four hex bolts (3), flat washers (4), and lockwashers (5). 9. Remove lifting device strapping from hydrostatic tandem pump set/auxiliary hydraulic pump assembly. 10. Position pump turnbuckle (1) onto hydrostatic tandem pump/auxiliary hydraulic pump assembly (2) and install at ball joint. 11. Uncap and unplug each line/fitting and connect hydraulic hoses to applicable connection points. Remove tagging on hoses. NOTE: During the hose reconnecting, new o-rings, or o-rings in good condition, should be used, and should be lubricated with Vaseline or motor assembly lube (not grease).

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Engine - Pump drives

12. Connect all electrical connections to the applicable connection points. 13. Release the vacuum form the hydraulic tank. Operate the engine and check for leaks and proper function of the system.

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Index Engine - 10 Pump drives - 114 Hydraulic pump drive coupler - Install - Hydrostatic pump drive coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Hydraulic pump drive coupler - Remove - Hydrostatic pump drive coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Engine - 10 Fuel tanks - 216

SP.295F SP.300F SP.345F SP.400F

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Contents Engine - 10 Fuel tanks - 216

SERVICE Fuel tanks Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Engine - Fuel tanks

Fuel tanks - Remove Prior operation: Remove the product tank Product tank - Remove (78.110) Prior operation: Remove the hand rinse tank Rinse tank - Remove - Hand rinse tank (78.110) 1. Drain the fuel from the fuel tank. 2. Remove the fuel valve. 3. Disconnect the electrical connector (1) on the top of the fuel tank.

RAIL13SP03793AA

RAIL13SP03795AA

RAIL13SP03794AA

4. Loosen the clamp (1) on the fuel line (2). 5. Remove the fuel line.

6. Attach a suitable lifting device to the fuel tank and the bracket assembly. 7. Remove the four hex bolts (1), eight flat washers (2), and four locknuts (3) that secure the fuel tank and the bracket assembly to the frame. 8. Remove the fuel tank and the bracket assembly from the frame.

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Engine - Fuel tanks

Fuel tanks - Install 1. With a suitable lifting device, position the fuel tank and the bracket assembly on the frame. 2. Secure the fuel tank and the bracket assembly to the frame with four hex bolts (1), eight flat washers (2), and four locknuts (3).

RAIL13SP03794AA

RAIL13SP03795AA

RAIL13SP03793AA

3. Install the fuel line on the fuel tank with one band clamp.

4. Connect the electrical connector (1) on the top of the fuel tank. 5. Install the fuel valve in the fuel tank. 6. Install the hand rinse tank Rinse tank - Install - Hand rinse tank (78.110). 7. Install the product tank Product tank - Install (78.110). 8. Fill the fuel tank with fuel. 9. Operate the vehicle and check for leaks and proper function of the system.

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Index Engine - 10 Fuel tanks - 216 Fuel tanks - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Fuel tanks - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Engine - 10 Fuel filters - 206

SP.295F SP.300F SP.345F SP.400F

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Contents Engine - 10 Fuel filters - 206

SERVICE Fuel-water separator filter Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Remove - Primary and secondary fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install - Primary and secondary fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Engine - Fuel filters

Fuel-water separator filter - Drain fluid 1.

WARNING Chemical hazard! When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions. Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect fluids in proper containers. Obey all local and environmental regulations when disposing of chemicals. Failure to comply could result in death or serious injury. W0371A

Shut off engine. Open drain valve (1) of fuel-water separator (2). Turn counterclockwise until valve drops down and draining occurs. Continue draining until fuel is clear of water. NOTICE: Do not overtighten fuel-water separator valve or damage to threads may occur, resulting in damage to equipment. 2. Shut the valve (1). Turn the valve knob clockwise until hand-tight. 3. If more than 59 ml (2 US fl oz) of fuel/water is drained, refill the separator with the hand pump. 4. Operate the engine and check for leaks. RAIL14SP01856AA

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Engine - Fuel filters

Fuel-water separator filter - Remove - Primary and secondary fuel filters 1. Drive the vehicle on to a hard level surface. 2. Turn the ignition key to the “OFF” position. Remove the key from the ignition. 3. Turn the master disconnect switch to the “OFF” position. Allow two minutes before shutting off the master disconnect switch in order for the DEF pump to purge the DEF lines. 4. Drain any remaining fuel from the fuel tank into a suitable container. Drain the tank by opening the drain cock located in the bottom of the tank. 5. Access the fuel filters by opening the engine enclosure belly pan door. The fuel filters are located at the right hand rear of the engine. 6. Remove the primary and the secondary filter from the filter head by turning the filter counter clockwise to remove. NOTE: Use the following steps to remove the complete filter head and mounting assembly. 7. Tag and mark the fuel and electrical lines attached to the fuel filter assembly. 8. Disconnect the fuel line attached to the inlet of the primary fuel filter/water separator assembly. Disconnect the fuel line from the primary fuel filter/water separator assembly to the fuel pump. Disconnect the fuel line from the fuel pump to the secondary fuel filter. Disconnect the fuel line from the secondary fuel filter to the fuel pump. Cap or plug the fuel line from the secondary fuel filter to the engine. Disconnect the electrical connector from the primary fuel filter/water separator assembly. 9. Remove the primary fuel filter/water separator (1) from the mounting plate (2) by removing the bolts, washers, and nuts (3). Remove the filter assembly from the vehicle. 10. Remove the secondary fuel filter (4) from the mounting plate by removing the four bolts and washers (5). Remove the filter from the vehicle.

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Fuel-water separator filter - Install - Primary and secondary fuel filters 1. Install the primary and the secondary filters by inserting the filters into the filter heads. Turn the filters clockwise to tighten the filters into place. NOTE: Use the following steps to install the filter heads, fuel lines, and mounting plate. 2. Attach the fittings (1) to the primary fuel filter/water separator (2). 3. Attach the primary fuel filter/water separator to the mounting bracket (3) using the bolts, washers, and nuts (4) . Tighten securely. 4. Attach the secondary fuel filter (5) to the mounting bracket using the bolts and washers (6) . tighten securely.

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5. Attach the fuel line from the fuel tank to the inlet of the primary fuel filter/water separator. Attach the fuel line from the primary fuel filter/water separator to the fuel pump. Attach the fuel line to the secondary fuel filter inlet. Attach the fuel line from the secondary fuel filter inlet to the fuel pump. Attach the fuel line from the engine to the secondary fuel filter outlet. 6. Connect the wire harness connection to the primary fuel filter/water separator. 7. Remove tags marking the lines.

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8. QSB Engines only: Operate the hand priming pump (1) to bring fuel to the primary filter (2). 9. QSL Engines only: Operate the engine and allow the electric fuel pump to bring fuel to the primary fuel filter.

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10. Access the engine area and check for any fuel leaks. Repair any leaks found.

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Index Engine - 10 Fuel filters - 206 Fuel-water separator filter - Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Fuel-water separator filter - Install - Primary and secondary fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Fuel-water separator filter - Remove - Primary and secondary fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Engine - 10 Air cleaners and lines - 202

SP.295F SP.300F SP.345F SP.400F

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Contents Engine - 10 Air cleaners and lines - 202

SERVICE Air cleaners and lines Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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Engine - Air cleaners and lines

Air cleaners and lines - Remove 1. Move the vehicle onto a hard level surface. 2. Turn the ignition to the “OFF” position. Remove the key from the ignition. 3. Turn the master disconnect switch to the “OFF” position. Allow the DEF module pump to run for approximately 2 minutes before turning the master disconnect switch off. 4. Gain access to the engine enclosure by opening the engine enclosure roof.

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5. Remove the engine enclosure front doors. The air cleaner assembly is attached to the support frame which is attached to the top of the engine enclosure frame.

6. Disconnect the intake air tube (1) from the side panel of the engine enclosure by removing the hose clamp (2) . 7. Disconnect the intake tube (1) from the air cleaner housing (3) by removing the hose clamp (4) .

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8. Disconnect the reducer tube (1) from the air cleaner housing by removing the hose clamp (2) . 9. Disconnect the reducer tube (1) from the intake elbow (3) by removing the hose clamp (4) .

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10. Disconnect the intake elbow (1) from the reducer elbow (2) by removing the hose clamp (3) . 11. Disconnect the reducer elbow (2) from the engine intake by removing the hose clamp (4) .

12. Disconnect the wire connection (1) to the restriction indicator sensor (2).

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13. Disconnect the wire connection to the Temperature Barometric Air Pressure (TBAP) sensor (1) located at the top of the air cleaner housing outlet.

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14. Remove the air cleaner housing from the air cleaner support bracket (1) by removing the bolts, lockwashers, and flat washers (2) . 15. Remove the air cleaner housing from the vehicle.

16. Disconnect the restriction indicator (1) from the air cleaner housing.

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17. Remove the pre-cleaner housing (1) from the air cleaner housing by opening the clamp (2) attaching the pre-cleaner to the housing. 18. Remove the Temperature Barometric Air Pressure (TBAP) sensor (3) from the air cleaner housing. 19. Remove the primary and secondary air filters (4) from the air cleaner housing by opening the cover (5) of the air cleaner housing.

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Air cleaners and lines - Install 1. Attach the pre-cleaner housing (1) to the air cleaner housing using the clamp (2). 2. Attach the Temperature Barometric Air Pressure (TBAP) sensor (3) to the air cleaner housing. 3. Install the primary and secondary air filters (4) into the air cleaner housing. Place the cover (5) on to the housing and clamp in place.

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4. Attach the restriction indicator (1) to the air cleaner housing.

5. Position the air cleaner housing at its mounting position in the engine enclosure. Attach the air cleaner housing to the air cleaner support bracket (1) using the bolts, lockwashers, and flat washers (2). Tighten securely.

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6. Connect the wire connection to the Temperature Barometric Air Pressure (TBAP) sensor (1).

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7. Connect the wire connection (1) to the restriction indicator sensor (2).

8. Connect the reducer elbow (1) to the engine intake using the hose clamp (2). 9. Connect the intake elbow (3) to the reducer elbow (1) using the hose clamp (4).

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10. Connect the reducer tube (1) to the intake elbow (2) using the hose clamp (3) . 11. Connect the reducer tube (1) to the air cleaner housing using the hose clamp (4) .

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12. Connect the intake tube (1) to the air cleaner housing using the hose clamp. (2). 13. Connect the intake tube to the side panel of the engine enclosure using the hose clamp (3).

14. Install the engine enclosure front doors.

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15. Close the engine enclosure roof.

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16. Start the engine of the vehicle and check the air cleaner connections for leaks. Repair any leaks found.

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Air cleaners and lines - Replace 1. Remove the front panel (1) off of the air cleaner housing (2) . 2. Install the secondary filter elements (3) into the air cleaner housing. Ensure that the elements are installed completely in place. 3. Install the primary filter elements (4) into the air cleaner housing. Ensure that the elements are installed completely in place. 4. Reattach the front panel onto the air cleaner housing and clamp in place. Ensure that the panel gasket is seated properly. RAIL14SP01855AA

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Index Engine - 10 Air cleaners and lines - 202 Air cleaners and lines - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Air cleaners and lines - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Air cleaners and lines - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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Engine - 10 Selective Catalytic Reduction (SCR) exhaust treatment - 500

SP.295F SP.300F SP.345F SP.400F

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Contents Engine - 10 Selective Catalytic Reduction (SCR) exhaust treatment - 500

FUNCTIONAL DATA Selective Catalytic Reduction (SCR) exhaust treatment Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Selective Catalytic Reduction (SCR) muffler and catalyst Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Diesel Exhaust Fluid (DEF)/AdBlueÂ® tank Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Coolant control valve Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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Selective Catalytic Reduction (SCR) exhaust treatment - Overview The Selective Catalytic Reduction (SCR) system attached the engine of the vehicle is used to reduce the amount of carbon dioxide emissions from the engine. The system components operate to deliver Diesel Exhaust Fluid (DEF) into the exhaust stream coming from the engine. The Selective Catalytic Reduction (SCR) system is composed of the Selective Catalytic Reduction (SCR) chamber (1) , the Decomposition Reactor Tube (DRT) (2), and the Diesel Oxidation Catalyst (DOC) (3). The SCR system is mounted a sheet steel enclosure attached to the top of the engine enclosure frame.

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Additional components required for the complete system are the DEF tank (1), the DEF supply module (2), and the coolant control valve.

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During engine operation, the exhaust gasses from the engine enter the DOC where the exhaust gas hydrocarbons are oxidized to carbon dioxide. The exhaust gasses then travel through the DRT where Diesel Exhaust Fluid is sprayed into the chamber. The exhaust gasses and DEF mixture pass through a mixer plate and the mixture turns into an ammonia and iso-cyanic acid. This mixture then passes into the SCR chamber and through the SCR catalyst. The exhaust gasses then exit the exhaust pipe as nitrogen and water vapor. The following figure shows the system components.

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Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Description Engine Engine control module Diesel Oxidation Catalyst (DOC) Decomposition Reactor Tube (DRT) Selective Catalyst Reduction (SCR) Diesel Exhaust Fluid (DEF) Dosing Module DEF Supply Module DEF Tank DEF quality sensor DEF line heaters Coolant flow control valve NOx Sensor â&#x20AC;&#x201D; Engine exhaust gasses out Temperature sensor NOx Sensor â&#x20AC;&#x201D; System exhaust gasses out Engine coolant supply line Engine coolant return line Analog signal/Wiring harness Diesel Exhaust Fluid (DEF) lines Analog signal/Wiring harness Engine coolant lines

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Diesel Oxidation Catalyst (DOC) The DOC (1) is connected to the exhaust outlet of the engine. The DOC has the primary function of oxidizing the remaining hydrocarbons of the engine exhaust, into carbon dioxide. The DOC is mounted to the engine at one end and the Decomposition Reactor Tube (DRT) at the other. The DOC is mounted to the SCR enclosure with metal straps. Attached to the DOC is a NOx sensor (2) , and two temperature sensors (3) . The NOx sensor senses the level of NOx coming from the engine exhaust. The temperature sensors sense the exhaust gas temperatures both before and after the gasses travel through the catalyst inside the DOC chamber.

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Decomposition Reactor Tube (DRT) The DRT (1) is connected to the DOC. The function of the DRT is to provide a mixing chamber for the exhaust gasses and the Diesel Exhaust Fluid (DEF). The DRT is mounted to the DOC at one end and the Selective Catalytic Reduction (SCR) chamber at the other. Attached to the DRT is the Dosing Module (2). The Dosing Modules function is to inject DEF into the DRT. Attached to the dosing module are the coolant supply and return lines (3), the DEF supply line (4), and a harness connection to the engine control (5).

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Selective Catalytic Reduction (SCR) The SCR (1) is connected to the DRT. The function of the SCR is to further reduce the NOx content in the exhaust gasses to nitrogen by allowing the exhaust gasses to pass through the catalyst within the SCR. The SCR is mounted to the DRT at one end, and has the tail pipe extension attached to the other end. The SCR is mounted to the SCR enclosure with metal straps. Attached to the SCR are two temperature sensors (2) . One sensor is attached to the inlet side of the SCR chamber, and the other temperature sensor is attached to the outlet side. Also attached to the SCR is a NOx sensor (3) at the outlet.

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Diesel Exhaust Fluid (DEF) tank The DEF tank (1) is mounted in the engine enclosure at the left hand side of the vehicle. The function of the DEF tank is to hold the supply of DEF for the vehicle as well as send feedback signals to the engine control regarding DEF level, quality, and temperature. The DEF tank is removable from the machine and is held in place with two straps. Connected to the DEF tank are the coolant circulation feed and return lines (2) , the DEF feed and return lines (3), a 12 volt power/ground to sensor CAN high/low wire (4) , and a vent tube (5) . Also connected to the tank is the tank fill tube (6) which can be accessed through the sliding doors at the front of the engine enclosure.

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The DEF tank supplies the DEF module as demanded. The combination temperature, level, and quality DEF sensor (1) sends signals back to the engine control. Coolant lines (2) attached to the tank are used to keep the supply of DEF from freezing.

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The level of DEF in the tank is a critical factor in the functioning of the vehicles engine. If the level of DEF drops to a low level the overhead DEF lamp will illuminate. If the DEF level continues to drop to the very low level, vehicle engine power will be reduced. If the level of DEF is zero, engine power will be further reduced, or limited to idle only. The DEF tank level status is displayed on the overhead display panel in the vehicle cab. The indicator icons will illuminated to signal critical DEF level situations. The level indicators are described in the following table. DEF level gauge (displayed on the chassis monitor)

Description

DEF level indicator icon

DEF lamp: Illuminates when the DEF level is low, and flashes when the DEF falls to a very low level.

Flashing DEF Lamp with Check engine lamp: Illuminates when DEF level is critically low. If tank is not filled immediately, power will be reduced.

Flashing DEF Lamp with Stop engine lamp: Illuminates when DEF gauge reads zero. Power will be reduced or limited to idle.

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Diesel Exhaust Fluid Module The DEF module (1) is mounted to the right of the DEF tank inside the engine enclosure. The function of the DEF module is to pump the supply of DEF to the dosing module mounted in the DRT. Attached to the DEF module are the DEF suction and throttle return lines which are connected to the DEF tank, the DEF pressure supply line which is connected to the dosing module, and the wire harness connected to the engine control. The DEF module supplies DEF to the dosing module as required from the engine control signal. The module also has internal DEF line heaters to prevent the DEF lines from freezing. The DEF module is programmed to run the DEF module pump for approximately 30 seconds after the vehicle engine has been turned off.

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A filter element (1) is located inside of the DEF module (2). The filter removes any contaminants from the DEF supply in the tank. The filter is located under a cap attached to the DEF module. Access the filter by removing the cap. The filter needs to be checked periodically and is removable from the DEF module using a special removal tool.

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Coolant Control Valve A coolant control valve (1) is mounted to the engine and is connected to the coolant feed going to the DEF tank. The valve is controlled by the engine control and supplies warm fluid as required to the DEF tank heater.

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Selective Catalytic Reduction (SCR) muffler and catalyst - Remove Prior operation: Remove the engine enclosure roof door and the engine enclosure rear door. Refer to Engine hood and panels Remove (90.100).

Diesel Oxidation Catalyst (DOC) removal 1. Move the vehicle onto a hard level surface. 2. Turn the ignition to the “OFF” position. Remove the key from the ignition. 3. Turn the master disconnect switch to the “OFF” position. Allow the DEF module pump to run for approximately 2 minutes before turning the master disconnect switch off. 4. Remove the air intake tube (1) from the inlet side of the Diesel Oxidation Catalyst (DOC) (2) by removing the clamp and gasket (3) attaching the tube to the DOC.

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5. Disconnect the Decomposition Reactor Tube (DRT) (1) from the DOC (2) by removing the clamp and gasket (3).

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6. Disconnect the wire harness connections (1) for the temperature probes and the NOx sensor from the DOC. 7. Remove the two straps (2) securing the DOC in place by removing the blots, washers, and nuts.

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8. Attach an appropriate lifting device to the DOC and lift the DOC from the vehicle.

Decomposition Reaction Tube (DRT) removal 9. Disconnect the coolant line connections (1) attached to the dosing module of the DRT. Plug or cap the coolant lines. 10. Disconnect the Diesel Exhaust Fluid (DEF) line (2) from the dosing module. Plug or cap the DEF line. 11. Disconnect the wire harness connection (3) from the dosing module.

12. Remove the smaller clamp and gasket (1) attaching the DRT (2) to the Selective Catalytic Reduction (SCR) catalyst (3). Do not remove the larger clamp which secures the reducer fitting to the DRT. Remove the DRT from the vehicle.

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Selective Catalytic Reduction (SCR) catalyst removal 13. Disconnect the wire harness connections (1) for the temperature probes and the NOx sensor from the SCR. 14. Remove the two straps (2) securing the SCR in place by removing the bolts, washers, and nuts.

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15. Attach an appropriate lifting device to the SCR and lift the SCR from the vehicle.

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Selective Catalytic Reduction (SCR) muffler and catalyst - Install Prior operation: Selective Catalytic Reduction (SCR) muffler and catalyst - Remove (10.500) 1. Attach an appropriate lifting device to the SCR and lift the SCR into place on the vehicle.

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2. Connect the wire harness connectors (1) to the temperature probe and NOx sensor connection points.

3. Attach the DRT (1) to the SCR (2) using the clamp and gasket (3). Position the gasket properly to ensure a leakâ&#x20AC;&#x201D;free seal between the two components. Ensure that the reducer fitting has been attached to the DRT before assembling the DRT to the SCR.

4. Secure the SCR in place using the two straps, bolts nuts and washers (1) . Tighten the bolts and nuts securely.

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5. Attach the coolant lines (1) , the DEF line (2) , and the wire harness connector (3) to the dosing module of the DRT. Ensure that the connections are secure.

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6. Attach an appropriate lifting device to the DOC and lift the DOC in to place on the vehicle.

7. Attach the DOC (1) to the DRT (2) using the clamp and gasket (3). Tighten the clamp securely.

8. Connect the wire harness connectors (1) to the temperature probe and NOx sensor connection points.

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9. Attach the exhaust tube (1) from the turbo charger to the DOC (2) using the clamp and gasket (3). Tighten the clamp securely.

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10. Secure the DOC in place using the two straps, bolts nuts and washers (1) . Tighten the bolts and nuts securely.

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11. Access the vehicle cab and start the vehicle. Allow for the DEF lines and the coolant lines to fill. Inspect the hose connections for leaks. Repair as required. 12. Verify that the system is operating properly by reviewing the overhead display panel icons.

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Diesel Exhaust Fluid (DEF)/AdBlue® tank - Remove Prior operation: Remove the Left side engine enclosure panel. Refer to Engine hood and panels - Remove (90.100) . 1. Move the vehicle to a hard level surface. 2. Turn the ignition key to the “OFF” position. Remove the key from the ignition. 3. Allow the vehicle engine to cool before servicing. 4. Turn the master disconnect switch to the “OFF” position.

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NOTE: Allow the SCR module pump to run fro approximately 2 minutes before turning the disconnect switch off. 5. Drain the DEF tank by removing the drain plug and washer (1) . Collect the DEF into a suitable container.

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6. Disconnect the lines connected to the DEF Header attached to the top of the DEF tank. Disconnect the DEF suction and return lines (1). Disconnect the Tank heater coolant inlet and return lines (2). Disconnect the wire harness connection (3). Cap and plug all lines and fittings.

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7. Remove the vent line (1) from the tank vent assembly (2) by removing the hose clamp (3) attaching the hose to the vent assembly.

8. Disconnect the filler tube hose (1) from the tank by removing the hose clamp (2) attaching the hose to the tank.

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9. Remove the straps (1) holding the tank in place by removing the nuts (2) , washers (3) , and hook bolts (4) attaching the straps to the vehicle frame. 10. Remove the DEF tank from the vehicle.

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11. Remove the DEF Header (1) from the DEF tank by removing the six bolts (2) . Carefully remove the DEF Header from the tank. 12. Remove the DEF vent assembly (3) from the tank.

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Diesel Exhaust Fluid (DEF)/AdBlueÂŽ tank - Install 1. Install the DEF vent assembly (1) into the DEF tank. 2. Install the DEF Header (2) into the DEF tank. Secure in place using the six bolts (3). Ensure that the DEF tank filter (4) is attached to the header assembly.

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3. Install the drain plug and washer (1) into the bottom of the DEF tank.

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4. Install the DEF tank into the vehicle. 5. Attach the hook bolts (1) to the brackets using the nuts and washers (2). Tighten securely. 6. Secure the DEF tank to the vehicle by placing the straps (3) over the DEF tank and attaching the strap to the hook bolts.

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7. Connect the filler tube hose (1) to the DEF tank using the hose clamp (2). Tighten securely.

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8. Attach the vent line (1) to the DEF tank vent assembly (2) using the hose clamp (3). Tighten securely.

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9. Attach the lines to the DEF Header assembly. Connect the DEF suction and return lines (1). Connect the tank heater coolant inlet and return lines (2). Connect the wire harness connection (3).

10. Fill the DEF tank with DEF fluid. 11. Turn the vehicle master disconnect switch to the â&#x20AC;&#x153;ONâ&#x20AC;? position. Start the vehicle and inspect the DEF tank and the hose connections for any leaks. Review that the indicators lights in the cab indicate that the DEF system is working properly.

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Engine - Selective Catalytic Reduction (SCR) exhaust treatment

Coolant control valve - Remove CAUTION Burn hazard! Wait for all components to cool before performing any operation. Failure to comply could result in minor or moderate injury. C0053A

1. Move the vehicle to a hard level surface. 2. Turn the ignition key to the “OFF” position. Remove the key from the ignition. 3. Allow the DEF module pump to run for approximately two minutes, or until it shuts off. Turn the master disconnect switch to the “OFF” position. 4. Access the coolant control valve (1) by opening the engine enclosure belly pan door. The coolant control valve is attached to the rear right hand side of the engine at the output end.

RAIL14SP01690FA

RAIL14SP01698AA

RAIL14SP01690FA

5. Remove the hose (1) running from the engine to the valve (2) by removing the hose clamp. Plug the hose to prevent coolant leakage. 6. Remove the DEF tank hose connection from the valve (3) by removing the hose clamp. Plug the hose to prevent coolant leakage.

7. Disconnect the wire connection (1) from the control valve. 8. Remove the bolts and washers securing the control valve to the mounting bracket (4) .

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Engine - Selective Catalytic Reduction (SCR) exhaust treatment

Coolant control valve - Install 1. Attach the coolant control valve (1) to the mounting bracket (2) using the two bolts and washers. 2. Connect the DEF tank coolant hose (3) to the control valve using the hose clamp. Tighten securely. 3. Connect the engine coolant hose (4) to the control valve using the hose clamp. Tighten securely.

RAIL14SP01698AA

RAIL14SP01690FA

4. Connect the wire connection (1) to the control valve.

5. Turn the master disconnect switch to the â&#x20AC;&#x153;ONâ&#x20AC;? position. 6. Start the vehicle and check for leaks at the hose connections to the valve. Repair any leaks found.

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Index Engine - 10 Selective Catalytic Reduction (SCR) exhaust treatment - 500 Coolant control valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Coolant control valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Diesel Exhaust Fluid (DEF)/AdBlue® tank - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Diesel Exhaust Fluid (DEF)/AdBlue® tank - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Selective Catalytic Reduction (SCR) exhaust treatment - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Selective Catalytic Reduction (SCR) muffler and catalyst - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Selective Catalytic Reduction (SCR) muffler and catalyst - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Engine - 10 Engine cooling system - 400

SP.295F SP.300F SP.345F SP.400F

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Contents Engine - 10 Engine cooling system - 400

SERVICE Engine cooling system Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Engine - Engine cooling system

Engine cooling system - Remove WARNING Hot liquid under pressure! Service when cool. Failure to comply could result in death or serious injury. W1187A

Prior operation: Remove the engine enclosure panels and doors. Refer to Engine hood and panels - Remove (90.100) Prior operation: Remove the cooling fan shroud. Refer to Fan and drive - Remove Fan shroud (10.414) Prior operation: Remove the cooling fan motor. Refer to Fan motor - Remove (35.752) 1. Move the vehicle to a hard level surface. 2. Turn the ignition key to the â&#x20AC;&#x153;OFFâ&#x20AC;? position. Remove the key from the ignition. 3. Note the assembly of the cooling package components. The assembly order is as follows from top to bottom: (1) Air conditioner condenser (2) Charge air cooler (3) Engine radiator (4) Hydraulic oil cooler (5) Oil cooler bypass valve 4. Tag and mark all lines, vents, and hoses, prior to removal. 5. Evacuate refrigerant from AC system. A qualified technician should perform this task. NOTE: Anytime the AC system is evacuated of refrigerant, a qualified technician should replace receiver dryer prior to recharging the system.

RAIL14SP01912AA

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Engine - Engine cooling system

6. Drain engine coolant following all applicable warnings and cautions. Open the drain cock (1) located in the radiator outlet tube at the underside of the engine compartment.

RAIL14SP01775AA

RAIL14SP01765AA

RAIL14SP01770AA

RAIL14SP01773AA

7. Drain hydraulic fluid from system following all applicable warnings and cautions. Remove the drain plug (1) from the bottom of the hydraulic tank and allow the hydraulic oil to drain into a suitable container.

8. Remove the inlet and outlet refrigerant lines (1) from the condenser. Cap or plug the lines and the connection points on the condenser. Move the disconnected lines out of the way. 9. Remove the charge air cooler tubes (2) from the charge air cooler by removing the hose clamps. Cap or plug the tubes and the tube connection points on the cooler. Move the tubes out of the way. 10. Remove the deaeration tank hose (3) from the radiator. Cap or plug the hose and the hose connection point.

11. Remove the upper and lower radiator hoses (1) from the radiator by removing the hose clamps. Cap or plug the hoses and the hose connection points on the radiator. Move the tubes out of the way.

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Engine - Engine cooling system

12. Remove the hydraulic lines (1) from the hydraulic oil cooler and the bypass valve (2) mounted to the cooler. Cap or plug the lines and the connection points on the cooler and the bypass valve.

RAIL14SP01769AA

RAIL14SP01762AA

RAIL14SP01763AA

13. Remove the hydraulic oil lines (1) attached the side mounting plate (2) of the oil cooler. Cap or plug the two lines.

14. Remove the bolts, washers, and nuts attaching the right hand and left hand upper isolation mounts to the cooling package.

15. Remove the bolts, washers, and nuts attaching the right hand and left hand lower isolation mounts to the cooling package.

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Engine - Engine cooling system

16. Attach an appropriate lifting device to the cooling package. Lift the cooling package from the vehicle.

RAIL14SP01772AA

RAIL14SP01764AA

17. Separate the four cooling package components from each other by removing the bolts, washers, and nuts attaching the components together.

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Engine - Engine cooling system

Engine cooling system - Install 1. Stack the cooling package components in the proper order. The proper stacking order is from top to bottom: (1) Air conditioner condenser (2) Charge air cooler (3) Radiator (4) Hydraulic oil cooler 2. Assemble the cooling package components together using the bolts, washers, and nuts. Tighten securely.

RAIL14SP01819AA

RAIL14SP01772AA

RAIL14SP01763AA

3. Attach an appropriate lifting device to the cooling package Lift the cooling package into place on the vehicle.

4. Attach the cooling package to the right hand and left hand lower isolation mounts using the bolts, washers, and nuts. Tighten securely.

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Engine - Engine cooling system

5. Attach the cooling package to the right hand and left hand upper isolation mounts using the bolts, washers, and nuts. Tighten securely.

RAIL14SP01762AA

RAIL14SP01776AA

RAIL14SP01769AA

RAIL14SP01773AA

6. Attach the hydraulic oil lines (1) to the side mounting plate (2) of the oil cooler.

7. Attach the hydraulic lines (1) to the hydraulic oil cooler and to the bypass valve (2) mounted on the cooler.

8. Attach the upper and lower radiator hoses (1) to the radiator using the hose clamps.

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Engine - Engine cooling system

9. Attach the deaeration tank hose (1) to the radiator using the hose clamp. 10. Attach the charge air cooler tubes (2) to the charge air cooler using the hose clamps. 11. Attach the inlet and outlet refrigerant lines (3) to the condenser.

RAIL14SP01770AA

12. Fill the hydraulic oil tank to the full level. 13. Fill the radiator with engine coolant. 14. Charge the air conditioning condenser to the proper level. A qualified technician should perform this task. 15. Install the cooling fan motor. Refer to Fan motor Install (35.752) 16. Start the vehicle and verify that all hose and tube connections to the cooling package are secure and not leaking.

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Index Engine - 10 Engine cooling system - 400 Engine cooling system - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Engine cooling system - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Engine - 10 Fan and drive - 414

SP.295F SP.300F SP.345F SP.400F

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Contents Engine - 10 Fan and drive - 414

SERVICE Fan and drive Remove Fan shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install Fan shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Accessory belt Remove - Serpentine belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install - Serpentine belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Engine - Fan and drive

Fan and drive - Remove Fan shroud Prior operation: Remove the engine enclosure panels and doors. Refer to Engine hood and panels - Remove (90.100) 1. Move the vehicle to a hard level surface. 2. Turn the ignition key to the â&#x20AC;&#x153;OFFâ&#x20AC;? position. Remove the key from the ignition. 3. Attach an appropriate lifting device to the fan shroud. 4. Remove the bolts, washers, and nuts (1) attaching the lower half of the fan shroud (2) to the upper mounting plate (3) of the cooling package. 5. Remove the bolts, washers, and nuts (4) attaching the upper half of the fan shroud (2) to the lower mounting plate (5) of the cooling package. 6. Remove the fan shroud from the vehicle.

RAIL14SP01826AA

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Engine - Fan and drive

Fan and drive - Install Fan shroud 1. Attach an appropriate lifting device to the fan shroud and lift the fan shroud into place on the vehicle. 2. Attach the fan shroud (1) to the upper and lower mounting plates (2) of the cooling package using the bolts, washers, and nuts (3). Tighten securely.

RAIL14SP01826AA

3. Start the engine of the vehicle and check the fan shroud is secure in place.

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Engine - Fan and drive

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Engine - Fan and drive

Accessory belt - Remove - Serpentine belt

RAIL13SP01112AA

Item 1 2 3 4 5 6

Description Water Pump Drive Pulley Vibration Damper Belt Tensioner Fixed Idler Pulley Alternator Serpentine Belt

NOTICE: Belt tensioner is spring-loaded and must be pivoted away from the serpentine drive belt. Pivoting in the wrong direction may result in damage to the belt tensioner. Applying excessive force in the opposite direction of windup or after the tensioner has been wound up to the positive stop can cause the tensioner arm to break. NOTE: Make a diagram of the belt arrangement of your vehicleâ&#x20AC;&#x2122;s engine configuration prior to removing the serpentine drive belt. This aids in proper routing of the drive belt during reinstallation. NOTE: The belt tensioner winds in the direction that the spring tang is bent over the tensioner body. To loosen the tension on the belt, rotate the tensioner so as to wind the spring tighter.

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Engine - Fan and drive

1. Pivot tensioner (1) in direction of spring tang to remove belt (2). 2. Remove the belt.

RAIL13SP03414AA

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Engine - Fan and drive

Accessory belt - Install - Serpentine belt

RAIL13SP01112AA

Item 1 2 3 4 5 6

Description Water pump drive pulley Vibration damper Belt tensioner Fixed idler pulley Alternator Serpentine drive pulley

1. Route serpentine drive belt onto appropriate pulleys following diagram created in removal step. NOTICE: Belt tensioner is spring-loaded and must be pivoted away from the serpentine drive belt. Pivoting in the wrong direction may result in damage to the belt tensioner. Applying excessive force in the opposite direction of windup or after the tensioner has been wound up to the positive stop can cause the tensioner arm to break.

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Engine - Fan and drive

2. Pivot tensioner (1) in direction of spring tang to install belt (2). 3. Double-check belt is aligned properly on tensioner and other pulleys.

RAIL13SP03414AA

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Index Engine - 10 Fan and drive - 414 Accessory belt - Install - Serpentine belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Accessory belt - Remove - Serpentine belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Fan and drive - Install Fan shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Fan and drive - Remove Fan shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404 SERVICE - Technical Publications & Tools

NEW HOLLAND policy is one of continuous improvement and the right to change prices, specification or equipment at any time without notices is reserved. All data given in this publication is subject to production variations. Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your NEW HOLLAND Dealer.

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SERVICE MANUAL Front axle system SP.295F SP.300F SP.345F SP.400F

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Contents Front axle system - 25

[25.100] Powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1

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Front axle system - 25 Powered front axle - 100

SP.295F SP.300F SP.345F SP.400F

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Contents Front axle system - 25 Powered front axle - 100

SERVICE Swing arm Remove - A-frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install - A-frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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Front axle system - Powered front axle

Swing arm - Remove - A-frame Swing arm pin removal kit 380003180 Steering pin removal kit 380003181 NOTE: Special tool are available through the parts system. 1. Adjust the track width of the vehicle to the widest setting. 2. Drive the vehicle onto level ground. 3. Disconnect the suspension linkage and completely lower the suspension. 4. Set the parking brake and shut off the engine.

RAIL13SP01000AA

RAIL13SP01056AA

RAIL13SP01002AA

5. Remove the suspension cam lever (1), spring (2), linkage (3), grease fitting (4) and hardware. from the swing arm being removed. Set aside for reassembly.

6. Unplug the lights in the styling fender.

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Front axle system - Powered front axle

7. Remove the plastic steering cover. Set aside for reassembly.

RAIL13SP01011AA

RAIL13SP01004AA

RAIL13SP01009AA

RAIL13SP01017AA

8. Remove the steel slider panel from the side of the vehicle. 9. Remove the lower panel mounting bracket. Set aside for reassembly.

10. With an appropriately sized jack, lift the vehicle under the main frame or the suspension cylinder mount. 11. Remove the tire and wheel assembly. Set aside the hardware for reassembly.

12. Place a jack stand directly under the frame rail, in line with the front axle. 13. Lower the vehicle down onto the jack stand and remove the jack.

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Front axle system - Powered front axle

14. Remove the fender, leave the brackets (1) attached to the leg. Set aside for reassembly.

RAIL13SP01007AA

RAIL13SP01012AA

15. Remove the crop shields, if equipped. Set aside for reassembly.

16. Remove the grease lines from the remote grease bracket. Remove the remote grease bracket (1). Remove auxiliary light bracket (2), if equipped. Set aside for reassembly. 17. Remove the bracket from the steering cover (3). Set aside the hardware for reassembly.

RAIL13SP01008AA

RAIL13SP01020AA

18. Remove the grease lines from the top of the steering kingpin and the rod end pin of the steering cylinder. Set aside thin manifold nut on the end of each grease line for reassembly.

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Front axle system - Powered front axle

19. Remove the retainer wire (1) from the bolts securing the steering kingpin cap (2) on the underside of the steering kingpin. Discard the safety wire. 20. Remove the bolts, the lockwashers (3), and the steering kingpin cap. Set aside the kingpin cap for reassembly, discard the hardware. 21. Remove the grease fitting from the bottom of the steering kingpin (4). Set aside for reassembly.

RAIL13SP01024AA

RAIL13SP01016AA

RAIL13SP01013AA

RAIL13SP01021AA

22. Remove the roll pin in the stud on the top of the steering weldment retaining the top of the steering kingpin if equipped. Set aside for reassembly.

23. Remove the roll pin (1) and steering cylinder rod end pin (2). Set aside for reassembly.

24. Remove the steering cylinder mounting bracket from the swing arm weldment. Leave the hydraulic hoses connected to the steering cylinder.

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Front axle system - Powered front axle

25. Remove the bolt, lockwasher (1) and pivot pin cap (2) on each end of the swing arm pivot pin. Set aside for reassembly. 26. Remove the set screw (3) from the collar at each end of the pivot pin. Set aside for reassembly.

RAIL13SP01014AA

RAIL13SP01015AA

RAIL13SP01026AA

RAIL13SP01019AA

27. Remove the roll pins (1) from each end of the pivot pin. Set aside for reassembly. 28. Spray the exposed ends of the pivot pins (2) with penetrating oil.

29. Remove the hose clamp and hoses from the swing arm adjacent to the suspension cylinder. Set aside for reassembly.

30. Install the leg stand from the kit onto the leg with .75 in bolts and nuts from the kit.

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Front axle system - Powered front axle

31. Support the leg with an appropriate lifting device. 32. Fold the steering cylinder, bracket, wire harness, and hoses (1) onto the deck next to the operator's cab.

RAIL13SP01022AA

RAIL13SP01018AA

RAIL13SP01025AA

RAIL13SP01023AA

33. Drive the steering kingpin upward with a rubber hammer from the bottom to start removing the pin (1). Continue to pull the pin out by prying with a pry bar from the top (2). If the steering kingpin will not come up, a puller will be required.

34. Plumb the adapter (1), the pressure gauge (2), and the port-a-power hose (3) to the port-a-power (4).

35. Assemble the two lifting plates (1) and three threaded rods (2) from the kit to the leg. Assemble the lifting plates with the flat edge of the plates forward. 36. Attach the plug (3) from the kit to the bottom of the steering kingpin using two .375 in socket head screws from the kit.

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Front axle system - Powered front axle

37. Place the hydraulic cylinder from the kit onto the lower lifting plate below the steering kingpin. Adjust the nuts on the threaded rods as required to provide more or less clearance. NOTE: Make sure the gap between the top and the bottom plate is equal at all three bolt locations and the plates are parallel. 38. Connect the hose from the port-a-power to the hydraulic cylinder. 39. Actuate the port-a-power to provide pressure and push the steering kingpin upward. NOTE: If the pin will not move with the 30 ton cylinder, a 100 ton cylinder will be required. Do not exceed 10,000 psi on the gauge.

RAIL13SP01030AA

RAIL13SP01027AA

RAIL13SP01031AA

40. As the steering kingpin is being pushed upward, the port-a-power cylinder may run out of stroke. In that case, retract the cylinder and insert the tube spacer from the kit to continue pushing the steering kingpin out. 41. With the leg fully supported by the overhead crane or other lifting device, completely remove the steering kingpin and the two plastic thrust washers. Set aside for reassembly. 42. Swing the leg out of the way and set it aside, setting it down carefully on the support.

43. Sling the swing arm to the lifting device so the swing arm will hang horizontally without twisting when the pivot pin is removed.

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Front axle system - Powered front axle

44. Remove the nut and drive the lower rod end bolt out of the rod end of the suspension cylinder. Set aside for reassembly. 45. With the lifting device, lower the swing arm away from the suspension cylinder rod end and swing the suspension cylinder out of the swing arm. 46. It is not necessary to disconnect the hoses. Remove the two hoses from the hose clamp on the side of the swing arm and pull the hoses under the swing arm to the inboard side of the swing arm.

RAIL13SP01028AA

RAIL13SP01032AA

RAIL13SP01029AA

RAIL13SP01034AA

47. Install the threaded puller rod from the kit into the threaded hole on the pivot pin.

48. Install the tube from the kit over the threaded puller rod.

49. Install the spacer plate from the kit over the threaded puller rod.

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Front axle system - Powered front axle

50. Install the port-a-power over the threaded puller rod.

RAIL13SP01033AA

RAIL13SP01036AA

RAIL13SP01035AA

RAIL13SP01042AA

51. Install washers (1) as required and a nut (2) from the kit over the threaded puller rod. Use the nut to snug up the assembly.

52. Place the two shims from the kit, with the half moon shaped edge upward, between the inboard side of the swing arm and the slider weldment.

53. Connect the port-a-power and actuate it to begin pulling out the pivot pin. If the pin does not move at 2500 psi on the port-a-power gauge, then remove the threaded rod from the 3-inch pivot pin and weld the big end of the threaded rod to the center of the 3-inch pin. Weld all the way around the threaded rod. If the pin does not move after a reasonable amount of time, the pin will have to be cut. ATTENTION: Death or serious injury will result if threaded rod should break loose from the pin while applying pressure. To avoid death or serious injury, do not allow anyone to stand directly in line with the threaded rod. 54. Continue to pull until the pin is out. Use spacers, from the kit, on the threaded puller rod if the cylinder runs out of stroke.

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Front axle system - Powered front axle

55. Remove the two thrust washers from between the swing arm and the slider weldment. Set aside for reassembly. 56. 57. Carefully lower the swing arm out of the way and to the ground. 58. Remove the rubber bumper from the swing arm. Set aside for reassembly.

RAIL13SP01037AA

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Front axle system - Powered front axle

Swing arm - Install - A-frame 1. Install the bumper and hardware to the new swing arm in the same location as on the original swing arm.

RAIL13SP01037AA

RAIL13SP01043AA

RAIL13SP01040AA

RAIL13SP01038AA

2. If the decals are not installed on the swing arm, then clean the area of the new swing arm in which the decals will be applied with a cleaner and degreaser. Attach the three decals from the kit to the swing arm.

3. Sling the new swing arm so it hangs horizontally when suspended from a suitable lifting device.

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Front axle system - Powered front axle

4. If the 3-inch pivot pin has the threaded rod welded to it, cut off the threaded rod. Discard the old 3-inch pivot pin. Use the new pin from the kit. 5. Be sure pivot pin is free of all debris. Liberally apply anti-seize compound to the pivot pin bores in the new swing arm and onto the pivot pin.

RAIL13SP01044AA

RAIL13SP01039AA

RAIL13SP01045AA

RAIL13SP01051AA

6. Apply grease to the two pivot thrust washers and place the thrust washers in position on the axle slider. The thicker washer (1) to the outboard the thinner washer (2) to the inboard. 7. Lift the swing arm into position, aligning the pivot bore and guiding the rod end of the suspension cylinder into alignment with the cylinder bore on the swing arm.

8. Install the pin alignment tool (1) from the kit onto the end of the pivot pin (2).

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9. Push the pivot pin into the swing arm and through the bore on the axle slider. NOTE: There is a .562 in diameter, .375 in deep hole in the side of the pin near each end (for the set screws). When pushing the pin into the bore, be sure these two holes are indexed downward. Completely drive the pin into position.

RAIL13SP01041AA

10. With the two .562 in diameter, .375 in deep holes in the side of the pin rotated downward, install the two set screws through the collars in the swing arm.

RAIL13SP01046AA

RAIL13SP01049AA

RAIL13SP01014AA

11. Remove the pin alignment tool from the inboard end of the pivot pin. 12. Install the roll pin into each end of the pivot pin.

13. Install the end caps onto each end of the pivot pin with a bolt and lockwasher.

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Front axle system - Powered front axle

14. Sling the swing arm and swing the arm so the cylinder bore in the arm is aligned with the rod end bore of the suspension cylinder. 15. Install the bolt and nut on the rod end of the suspension cylinder.

RAIL13SP01028AA

RAIL13SP01026AA

RAIL13SP01055AA

RAIL13SP01047AA

16. Pull the hydraulic hoses under the swing arm and reinstall the hose clamp.

17. Use the sling to attach the leg to the lifting device and bring into position near the swing arm. 18. Apply grease to the two thrust washers and place the thrust washers into position on the "tombstones" on the leg. 19. Bring the leg into position and align the bore of the leg with the bore of the swing arm.

20. Attach the kingpin alignment tool from the kit to the steering kingpin (1).

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21. Clean the kingpin and apply anti-seize compound to the entire pin. 22. Drop the steering kingpin (1) into the bore, be sure to keep the thrust washers (2) in place.

RAIL13SP01048AA

RAIL13SP01050AA

RAIL13SP01059AA

RAIL13SP01063AA

23. Align the lower keeper plate (1) on the steering kingpin with the stud (2) on the top of the swing arm. Completely install the steering kingpin. 24. Install the roll pin (3) in the stud on the top of the swing arm. 25. Remove the kingpin alignment tool from the steering kingpin.

26. Install the grease fitting (1) on the bottom of the steering kingpin. 27. Apply LOCTITE® 272™ or equivalent to the threads of the two grade 8 bolts (2) with holes in the bolt head. 28. Install the pin spacer from the kit and the pin cap (3) to the end or the steering kingpin, secure with the two grade 8 bolts and two lockwashers torque to 47.5 N·m (35.0 lb ft) .

29. Install lockwire from the kit through the heads of the two grade 8 bolts and tighten the lock wire to lock the bolt heads from turning. The safety wire should be threaded through each bolt to create tension in the opposite direction of the bolts removal. The safety wire, when installed, should put tension on the bolt in a clockwise direction, since that is the direction that the bolt turns to tighten.

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Front axle system - Powered front axle

30. Acceptable technique includes securing the two bolts against each other. The safety wire is run through the head of the first bolt (creating tension in the direction of tightness for that bolt), twisted five to seven twists per inch, and then run through the second bolt to create tension, through the safety wire, in the direction of tightening for each bolt. After routing one of the wires through the second bolt, twist the two wires together an additional five to seven twists.

RAIL13SP00957AA

RAIL13SP01054AA

RAIL13SP01052AA

RAIL13SP01065AA

31. The lockwire locking device configuration shown in step 29 and 30 is used on units produced prior to Serial Number YAYM00145. The locking device configuration now used, starting with the previously mentioned Serial Numbered units. The two locking device configurations are not interchangeable.

32. Move the steering cylinder and bracket into position and mount the bracket to the swing arm.

33. Install the pin (1) into the rod end of the steering cylinder. 34. Install the roll pin (2) into the steering cylinder rod end pin. 35. Install the grease hose (3) into the steering cylinder rod end pin. 36. Install the grease hose (3) into the end of the steering kingpin.

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37. Remove the leg stand from the leg.

RAIL13SP01019AA

RAIL13SP01009AA

RAIL13SP01056AA

RAIL13SP01057AA

38. Install the tire and wheel assembly. Torque the wheel lug nuts to 610.1 NÂˇm (450.0 lb ft) 39. Remove the lifting sling from the leg.

40. Install the suspension cam lever (1), the suspension spring (2) , the suspension linkage (3) , the grease fitting (4) and hardware. Adjust the tension of the coil spring to 25 mm (1 in) of exposed thread beyond the retaining nut. Test that the linkage works freely and lubricate if needed.

41. Install the fender.

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42. Install the remote grease bracket (1) and work light bracket (2). 43. Reinstall the grease hoses to the remote grease bracket. 44. Connect the wire harness to the work light.

RAIL13SP01058AA

RAIL13SP01011AA

RAIL13SP01002AA

RAIL13SP01070AA

45. Install the styling fender and the styling fender spacers.

46. Connect the wire harness to the lights mounted in the styling fender.

47. Install the crop shield if equipped.

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48. Install the sheet metal slider panel and the lower mounting bracket.

RAIL13SP01004AA

RAIL13SP01017AA

RAIL13SP01061AA

49. Use an appropriately sized jack to lift the vehicle. Lift on the main frame or under the suspension cylinder mount. 50. Remove the jack stand from under the axle. Lower the vehicle to the ground and remove the jack.

51. Make sure the park brake is off. Start the engine. Stroke the suspension cylinder valve so that 4 inches of cylinder rod is exposed. Adjust the suspension cylinder linkage as required such that the linkage pins fit freely. Completely assemble the linkage. 52. Grease the steering kingpin, steering cylinder rod end pin, pivot pin, and suspension cam lever as required.

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Index Front axle system - 25 Powered front axle - 100 Swing arm - Install - A-frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Swing arm - Remove - A-frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404 SERVICE - Technical Publications & Tools

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SERVICE MANUAL Hydrostatic drive SP.295F SP.300F SP.345F SP.400F

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Contents Hydrostatic drive - 29

[29.218] Pump and motor components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.1

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SP.295F SP.300F SP.345F SP.400F

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Contents Hydrostatic drive - 29 Pump and motor components - 218

TECHNICAL DATA Pump General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Pump and motor components Overview - Ground drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Motor Identification - MW-24 Wheel motor trouble shooting and identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . 10 Identification - MW-14 Wheel motor trouble shooting and identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . 12 Identification - MS-18 Wheel motor trouble shooting and identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . 14 Hydraulic schema - SP295F hydrostat Schematic (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Hydraulic schema - SP300F hydrostat Schematic (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Hydraulic schema - SP345F hydrostat Schematic (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Hydraulic schema - SP400F hydrostat Schematic (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

SERVICE Pump and motor components Service instruction - Moving a downed SP.295F or SP.300F (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Service instruction - Moving a downed SP.345F (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Service instruction - Moving a downed SP.400F (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Pump Remove - 75cc and 100cc hydrostatic pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Install - 75cc and 100cc hydrostatic pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Adjust â&#x20AC;&#x201C; 75cc and 100cc hydrostatic pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Remove - 130cc H1 hydrostatic pump (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Install - 130cc H1 hydrostatic pump (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Adjust - 130cc H1 hydrostatic pump (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Motor Remove - Wheel motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Install - Wheel motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Service instruction - Startup and air bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 (*) See content for specific models 47691240 24/02/2015

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Disassemble - MW24 Wheel motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Assemble - MW-24 Wheel motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Disassemble - MW-14 Wheel motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Assemble - MW-14 Wheel motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Disassemble - MS-18 Wheel motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Assemble - MS-18 Wheel motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Disassemble - Case drain test kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Assemble - Case drain test kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Service instruction - Case drain leak test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

(*) See content for specific models 47691240 24/02/2015

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Pump - General specification Model SP.295F - 75 cc pumps are common charge pressure, 28 - 32 bar (410 - 460 psi) • Charge pressure shuttle drop 5.5 - 6.2 bar (80.0 - 90.0 psi) • High pressure settings 441 - 448 bar (6400 - 6500 psi) • Timing adjustment of high pressure raise rate of the pumps equally Models SP.300F - 100 cc pumps are common charge pressure 36 - 39 bar (515 - 565 psi) • Charge pressure shuttle drop 6.6 - 7.2 bar (95.0 - 105.0 psi) • High pressure settings 441 - 448 bar (6400 - 6500 psi) • Timing adjustment of high pressure raise rate of the pumps equally Models SP.345F - 130 cc pumps are common charge pressure 36 - 39 bar (515 - 565 psi) • Charge pressure shuttle drop 10.0 - 10.7 bar (145.0 - 155.0 psi) • High pressure settings 441 - 448 bar (6400 - 6500 psi) • Timing adjustment of high pressure raise rate of the pumps equally Models SP.400F - 130 cc pumps are common charge pressure 36 - 39 bar (515 - 565 psi) • Charge pressure shuttle drop 10.0 - 10.7 bar (145.0 - 155.0 psi) • High pressure settings 441 - 448 bar (6400 - 6500 psi) • Timing adjustment of high pressure raise rate of the pumps equally

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Pump and motor components - Overview - Ground drive system The front boom sprayers use hydraulic wheel motors to drive the vehicle. The wheel motors are supplied hydraulic flow from the hydrostat pumps working through the shuttle valve. The internal charge pumps, in addition to providing flow to the high pressure side of the hydrostat, are also used for speed shifting of the motors and is controlled through the shift valve. The shift valve on SP.295F and SP.300F model sprayers is supplied hydraulic pressure from the charge pumps. The shift valve on SP.345F and SP.400F model sprayers is supplied hydraulic pressure from the tandem pump. Operator control of the ground drive system is accomplished through the use of the grip control on the right hand console. Pushing the grip forward increases hydraulic oil flow to the motors thus increasing vehicle speed. Direction mode selection, forward and reverse, is accomplished by moving the hydrostat lever, from neutral, ahead for forward and rearward for reverse. Speed shifting also is accomplished using the shift button on the grip. The following diagrams illustrate the basic hydraulic flow path of the front boom ground drive system. The first diagram is for SP.295F and SP.300F sprayers, The second diagram is for SP.345F and SP.400F sprayers.

RAIL14SP00317FA

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RAIL14SP00318FA

Ground drive system components Pumps The hydrostatic pumps (1) used on the sprayers vary depending upon the model number. The SP.295F model uses a Danfoss Tandem 90 series 75 cm³ pump. The SP.300F model uses a Danfoss Tandem 90 series 100 cm³ pump. The SP.345F and SP.400F models use a Danfoss Tandem H1 130 cm³ pumps. There are two pumps mounted to the flywheel of the engine by means of a flex coupling. The pumps are attached in line (back to back). Attached to each pump is a charge pump (2). These charge pumps supply hydraulic pressure to each of the hydrostatic pumps, and also to the shift valve on SP.295F and SP.300F sprayers. The hydrostatic pump mounted closest to the engine feeds the right front and the left rear wheel motors The second hydrostat feeds the left front and right rear wheel motor. Flow from the hydrostatic pumps goes to the shuttle valve and then to the wheel motors on all models of sprayers. The tandem pump is mounted directly to the side of the engine and is driven from the air compressor auxiliary drive. The tandem pump supplies hydraulic pressure to the shift valve on SP.345F and SP.400F model sprayers.

RAIL14SP00310AA

There are charge pressure sensors mounted to the pumps of the ground drive system. Charge pressure 1 sensor is mounted to the pump closest to the engine. Charge pressure 2 is mounted on the pump furthest from the engine. The charge pressure 3 sensor is mounted to the shift valve. 47691240 24/02/2015

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Shuttle Valve The shuttle valve is located on the rear frame cross brace and is accessed via the lower engine service door. It performs two main functions â&#x20AC;&#x201C; oil balancing and directs oil to the cooler when moving. It also contains the test ports for drive pressure. The following schematic identifies the ports of the valve. A1 and A2 are pump ports in the forward direction. B1 and B2 are pump ports in the reverse direction. NVA and NVB are needle valves. HS1 and HS2 are hot shuttle valves. RV1 and RV2 are charge relief valves when the sprayer is moving. GA1 and GA2 are forward test ports. GB1 and GB2 are reverse test ports

RAIL14SP00320FA

During normal operations the two hydro pumps to work together. This is done by combining the flows for all the A Ports together and all the B ports together. This has a balancing effect, making sure one hydro doesnâ&#x20AC;&#x2122;t over power the other. The NVA and NVB valves are used to isolate one side from the other for testing purposes but are open for balance during normal operation. The other function of this valve is to shuttle hot oil out of the closed loops and back to the cooler and tank. This is done with the HS1/RV1 and HS2/RV2 valves. When the sprayer is moving, one side, A or B, is high pressure and the other side is filled with charge pressure. The HS valves shuttle to allow charge pressure access to the adjustable RV valves. These valves direct oil out of the loop and back to cooler and tank. The shuttle valve cartridge allows oil from the closed loop to be removed from the system via the RV1/RV2 and returned to filtration and cooling. There is a switch in the shuttle valve that controls the brake lights. When the throttle is pulled back to decrease speed and stop, the brake pressure switch activates the stop lights to indicate the slowing and stopping of the vehicle.

Shifting valve The number 2 hydrostat (furthest from the engine) charge pump flow is directed to the shift valve on SP.295F. The number 1 hydrostat charge flow is directed to the shift valve on SP.300F.On models SP.345F and SP.400F the hydraulic flow is sent from the tandem pump to the shift valve. The shift valve It is located on the left rear corner of the machine just forward of ladder. The shift logic for each model is programmed into the MC2 master controller. On SP.295F sprayers, three shift solenoids are installed in the shift valve. The solenoids are labeled A, C, and D from top to bottom. A cavity plug is installed at location B. Valves may be normally open or closed, dependant on the model of vehicle. Energizing the coils applies pressure to the wheel motor shift spools allowing for changing the displacement. 47691240 24/02/2015

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On SP.300F and SP.345F sprayers, two shift solenoids are installed in the shift valve. The solenoids are labeled A and B from top to bottom. Both valves are normally OPEN (oil through them) which pressurizes wheel motor shift spools. Energizing the coils allows the wheel motor shift spools to drain to tank changing the displacement. On SP.400F sprayers, four shift solenoids are installed in the shift valve. The solenoids are labeled A, B, C, and D from top to bottom. All valves are normally closed (no oil through them) which connects wheel motor shift spools to tank. Energizing the coils applies pressure to the wheel motor shift spools allowing for changing the displacement. The following tables diagram the shifting sequence for the appropriate model of sprayer. SP.295F shifting (5 speed) Range

1 2 3 4 5

Coils Engaged

C only None A and C A only A and D

Front Wheel Motor Ports Pressurized MW14 motors 3 speed motor Y1 None Y1 None Y3

Rear Wheel Motor Ports Pressurized MS18 motors 2 speed motor None None Y Y Y

Front Wheel Motor Ports Pressurized MW18 motors 2 speed motor None Y Y Y Y

Rear Wheel Motor Ports Pressurized MW18 motors 2 speed motor None None Y Y Y

Front Wheel Motor Ports Pressurized MW24 motors 4 speed but only 3 are used None None Y1 Y2 Y2

Rear Wheel Motor Ports Pressurized MW24 motors 4 speed but only 3 are used None Y1 Y1 Y1 Y2

SP.300F and SP.345F shifting (3 speed) Range

1 2 3 4 5

Coils Engaged

A and B B only None None None

SP.400F shifting (5 speed) Range

1 2 3 4 5

Coils Engaged

None A only A and C A and D B and D

Models SP.295F and SP.400F only (5speed) have two shift accumulators to dampen the effects of shifting the wheel motors. They are mounted in the engine bay near the batteries. They are teed into the charge pressure lines after they leave the charge filters. They are charged with 250PSI of dry nitrogen gas

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Wheel Motors The wheel motors attached to the sprayer are Poclain radial piston type motors with integral park and service brakes. Three different size wheel motors, MW-14, MS-18, and MW-24, are used depending upon the model of vehicle. The wheel motors are attached to the wheel legs of the sprayer. The motors are driven by hydraulic oil flow from the front and rear hydrostatic pumps. Shifting of the motors is controlled by the hydraulic oil flow from the shifting valve. The size of wheel motor used is as follows: Models SP.295F use two MW-14 wheel motors on the front wheels, and two MS-18 wheel motors on the rear wheels. Models SP300F and SP.345F use four MS-18 wheel motors. Models SP.400F use four MW-24 wheel motors.

RAIL14SP00311AA

The MW-14 wheel motor is a 3 speed motor. MS-18 wheel motor is a 2 speed motor. MW-24 is a 3 speed wheel motor, although it actually has 4 speeds only the lowest 3 speeds are used. Refer to the wheel motor section of this manual for details on the wheel motors.

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Motor - Identification - MW-24 Wheel motor trouble shooting and identification SP.400F

Symptom Motor is noisy without load

Motor is noisy under load

The motor does not revolve

The motor does not revolve at its normal speed under load

The motor revolves irregularly

The motor leaks

Probable cause Regular rumbling : worn bearing support Vibrations : mountings and/or hydraulic piping become loose Clattering : boost pressure too low Cavitation: excessive internal leaks

Corrective action Replace the bearing support Tighten to torque

Set the counterpressure valve Replace the cylinders block and valving assembly No flow to the motor Check the pump drive and pump inlet The circuit does not reach working Check the safety valve condition pressure (regulator) Excessive internal leaks Replace the cylinders block and valving assembly The brake reminds engaged Check the brake pilot circuit Pump flow is too low Check the pump drive speed Working pressure is too low Check the safety valve setting pressure (regulator) Bad working of the replenishing circuit Check the replenishing circuit Excessive internals leaks Replace the cylinders block and valving assembly Pump flow is irregular Check the pump flow Excessive internals leaks Replace the cylinders block and valving assembly The housing pressure is too high Check the drain circuit and filter condition The seals are deteriorated Replace the seals The assembly is incorrect Check tightening of mounting screws, bleed screws and hydraulic fittings

MW-24 Component identification Identification of the hydrostatic motor can be made by reviewing the nameplate attached to the motor. The part number and the chronological serial number must be specified to order spare parts.

RAIL13SP04570AA

Item 1 2

Designation Commercial description Part number

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Item 3 4

Designation Manufacturing batch number Chronological serial number

In order to identify a hydrostat motor, read the Commercial description listed on the nameplate. The following example details the Commercial description number. Explanation of Commercial description: MW24–1AH2–4D70–7721–20000 • MW-24 = motor model • -1AH2 = Cam track option — 1 or 2 • -4G70 = Direction of normal rotation. D = clockwise (right side), G = counter clockwise (left side)

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Motor - Identification - MW-14 Wheel motor trouble shooting and identification SP.295F

Symptom Motor is noisy without load

Motor is noisy under load

The motor does not revolve

The motor does not revolve at its normal speed under load

The motor revolves irregularly

The motor leaks

Probable cause Regular rumbling : worn bearing support Vibrations : mountings and/or hydraulic piping become loose Clattering : boost pressure too low Cavitation: excessive internal leaks

Corrective action Replace the bearing support Tighten to torque

Set the counterpressure valve Replace the cylinders block and valving assembly No flow to the motor Check the pump drive and pump inlet The circuit does not reach working Check the safety valve condition pressure (regulator) Excessive internals leaks Replace the cylinders block and valving assembly The brake reminds engaged Check the brake pilot circuit Pump flow is too low Check the pump drive speed Working pressure is too low Check the safety valve setting pressure (regulator) Bad working of the replenishing circuit Check the replenishing circuit Excessive internal leaks Replace the cylinders block and valving assembly Pump flow is irregular Check the pump flow Excessive internals leaks Replace the cylinders block and valving assembly The housing pressure is too high Check the drain circuit and filter condition The seals are deteriorated Replace the seals The assembly is incorrect Check tightening of mounting screws, bleed screws and hydraulic fittings

MW-14 Component identification Identification of the hydrostatic motor can be made by reviewing the nameplate attached to the motor. The part number and the chronological serial number must be specified to order spare parts.

RAIL13SP04571AA

Item A B

Description Commercial description Part Number

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Item C D

Description Manufacturing batch number Chronological serial number

In order to identify a hydrostat motor, read the Commercial description listed on the nameplate. The following example details the Commercial description number. Explanation of Commercial description: MW14–3020–3D70–7721–500000 • MS14 = motor model • -3020 = Cam track option — 0 or 02 • -3D70 = Direction of normal rotation. D = clockwise (right side), G = counter clockwise (left side)

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Motor - Identification - MS-18 Wheel motor trouble shooting and identification SP.295F SP.300F SP.345F

Symptom Motor is noisy without load

Motor is noisy under load

The motor does not revolve

The motor does not revolve at its normal speed under load

The motor revolves irregularly

The motor leaks

Probable cause Regular rumbling : worn bearing support Vibrations : mountings and/or hydraulic piping become loose Clattering : boost pressure too low Cavitation: excessive internal leaks

Corrective action Replace the bearing support Tighten to torque

MS-18 Component identification Identification of the hydrostatic motor can be made by reviewing the nameplate attached to the motor. The part number and the chronological serial number must be specified to order spare parts.

RAIL13SP04572AA

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Description

Item A B C

Model code Part number Serial number

In order to identify a hydrostat motor, read the model code listed on the nameplate. The following example details the model code number. Explanation of model code: MS18–2–D11–F19–2A10–K0–00 • MS18 = motor model • -2 = Cam track option — 0 or 02 • -D11 = Direction of normal rotation. D = clockwise (right side), G = counter clockwise (left side)

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Hydrostatic drive - Pump and motor components

Motor - Hydraulic schema - SP295F hydrostat Schematic SP.295F

This schematic is for reference only. Item 1 2 3 4 5 6 7

Description Brake Valve MW-14 Hydraulic Motor MS-18 Hydraulic Motor Brake Valve â&#x20AC;&#x201D; 3 spool Shuttle Valve Tandem Pump Hydraulic Reservoir

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Hydrostatic drive - Pump and motor components

RAIL13SP05096AA

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Hydrostatic drive - Pump and motor components

Motor - Hydraulic schema - SP300F hydrostat Schematic SP.300F

This schematic is for reference only. Item 1 2 3 4 5 6

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Description Brake Valve MS-18 Hydraulic Motor Brake Valve â&#x20AC;&#x201D; 3 spool Shuttle Valve Tandem Pump Hydraulic Reservoir

Hydrostatic drive - Pump and motor components

RAIL13SP05093AA

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Hydrostatic drive - Pump and motor components

Motor - Hydraulic schema - SP345F hydrostat Schematic SP.345F

This schematic is for reference only. Item 1 2 3 4 5 6

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Description Park Brake MS-18 Hydraulic Motor Brake Valve â&#x20AC;&#x201D; 3 spool Shuttle Valve Tandem Pump Hydraulic Reservoir

Hydrostatic drive - Pump and motor components

RAIL13SP05094AA

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Hydrostatic drive - Pump and motor components

Motor - Hydraulic schema - SP400F hydrostat Schematic SP.400F

This schematic is for reference only. Item 1 2 3 4 5 6

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Description Brake Valve MS-24 Hydraulic Motor Brake Valve â&#x20AC;&#x201D; 3 spool Shuttle Valve Tandem Pump Hydraulic Reservoir

Hydrostatic drive - Pump and motor components

RAIL13SP05095AA

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Hydrostatic drive - Pump and motor components

Pump and motor components - Service instruction - Moving a downed SP.295F or SP.300F SP.295F SP.300F

1. Obtain two O-ring face seal run tees and Port-A-Power adapter. Fill the Port-A-Power with clean, NEW HOLLAND AMBRA MASTERTRANÂŽ ULTRACTION to prevent contamination of the hydraulic system. Add additional oil as needed to maintain pressure. 2. Locate the Brake Over Under (BOU) block, located in front of the ladder.

RAIL13SP00981FA

Item 1 2 3 4 5 6 7

Description Cap, 06 ORFS Tee, 06RFS run Tee, 06 SN run Adapter, 6 ORFS x .25 in Gauge, 200 psi liquid Connector, 06 ORFS x 06 MPT Connector, 06 MJIC x .375 in

3. Prepare for hose disconnects and valve plugging; set out the Port-A-Power, along with the following required fittings and gauge above. 4. Locate ports labeled X, X1, and X2 on the BOU block. 5. Remove the hose connected at the X port and connect it to one of the tee fittings. Insert a plug into the valve connection point from which the hose was removed.

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6. Remove the hose connected at the X1 port and connect it to one of the tee fittings. Insert a plug into the valve connection point from which the hose was removed. 7. Remove the hose connected at the X2 port and connect it to one of the tee fittings. Insert a plug into the valve connection point from which the hose was removed. 8. Locate the four multifunction cartridges located on the back side of the hydrostat. Rotate the second hex coupling nut counterclockwise three full turns. NOTE: To prevent external leakage do not exceed three full turns of the second hex coupling nut. 9. In the cab move the hydro lever to the forward position. Pump the Port-A-Power to a minimum of 180 psi to release the brakes. NOTE: You must keep pressure at a minimum of 180 psi to keep the brakes released. Monitor the pressure gauge when the machine is moving. 10. Tow the machine at a slow speed 1.6 - 4.8 km/h (1.0 3.0 mph) only far enough to remove the machine from the roadway or to load onto a trailer. NOTICE: Severe damage to the machine will result from towing an extended distance.

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Hydrostatic drive - Pump and motor components

Pump and motor components - Service instruction - Moving a downed SP.345F SP.345F

RAIL13SP00981FA

Item 1 2 3 4 5 6 7

Description Cap, 06 ORFS Tee, 06RFS run Tee, 06 SN run Adapter, 6 ORFS x .25 in Gauge, 200 psi liquid Connector, 06 ORFS x 06 MPT Connector, 06 MJIC x .375 in

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Hydrostatic drive - Pump and motor components

Pump and motor components - Service instruction - Moving a downed SP.400F SP.400F

RAIL13SP00981FA

Item 1 2 3 4 5 6 7

Description Cap, 06 ORFS Tee, 06RFS run Tee, 06 SN run Adapter, 6 ORFS x .25 in Gauge, 200 psi liquid Connector, 06 ORFS x 06 MPT Connector, 06 MJIC x .375 in

3. Prepare for hose disconnects and valve plugging; set out the Port-A-Power, along with the following required fittings and gauge above. 4. Locate ports labeled X1, and X2 on the BOU block. 5. Remove the hose connected at the X1 port and connect it to one of the tee fittings. Insert a cap on the fitting from which the hose was removed.

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6. Remove the hose connected at the X2 port and connect it to one of the tee fittings. Insert a cap on the fitting from which the hose was removed. 7. Run the hose from the open port on the tee to the valve block in the middle of the machine. 8. Find port 1 located on the right side of the block, it will have a (-8) bulkhead tee hooked to it. Remove the bulkhead from the fitting and place the end of the hose into the fitting. Place a (-8) cap on the block fitting. Now the brake ports should be sealed to a port-a-power. 9. Locate the four multifunction cartridges located on the back side of the hydrostat. Rotate the second hex coupling nut counterclockwise three full turns. NOTE: To prevent external leakage do not exceed three full turns of the second hex coupling nut. 10. In the cab move the hydro lever to the forward position. Pump the Port-A-Power to a minimum of 180 psi to release the brakes. NOTE: You must keep pressure at a minimum of 180 psi to keep the brakes released. Monitor the pressure gauge when the machine is moving. 11. Tow the machine at a slow speed 1.6 - 4.8 km/h (1.0 3.0 mph) only far enough to remove the machine from the roadway or to load onto a trailer. NOTICE: Severe damage to the machine will result from towing an extended distance.

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Pump - Remove - 75cc and 100cc hydrostatic pumps Prior operation: Remove the right-hand engine door and upper panel. Prior operation: Place a vacuum hold on the hydraulic oil tank Oil reservoir - Service instruction - Tank vacuum procedure (35.300) 1. Tag and mark all hydraulic lines and electrical connections prior to removal. Additionally, take several photos of hose connections and routings to aid in reinstallation of hoses. 2. If replacing the tandem pump assembly only, remove auxiliary hydraulic pump. Refer to Auxiliary Hydraulic Pump Removal procedure. Auxiliary hydraulic pump - Remove (35.220). 3. Disconnect the 10 hydraulic lines from tandem pump assembly. 4. Cap and plug all hydraulic lines. 5. Disconnect two electrical connections. One electrical connection is on top of the tandem pump assembly and one is located on the rear side of the pump next to the flywheel housing mount. 6. Disconnect pump turnbuckle (1) at ball joint and remove from tandem pump assembly (2). 7. Attach suitable lifting device to tandem pump assembly (2). 8. Remove four hex bolts (3), flat washers (5), and lockwashers (4). 9. Using lifting device, remove tandem pump assembly (2) from flywheel housing mount (6).

RAIL13SP01125AA

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Pump - Install - 75cc and 100cc hydrostatic pumps 1. Attach suitable lifting device to tandem pump assembly (2). 2. Using lifting device, position tandem pump assembly (2) on flywheel housing mount (6) making sure shaft on tandem pump assembly is properly aligned with splines of hydrostat coupling. 3. Install tandem pump assembly (2) to flywheel housing mount (6) using four lockwashers (4), flat washers (5), and hex bolts (3). tighten the bolts securely to the specified torque. 4. Connect pump turnbuckle (1) at ball joint on tandem pump assembly (2).

RAIL13SP01125AA

5. Connect two electrical connections. One electrical connection is on top of the tandem pump assembly and one is located on the rear side of the pump next to the flywheel housing mount. 6. Connect the 10 hydraulic lines from tandem pump assembly. 7. If the auxiliary hydraulic pump was removed, install auxiliary hydraulic pump. Auxiliary hydraulic pump - Install (35.220) 8. Remove vacuum from tank. 9. Perform hydraulic fluid level checks and pressure tests. Start engine and check for leaks.

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Pump - Adjust â&#x20AC;&#x201C; 75cc and 100cc hydrostatic pumps 1. Install two 69 bar (1000 psi) gauges into quick disconnect test ports 1 and 2, located below the auxiliary pump and outer hydrostat. The test port 1 (1) is for the hydrostat furthest from the engine, while test port 2 (2) will measure the unit closest to the engine.

RAIL13SP03471AA

RAIL13SP03484AA

RAIL13SP03475AA

RAIL13SP03478AA

2. Prior to adjusting pressures, the following must be completed. Balance valves must be closed in order to separate hydrostatic pumps. Loosen both jam nuts (3) and turn both balance valves clockwise until bottomed (approximately 1-1/2 turns). Next, loosen jam nuts on both loop flush charge pressure drop adjusters (4) and turn clockwise to bottom of adjustment, for now.

3. Start engine and operate vehicle to bring hydraulic oil to normal operating temperature 43 - 60 Â°C (110 - 140 Â°F) before setting. Apply park brake, and increase engine to high idle. The charge pressure adjusters for each pump are located on top of the hydrostatic pumps (5) (6).

4. With an open end wrench (7), loosen (counterclockwise) the locking collars located on top of the hydrostatic pumps. Using a socket (8), adjust clockwise to increase pressure, and adjust counterclockwise to decrease pressure.

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5. Model SP.295F - Adjust pressure to 28 - 32 bar (410 460 psi). Lock retaining collar clockwise once pressure is set. Repeat procedure for the second pump. 6. Model SP.300F- Adjust pressure to 36 - 39 bar (515 565 psi). Lock retaining collar clockwise once pressure is set. Repeat procedure for second pump. 7. To adjust shuttle valve loop flush pressure drop, loosen locking jam nuts (9) (10). With a hex wrench, adjust counterclockwise to increase or adjust clockwise to decrease the pressure drop. Operate vehicle at high idle and with park brake on, in high range third for three range units, or in fifth for five range models. With wheels blocked, bring each pump on stroke, viewing the reduction (drop) of charge pressure while on stroke. Adjust until the following settings for your model is correct: SP.295F - Charge pressure drop 4.8 - 5.5 bar (70.0 - 80.0 psi) SP.300F- Charge pressure drop 5.9 - 6.6 bar (85.0 - 95.0 psi)

RAIL13SP03484AA

RAIL13SP03477AA

RAIL13SP03480AA

8. Before checking and setting the high pressure of the hydrostatic pumps, disconnect cable from dual linkage connection (11) (12) as shown to allow individual operation of each hydrostatic pump during setting procedure.

9. Install two 690 bar (10000 psi) high pressure gauges into test ports (13) (14): â&#x20AC;˘ Callout No. 13 = reverse direction of hydrostat No. 1 (closest to engine), drives right front and left rear motors. â&#x20AC;˘ Callout No. 14 = reverse direction hydrostat No. 2 (farthest from engine) which drives left front and right rear motors).

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10. With brakes applied, wheels blocked, and in high range switch position, rotate hydrostat linkage to engage drive, checking pressure on each hydrostatic pump. 11. Reverse direction pressure is adjusted by loosening outermost jam nuts on the multifunction valve (15) (16). Adjust to 441 - 448 bar (6400 - 6500 psi) by turning a 5 mm hex wrench clockwise to increase and counterclockwise to decrease the pressure. Lock jam nuts once adjusted and confirm setting.

RAIL13SP03481AA

RAIL13SP03479AA

12. Install two 690 bar (10000 psi) high pressure gauges into test ports (17) (18). â&#x20AC;˘ Callout 17 = forward direction hydrostat No. 1 (closest to engine), driving front right and left rear motors. â&#x20AC;˘ Callout 18 = forward direction hydrostat No. 2 (farthest from engine) driving front left and right rear motors.

13. With the park brakes applied, wheels blocked, and shift selector in high range switch position, rotate hydrostat linkage to engage drive, checking pressure on each hydrostatic pump. 14. The forward direction pressure is adjusted by loosening outer jam nut on multifunction valve (19) (20). Adjust to 441 - 448 bar (6400 - 6500 psi) by turning clockwise to increase and counterclockwise to decrease pressure. 15. Lock jam nuts, once adjusted, and cycle to confirm setting. RAIL13SP03481AA

RAIL13SP03483AA

16. The timing of hydrostatic pumps is accomplished by reconnecting the linkage between the units and adjusting the length of the turnbuckle. Loosen both jam nuts at each end to allow adjustment. With the park brake on, wheels blocked, and high range selected, bring pumps on stroke while viewing the high pressure gauges. Adjust turnbuckle (21) with a 1/2-in., open-end wrench (22), as needed to raise the pressure evenly on both gauges. Once gauges are close, lock jam nuts and cycle to confirm setting. Reconnect hydrostat cable to linkage. NOTE: If a second person is available, connect the hydrostat cable and bring the pumps on stroke with the hydro handle in the cab. The balance valves, once opened, will complete and balance the timing.

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17. With a hex wrench, turn adjusting screws (23) (24) out 1-1/2 turns counterclockwise. This will allow balancing of the hydrostatic pumps internally through the shuttle block. Tighten jam nuts to lock in position. Operate the vehicle to confirm performance.

RAIL13SP03484AA

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Pump - Remove - 130cc H1 hydrostatic pump SP.345F SP.400F

Prior operation: Remove the right-hand engine door and upper panel. Prior operation: Place a vacuum hold on the hydraulic oil tank Oil reservoir - Service instruction - Tank vacuum procedure (35.300) 1. Tag and mark all hydraulic lines and electrical connections prior to removal. Additionally, take several photos of hose connections and routings to aid in reinstallation of hoses. 2. If replacing the tandem pump assembly only, remove auxiliary hydraulic pump. Refer to Auxiliary Hydraulic Pump Removal procedure. Auxiliary hydraulic pump - Remove (35.220). 3. Disconnect the hydraulic lines and fittings from tandem pump assembly. 4. Cap and plug all hydraulic lines. 5. Disconnect two electrical connections located on the top of each pump. 6. Disconnect the cable (1) from the dual linkage connection (2) at ball joint by removing the nut. Remove the cable connection from tandem pump assembly.

RAIL15SP00103AA

RAIL15SP00201AA

7. Attach suitable lifting device to tandem pump assembly. 8. Remove four hex bolts and flat washers (1) attaching the tandem pumps to the flywheel housing mount. Remove the pumps from the vehicle.

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Pump - Install - 130cc H1 hydrostatic pump SP.345F SP.400F

1. Attach suitable lifting device to tandem pump assembly (1). 2. Using lifting device, position tandem pump assembly on flywheel housing mount (2) making sure shaft on tandem pump assembly is properly aligned with splines of hydrostat coupling. 3. Install tandem pump assembly to flywheel housing mount using four, flat washers and hex bolts (3). Tighten the bolts securely.

RAIL15SP00201AA

RAIL15SP00103AA

4. Connect the cable (1) to the dual linkage connection (2) using the nut. Tighten securely.

5. Connect two electrical connections located on the top of each pump. 6. Connect the hydraulic lines and fittings to the tandem pump assembly. 7. If the auxiliary hydraulic pump was removed, install auxiliary hydraulic pump. Auxiliary hydraulic pump - Install (35.220) 8. Check and fill the hydraulic reservoir to the proper level. 9. Perform hydraulic fluid level checks and pressure tests. Start engine and check for leaks.

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Pump - Adjust - 130cc H1 hydrostatic pump SP.345F SP.400F

Separating the hydrostatic pumps 1. Close the balance valves in order to separate the hydrostatic pumps prior to adjusting the pressures. Loosen both jam nuts (1) and use a hex key to turn both balance valve adjusters clockwise until bottomed (approximately 1/2 turn). Next, loosen jam nuts on both loop flush charge pressure drop adjusters (2) and use a hex key and turn the adjusters clockwise to the bottom of the adjustment range.

RAIL13SP03484AA

RAIL15SP00073AA

RAIL15SP00106AA

Installing the charge pressure gauges 2. Install two 69 bar (1000 psi) gauges into the test ports (1) and (2) located on the backside of the hydrostatic pumps. Test port (1) is for the hydrostat closest to the engine (charge 1), and test port (2) is for the hydrostat furthest from the engine (charge 2). In order to compare the gauges to the sender readings, view the hydraulic menu on the chassis monitor in the vehicle cab.

Adjusting the charge pressure 3. Start engine and operate vehicle to bring hydraulic oil to normal operating temperature 43 - 60 Â°C (110 - 140 Â°F) before setting. Apply park brake, and increase engine to high idle. The charge pressure adjusters (1) for each pump are located adjacent to the pressure test points of the pumps. 4. Loosen the jam nut (2) securing the charge pressure adjuster. Use a hex key to adjust the charge pressure setting. Turn the adjuster clockwise to increase pressure. Turn the adjuster counterclockwise to decrease pressure. 5. Adjust pressure to 36 - 39 bar (515 - 565 psi). Lock the jam nut clockwise once pressure is set. Repeat the charge pressure adjusting procedure for the second pump.

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Adjusting charge pressure loop flush 6. Adjust the shuttle valve loop flush amount by pressure drop. With the park brake on, operate the engine at high idle in high range third for 3 speed units, or fifth for 5 speed models, and positive wheels blocked. Bring each pump on stroke, viewing the initial reduction (drop) of the charge pressure while on stroke. Use a hex key and adjust the loop flush charge pressure drop adjusters (1). Turn the adjusters counterclockwise to increase, or clockwise to decrease the pressure drop. Adjust until the desired setting of 10.0 - 10.7 bar (145.0 - 155.0 psi) is achieved. Lock the jam nuts to secure the setting 7. Remove the pressure gauges installed into the hydrostatic pumps after setting the pressure.

RAIL13SP03484AA

RAIL15SP00103AA

RAIL15SP00105AA

Removing the hydrostat cable and linkage 8. Before checking and setting the high pressure of the hydrostatic pumps, disconnect the cable (1) and the linkage (2) from the dual linkage connection as shown, to allow individual operation of each hydrostat during the setting procedure. 9. Remove the nut (3) attaching the cable to the linkage pivot. Remove the cable connection. Remove the nut (4) attaching the linkage to the number two hydrostatic pump and pull the linkage rod end off of the connection point. The hydrostatic pumps are now separated and may be operated independently.

Adjusting the reverse high pressure settings 10. Install two high pressure gauges into the reverse test ports located on the back side of the shuttle valve. Install one gauge into the reverse direction port (1) for the reverse direction of the number one hydrostat (closet to the engine) which drives the right front and left rear wheel motors. Install one gauge into the reverse direction port (2) for the reverse direction of the number two hydrostat (furthest from the engine) which drives the left front and right rear wheel motors. 11. Block the vehicle wheels. Apply the vehicle brakes and start the vehicle engine. Run the engine to high idle in third for 3 speed units, or fifth for 5 speed models. 12. Rotate the hydrostat linkage of the number two hydrostat to engage the drive. Check the pressure for the hydrostatic pump number two in the reverse direction. Reverse direction pressure should be 441 - 448 bar (6400 - 6500 psi).

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13. Adjust the reverse direction pressure of the number two hydrostatic pump by loosening the outer jam nut (1) of the adjuster installed in to the top of the number two hydrostatic pump. Use a hex key to turn the adjuster (2) clockwise to increase the pressure, or counterclockwise to decrease the pressure. 14. Lock the jam nut once the adjustment setting has been confirmed.

RAIL15SP00104AA

RAIL15SP00105AA

15. Adjust the reverse direction pressure of the number one hydrostatic pump by loosening the outer jam nut (1) of the adjuster installed in to the top of the number one hydrostatic pump. Use a hex key to turn the adjuster (2) clockwise to increase the pressure, or counterclockwise to decrease the pressure. 16. Lock the jam nut once the adjustment setting has been confirmed.

Adjusting the forward high pressure settings 17. Install two high pressure gauges into the forward test ports located on the back side and the side of the shuttle valve. Install one gauge into the forward direction port (1) for the forward direction of the number one hydrostat closet to the engine which drives the right front and left rear wheel motors. Install one gauge into the forward direction port (2) for the forward direction of the number two hydrostat (furthest from the engine) which drives the left front and right rear wheel motors. 18. Block the vehicle wheels. Apply the vehicle brakes and start the vehicle engine. Run the engine to high idle in third for 3 speed units, or fifth for 5 speed models. 19. Rotate the hydrostat linkage of the number two hydrostat to engage the drive. Check the pressure for the hydrostatic pump number two in the forward direction. Forward direction pressure should be 441 - 448 bar (6400 - 6500 psi).

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20. Adjust the forward direction pressure by loosening the outer jam nut (1) of the adjuster installed into the top of the number two hydrostatic pump. Use a hex key to turn the adjuster (2) clockwise to increase the pressure, or counterclockwise to decrease the pressure. 21. Lock the jam nut once the adjustment setting has been confirmed. Repeat the forward high pressure adjustment procedure for the number one hydrostat.

RAIL15SP00104AA

RAIL15SP00103AA

Timing of the hydrostat pumps 22. Reconnect the linkage between the two hydrostatic pumps by placing the linkage (1) onto the connection point of the number two hydrostatic pump. Secure the linkage in place using the nut (2) previously removed. 23. Loosen both jam nuts (3) at the ends of the linkage turnbuckle. 24. With the park brake on and the wheels blocked, select the high range and bring the engine up to 1800 RPM. 25. Bring the pumps on stroke while viewing both high pressure gauges which are attached to the forward direction test ports of the shuttle valves. Adjust the linkage turnbuckle as needed to raise the pressure evenly on both gauges. Once the gauge readings are close in value, lock the jam nuts and cycle to confirm the adjustment. 26. Reconnect the hydrostat cable (1) to the linkage using the nut (2) previously removed.

NOTE: If an assistant is available to help with the adjustment, connect the cable to the hydrostat linkage and have the assistant bring the pumps on stroke using the hydro handle in the cab. The balance valves, once opened, will complete the timing balance. 27. Remove the pressure gauges installed into the forward direction test ports attached to the shuttle valve.

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Resetting the hydrostat shuttle balance valves 28. Use a hex key to turn the balance valve adjusters (1) counterclockwise 1/2 turn. This will allow balancing of the hydrostatic pumps internally through the shuttle block. 29. Tighten both of the jam nuts (2) to secure the setting. Operate the machine to confirm performance.

RAIL13SP03484AA

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Motor - Remove - Wheel motor Prior operation: Remove the front tire from the drive wheel. Front wheels - Remove (44.511) Prior operation: Remove the rear tire from the drive wheel. Rear wheels - Remove (44.520) NOTE: The following describes removal of the front left wheel drive motor assembly. The front right, and both rear wheel drive motor assemblies are removed in the same way as described below. The SP.275F model wheel drive motors are depicted. The number of hydraulic lines could be different and the quantities of hardware could be different than as described here, depending upon the sprayer model and wheel drive motor types used on it. 1. Tag and mark hydraulic lines, then disconnect six hydraulic lines (1). 2. Cap and plug hydraulic lines and fittings.

RAIL13SP03406AA

RAIL13SP03407AA

RAIL13SP03412AA

3. Support wheel drive motor leg with suitable lifting device. 4. Remove 10 nuts (2) and bolts (3) from wheel drive motor housing (4). 5.

WARNING Crushing hazard! Wheel drive assemblies are heavy. Use an adequate lifting device. Reposition one side at a time. Failure to comply could result in death or serious injury. W0019B

Remove wheel drive motor (4) from leg assembly.

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Motor - Install - Wheel motor 1.

WARNING Crushing hazard! Wheel drive assemblies are heavy. Use an adequate lifting device. Reposition one side at a time. Failure to comply could result in death or serious injury. W0019B

Install wheel drive motor housing onto leg assembly. 2. Install wheel drive motor housing (4) to leg assembly with 10 nuts (2) and bolts (3).

RAIL13SP03412AA

RAIL13SP03406AA

RAIL13SP03407AA

3. Remove caps and plugs from hydraulic lines and fittings. 4. Connect six hydraulic lines (1).

5. Install the front and rear tires Front wheels - Install (44.511) and Rear wheels - Install (44.520) 6. Repressurize the hydraulic system Motor - Service instruction - Startup and air bleed (29.218)

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Motor - Service instruction - Startup and air bleed NOTE: Two persons are required to perform the air bleed steps. 1. Prior to start up, apply less than 34 kPa (5 psi) air pressure to hydraulic oil reservoir to feed oil to hydraulic motors. 2. Loosen and partially remove air bleed set screw on either the MS wheel drive (1), or the MW wheel drive (2), until air has escaped and only oil flows from set screw plug. Watch for oil flow at set screw opening to become free of air bubbles. 3. When air bubbles in oil have ceased, tighten bleed screw (1) or (2). 4. Check oil supply and add oil as required. RAIL13SP03473AA

RAIL13SP03379AA

RAIL13SP03473AA

5. After the wheel motor has been bled and operated, also bleed air from foot brake, at foot brake fitting port (XD port) (3) as follows. 6. Loosen set screw (4) 1 to 1-1/2 turns counterclockwise. 7. With engine running at low idle, apply foot brake and hold. Watch for oil flow at set screw opening to become free of air bubbles, then tighten bleed set screw (3). 8. Check oil supply and add oil as required. NOTE: It will not be necessary to bleed the park brake port (X) since the park brake has a flushing orifice which allows air to escape during normal operation.

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Motor - Disassemble - MW24 Wheel motor SP.400F

DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A

Prior operation: Remove the wheel motor from the machine. Motor - Remove - Wheel motor (29.218).

Cam removal: 1. Place the wheel motor on its studs in an upright position

RAIL13SP03696AA

RAIL13SP03697AA

2. Remove the cam from the motor. Mark cams position (1) in relation with the valving cover (2) and the bearing support (3).

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3. Remove the moving screws (1) located in front of the A feed port.

RAIL13SP03698AA

RAIL13SP03699AA

RAIL13SP03700AA

4. Install a flange (see tools page 42) on A feed port.

5. Hold the valving into the valving cover by attaching a Valve Holding Rod (1) (see tools page 42) into the feed ports A. tighten the rods securely.

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6. Remove the valve cover mounting screws (1) by blocking the ears on the valve cover (2) and break the mounting screws bond. Remove the mounting screws from the cover.

RAIL13SP03702AA

RAIL13SP03704AA

RAIL13SP03705AA

7. Attach an appropriate lifting device to the valve cover and remove the cover from the cam.

8. Remove the O-ring (1) from the cover. Discard the Oâ&#x20AC;&#x201C;ring.

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9. Remove the first cam.

RAIL13SP03711AA

10. Remove the O-ring (1) from the first cam (2). Discard the O-ring.

RAIL13SP03706AA

RAIL13SP03707AA

11. Remove the second cam.

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Cylinder block disassembly: 12. Remove the cylinder block assembly. Use two screwdrivers to pry the cylinder block assembly upward. Discard the cylinder block assembly if necessary.

RAIL13SP03716AA

RAIL13SP03714AA

RAIL13SP03717AA

13. Remove the spring (1) from the center shaft.

14. Remove the O-ring from the bearing support assembly. Discard the spring.

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15. Access the cylinder block assembly (1) previously removed and remove the two screws (2) attaching the center spool (3).

RAIL13SP03718AA

RAIL13SP03719AA

RAIL13SP03731AA

16. Remove the center spool from the cylinder block and retain for reassembly.

Valving disassembly: 17. Remove the plastic plug (1) in order to decompress the valving.

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18. Remove the pusher (1) from the valving (2).

RAIL13SP03732AA

RAIL13SP03734AA

RAIL13SP03733AA

19. Remove the valving (1) from the cover (2).

20. Remove the backup rings (1) from the cover (2) with a screwdriver. 21. Discard the backup rings.

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22. Remove the O-ring (1) from the cover (2). 23. Discard the O-ring.

RAIL13SP03735AA

RAIL13SP03737AA

RAIL13SP03736AA

24. Remove the pin (1).

NOTE: Removing the pin is only necessary if the cover is being changed. 25. Remove the springs (1) from the valving (2).

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26. Remove the O-ring (1) from the valving (2). 27. Discard the O-ring.

RAIL13SP03740AA

RAIL13SP03746AA

RAIL13SP03744AA

Check valve disassembly: 28. Remove the plug (1) from the end cover.

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29. Install the special tool into the check valve mounting hole.

RAIL13SP03749AA

RAIL13SP03747AA

RAIL13SP03750AA

30. Remove the special tool from the previous step.

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31. Remove the check valve (1). 32. Discard the check valve.

RAIL13SP03748AA

RAIL13SP03753AA

33. Remove the filter (1). 34. Discard the filter.

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35. Flip the cover (1) and remove the valve (2) using special tool.

RAIL13SP03751AA

RAIL13SP03760AA

RAIL13SP03751AA

36. Remove the special tool used in the previous step.

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37. Remove the check valve (1). 38. Discard the check valve.

RAIL13SP03757AA

RAIL13SP03756AA

RAIL13SP03763AA

Displacement change spool disassembly: 39. Remove the snap ring (1) with a press (2). Apply a force of 922 - 938 NÂˇm (680 - 692 lb ft) to the spool (not shown) to remove the snap ring.

40. Remove the plug (1).

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41. Remove the spool (1).

RAIL13SP03759AA

RAIL13SP03758AA

RAIL13SP03761AA

42. Remove the O-ring (1). 43. Discard the O-ring.

44. Remove the snap ring (4) from the spool (2) with a pair of internal snap ring pliers. 45. Remove the washer (3). 46. Remove the spring (1).

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Motor - Assemble - MW-24 Wheel motor SP.400F

Cam assembly: 1. Install the new O-ring (1) onto the bearing support (2).

RAIL13SP03708AA

NOTE: Cam alignment on next page.

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Cam alignment upon installation:

RAIL13SP04576AA

Medium displacement NOTE: Position the cam to line up with the letter M on the alimentation feed hole. NOTE: The blind (locating) hole should face towards the bearing support. Ref. 1 2

Description Needle roller Pin on valving align with “R”

Ref. 3 4

RAIL13SP04577AA

Description Locating mark Pin on valving align with “L”

Small displacement NOTE: Position the cam to line up with the letter P on the alimentation feed hole. NOTE: The blind (locating) hole should face towards the bearing support. Ref. 1 2

Description Locating mark Pin on valving align with “R”

Ref. 3 4

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Description Needle roller Pin on valving align with “L”

Hydrostatic drive - Pump and motor components

2. Install the second cam (1) onto the bearing support (2). NOTE: For proper cam installation, refer to 2 or 3.

RAIL13SP03707AA

RAIL13SP03706AA

RAIL13SP03711AA

3. Lubricate and install the O-ring (1) onto the first cam (2).

4. Install the first cam (1).

NOTE: For proper cam installation, refer to 2 or 3.

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5. Lubricate and install the O-ring (1) onto the cover (2).

RAIL13SP03705AA

RAIL13SP03710AA

RAIL13SP03704AA

6. Oil the plating valve (1).

7. Install the valving cover (1) in-line with the marks made before disassembly.

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8. Hand tighten the valving cover mounting screws (1) in front of feed port B (2).

RAIL13SP03703AA

RAIL13SP03701AA

RAIL13SP03700AA

9. Remove the valve holding rod (1) to release the valving (2).

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10. Remove the flange (1) on port A.

RAIL13SP03699AA

RAIL13SP03712AA

RAIL13SP03713AA

11. Hand tighten the valving mounting screws (1) in front of feed port A (2).

12. Torque all of the valving mounting screws (1) to 320 390 NÂˇm (236 - 288 lb ft).

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Cylinder block assembly: 13. Lubricate and install the O-ring (1).

RAIL13SP03724AA

RAIL13SP03723AA

RAIL13SP03714AA

14. Install the cylinder block assembly (1) with the pistons (2) pushed into their bores.

15. Install the spring (1) into the middle of the cylinder block (2).

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16. Install the center spool (1).

RAIL13SP03726AA

RAIL13SP03728AA

RAIL13SP03727AA

17. Put a drop of LOCTITE® 243™ in the tapped holes (1) in the cylinder block.

18. Install the mounting screws (1).

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19. Torque the mounting screws (1) to 4 - 6 NÂˇm (3 - 4 lb ft).

RAIL13SP03730AA

RAIL13SP03738AA

RAIL13SP03740AA

Valving assembly: 20. Grease the new O-ring (1).

21. Install the new O-ring (1) onto the valving (2).

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22. Fill the spring holes with NEW HOLLAND AMBRA GR 75 MD and install the springs (1) into the valving (2).

RAIL13SP03739AA

RAIL13SP03737AA

RAIL13SP03741AA

23. If the pin (1) was removed, install the pin according to the direction of the motors rotation.

24. Lubricate the new seals (1). 25. Install the seals into the cover (2).

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26. Lubricate the new backup rings (1). 27. Install the new backup rings into the cover (2).

RAIL13SP03735AA

RAIL13SP03754AA

RAIL13SP03743AA

NOTE: Ensure the backup rings are twisted as little as possible during installation. 28. Install the valving (1) into the cover (2) in line with the pin (not shown).

29. Press the valving (not shown) into the cover (1) using a plastic mandrel (2). 30. Secure the valving with the valving holding rod (3).

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31. Install the pusher (1) into the cover (2).

RAIL13SP03732AA

RAIL13SP03731AA

RAIL13SP03748AA

32. Install the plug (1).

33. Lubricate the valving.

Check valve assembly: 34. Install the new check valve (1).

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35. Torque the check valve (1) to 27 - 33 NÂˇm (20 - 24 lb ft) using the special tool (2).

RAIL13SP03760AA

RAIL13SP03753AA

RAIL13SP03748AA

36. Flip the cover and install the new filter (1).

NOTE: Install the filter with the bulging side entering the cover first. 37. Install the new check valve (1).

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38. Torque the new check valve to 54 - 66 NÂˇm (40 - 49 lb ft) using the special tool (1).

RAIL13SP03752AA

RAIL13SP03744AA

RAIL13SP03761AA

39. Install the plug (1). 40. Torque the plug to 59 - 71 NÂˇm (44 - 52 lb ft).

Displacement change spool assembly: 41. Install the spring (1) and the washer (2) onto the spool (3). 42. Install the snap ring (4) with a pair of snap ring pliers.

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43. Install the O-ring (1).

RAIL13SP03758AA

RAIL13SP03759AA

RAIL13SP03763AA

44. Lubricate the spool (1) with NEW HOLLAND AMBRA MASTERTRANÂ® ULTRACTION and install.

45. Install the plug (1).

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46. Apply 922 - 938 NÂˇm (680 - 692 lb ft) of force on the plug with a special tool (1) and install the snap ring (not shown) with a pair of internal snap ring pliers (2).

RAIL13SP03762AA

Check the static brake torque before mounting the motor onto the sprayer.

RAIL13SP04573AA

Static brake torque test Ref. 1 2 3

Description Tank feed port Return line pressure gauge Dynamic shaft port

Ref. 4 5 6

Description Supply pressure gauge Brake feed port Feed port

47. Connect the brake feed port line to the brake feed port (5). 48. Connect the supply pressure gauge (4) to the feed port (6). 49. Connect the return line pressure gauge (2) to the tank feed port (1). 50. Open the two-speed shift spool ports (8). 51. Open the drain port (7).

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Ref. 7 8

Description Drain port Two-speed shift spool port

Hydrostatic drive - Pump and motor components

52. Open the dynamic shaft port (3). 53. Supply pressure to the brake. • Release pressure minimum: 14 bar (203 psi). • Release pressure maximum: 30 bar (435 psi). 54. Stop the brake release pressure. NOTE: Make sure the brake release pressure is 0 (zero). 55. Increase the motor main supply pressure until the pressure reaches the limit indicated in the table below. 56. Calculate the pressure limit with the following equation in the table.

ΔP C 15.9 0.9 Displ.

ΔP = C / (15.9 x 0.9 x Displ.) Pressure limit for the brake test, in bar. This value is the difference between the supply pressure PA and the return line pressure PR. For a result in PSI, multiply by 14.5. Residual parking brake torque (in case the brake had been used dynamically), in N·m. If this value is not indicated, subtract 25% from the value of the parking brake torque (new brake). Coefficient Efficiency Motor displacement in l/rev.

NOTE: Do not exceed the maximum pressure of the motor operation. NOTE: The motor shaft must not turn, otherwise it is necessary to verify the brake assembly. Motor test pressure limit ΔP Motor ΔP

1.947 269 bar (3900 psi)

2.252 233 bar (3378 psi)

Liters / revolution 2.449 2.506 214 bar 209 bar (3103 psi) (3030 psi)

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2.587 203 bar (2944 psi)

2.857 183 bar (2654 psi)

Hydrostatic drive - Pump and motor components

Motor - Disassemble - MW-14 Wheel motor SP.295F

Prior operation: Remove the wheel motor from the machine Motor - Remove - Wheel motor (29.218).

Cam removal: 1. Place the motor on its studs.

RAIL13SP03666AA

RAIL13SP03667AA

RAIL13SP03668AA

2. Remove the two screws (1) and the two gasekts (2).

3. Remove the mounting bolts (1) from the valving cover (2).

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4. Using the proper lifting device, remove the valving cover (1).

RAIL13SP03669AA

RAIL13SP03670AA

RAIL13SP03671AA

5. Remove and discard the O-ring (1) from the cover (2).

6. Remove the cam (1).

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Cylinder block disassembly: 7. Remove the cylinder block (1).

RAIL13SP03678AA

RAIL13SP03672AA

RAIL13SP03679AA

8. Remove and discard the O-ring (1) on the bearing support (2).

Valving disassembly: 9. Remove the two screws (1) and the two washers (2).

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10. Remove the valving (1) from the cover (2).

RAIL13SP03680AA

RAIL13SP03687AA

RAIL13SP03691AA

11. Remove the blocks (1).

12. Remove the springs (1).

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Change spool disassembly: 13. Remove the snap ring (1) with a pair of snap ring pliers.

RAIL13SP03682AA

RAIL13SP03686AA

RAIL13SP03689AA

14. Remove the valve spool (1).

15. Remove and discard the O-ring (1).

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16. Remove the snap ring (1) with a pair of snap ring pliers.

RAIL13SP03688AA

RAIL13SP03690AA

RAIL13SP03693AA

17. Remove the plug (1).

18. Remove and discard the O-ring (1).

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Motor - Assemble - MW-14 Wheel motor SP.295F

Displacement change spool assembly: 1. Lubricate the O-ring (1) with NEW HOLLAND AMBRA MASTERTRANÂ® ULTRACTION.

RAIL13SP03692AA

RAIL13SP03693AA

RAIL13SP03690AA

2. Install the O-ring (1).

3. Install the plug (1).

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4. Install the snap ring (1) with a pair of snap ring pliers.

RAIL13SP03688AA

RAIL13SP03692AA

RAIL13SP03689AA

5. Lubricate the O-ring (1) with NEW HOLLAND AMBRA MASTERTRANÂ® ULTRACTION.

6. Install the O-ring (1).

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7. Lubricate the cover (1) with NEW HOLLAND AMBRA MASTERTRAN® ULTRACTION to help with the installation of the spool.

RAIL13SP03694AA

RAIL13SP03695AA

RAIL13SP03686AA

8. Lubricate the spool (1) with NEW HOLLAND AMBRA MASTERTRAN® ULTRACTION.

9. Install the spool (1).

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10. Install the snap ring (1).

RAIL13SP03682AA

RAIL13SP03691AA

RAIL13SP03687AA

Valving assembly: 11. Install the springs (1).

12. Install the blocks (1).

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13. Lubricate the valving housing with NEW HOLLAND AMBRA MASTERTRAN® ULTRACTION and install the valving (1) in-line with the pin (not shown).

RAIL13SP03680AA

RAIL13SP03684AA

RAIL13SP03681AA

14. Install the two screws (1) and the two washers (2) into the valving (3).

15. Torque the screw to 23 - 27 N·m (17 - 20 lb ft). 16. Check that the blocks are well positioned.

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17. Lubricate the valving (1) with NEW HOLLAND AMBRA MASTERTRAN® ULTRACTION.

RAIL13SP03683AA

Cylinder block assembly: NOTE: Before assembling the cylinder block, make sure that all parts, sealing surfaces, and grooves are clean. 18. Lubricate the O-ring (1) with NEW HOLLAND AMBRA MASTERTRAN® ULTRACTION.

RAIL13SP03677AA

RAIL13SP03672AA

19. Install the O-ring (1).onto the bearing support assembly (2).

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20. Install the cylinder block assembly (1) with the pistons (2) pushed into their bores.

RAIL13SP03678AA

RAIL13SP03672AA

RAIL13SP03671AA

Cam replacement: 21. Install the O-ring (1) onto the bearing support (2).

22. Install the cam (1).

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23. Lubricate the O-ring (1) with NEW HOLLAND AMBRA MASTERTRAN® ULTRACTION.

RAIL13SP03677AA

RAIL13SP03670AA

RAIL13SP03675AA

24. Install the O-ring (1) onto the cover (2).

25. Lubricate the valving plate (1) with NEW HOLLAND AMBRA MASTERTRAN® ULTRACTION.

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26.

Using the proper lifting equipment, install the valving cover (1).

RAIL13SP03669AA

RAIL13SP03673AA

RAIL13SP03674AA

27. Install the locating pin (1) to hold the cover (2) in the proper position. 28. Remove the lifting equipment from the cover.

29. Install the mounting bolts (1).

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30. Torque the mounting bolts (1) to 352 - 358 NÂˇm (260 264 lb ft).

RAIL13SP03668AA

RAIL13SP03667AA

RAIL13SP03676AA

31. Install the gaskets (1) and the screws (2) into the cover (3).

32. Torque the screw to 7 - 9 NÂˇm (5 - 7 lb ft).

Check the static brake torque before mounting the motor onto the sprayer.

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RAIL13SP04574AA

Ref. 1 2 3

Description Tank feed port Return line pressure gauge Dynamic shaft port

Ref. 4 5 6

Description Supply pressure gauge Brake feed port Feed port

Ref. 7 8

Description Drain port Two-speed shift spool port

33. Connect the brake feed port line to the brake feed port (5). 34. Connect the supply pressure gauge (4) to the feed port (6). 35. Connect the return line pressure gauge (2) to the tank feed port (1). 36. Open the two-speed shift spool ports (8). 37. Open the drain port (7). 38. Open the dynamic shaft port (3). 39. Supply pressure to the brake. • Release pressure minimum: 14 bar (203 psi). • Release pressure maximum: 30 bar (435 psi). 40. Stop the brake release pressure. NOTE: Make sure the brake release pressure is 0 (zero). 41. Increase the motor main supply pressure until the pressure reaches the limit indicated in the table below. 42. Calculate the pressure limit with the following equation in the table.

ΔP C 15.9

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0.9 Displ.

Efficiency Motor displacement in l/rev.

NOTE: Do not exceed the maximum pressure of the motor operation. NOTE: The motor shaft must not turn, otherwise it is necessary to verify the brake assembly. Motor test pressure limit Î&#x201D;P MW14 Motor

Liters / revolution 1.401

Motor Î&#x201D;P bar ( PSI )

284 bar (4118 psi)

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Motor - Disassemble - MS-18 Wheel motor SP.295F SP.300F SP.345F

Prior operation: Remove the wheel motor from the machine. Motor - Remove - Wheel motor (29.218)

DYNA+ disassembly 1. Place the motor on the bearing support and unscrew the screws

RAIL13SP03624AA

RAIL13SP03626AA

RAIL13SP03630AA

2. Remove the screws and the end cover.

3. Remove the valve spool.

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4. Remove and discard the O-ring.

RAIL13SP03629AA

RAIL13SP03627AA

RAIL13SP03631AA

5. Remove and discard the O-ring.

6. Unscrew the screws

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7. Remove the valving cover equipped with the valving. Mark the location of the valving in relation to the valving cover.

RAIL13SP03628AA

RAIL13SP03635AA

RAIL13SP03632AA

8. Remove the cam and locate it compared to the cover in order to locate the position of the cams with unequal lobes "P" and "M"

9. Remove the cylinders block assembly.

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10. Remove and discard the O-ring.

RAIL13SP03633AA

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Motor - Assemble - MS-18 Wheel motor SP.295F SP.300F SP.345F

DYNA+ assembly 1. Before reassembling it is necessary to ensure that the groove is clean. All traces of rust, mud, water must be removed. 2. Install a new O-ring in the groove of the bearing support. Install the O-ring without greasing it.

RAIL13SP03633AA

RAIL13SP03627AA

RAIL13SP03629AA

3. Install a new O-ring coated with anti-oxidizing grease in the groove of the valving cover.

4. Install a new O-ring coated with anti-oxidizing grease in the groove of the valve spool.

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5. Install the cylinders-block assembly.

RAIL13SP03632AA

RAIL13SP03635AA

RAIL13SP03636AA

6. Install the cam.

7. Lubricate with hydraulic fluid the top of the cylinderblock.

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Valving reassembly 8. Lubricate and install new seals and back-up rings, ensuring the back up rings are twisted as little as possible. 9. Place the springs in their housings, previously filled with grease. 10. Lubricate the faces of the seals of the valving. 11. Press the valving into the cover.

RAIL13SP03660AA

RAIL13SP04586AA

RAIL13SP03653AA

12. Place the chosen letter, R or L, indicating the rotation direction in front of the displacement change spool (1).

13. If there is no letter, do the indexing according to the marks made during disassembly.

RAIL13SP03654AA

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14. Install the valving cover assembly on the unit. Use 2 positioning pins (1).

RAIL13SP03637AA

RAIL13SP03631AA

RAIL13SP03630AA

15. Install and tighten the screws to a torque of 320 390 NÂˇm (236 - 288 lb ft). Remove the positioning pins after tightening.

16. Install the valve spool.

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End cover reassembly 17. Install a new O-ring.

RAIL13SP03659AA

RAIL13SP03664AA

RAIL13SP03626AA

18. Install a new O-ring if the motor has 2-displacement.

19. Install the end cover.

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20. Install and tighten the screws to a torque of 44 54 NÂˇm (54 - 40 lb ft).

RAIL13SP03624AA

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Motor - Disassemble - Case drain test kit. CAUTION Escaping fluid! Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Before applying pressure, make sure all connections are tight and all components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in minor or moderate injury. C0104A

WARNING Pressurized hydraulic fluid can penetrate the skin and cause severe injuries. Tighten all of the connections before starting the engine. If hydraulic fluid has penetrated the skin, seek medical assistance immediately. Failure to comply could result in death or serious injury. W0117A

WARNING Burn hazard! Before performing any service on the hydraulic system, you must allow it to cool. Hydraulic fluid temperature should not exceed 40 Â°C (104 Â°F). Failure to comply could result in death or serious injury. W0241A

WARNING Escaping fluid! Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Make sure all components are in good condition and tighten all connections before pressurizing the system. DO NOT use your hand to check for leaks. Use a piece of cardboard or paper. Failure to comply could result in death or serious injury. W1140A

MW-14 and MS-18 motors: 1. Remove the hook (1) from the railing by the cab door and route the hook and hoses down from the railing to ground level.

RAIL13SP05147AA

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2. Remove the straight end of the 7925 mm (312 in) case drain return line (1) from the port on the tee fitting.

RAIL13SP05156AA

RAIL13SP05146AA

RAIL13SP05156AA

3. Remove the male end of the 7518 mm (296 in) case drain supply line (1) from the case drain line from the wheel motor.

4. Assemble the case drain line (1) to the tee fitting on the wheel motor and tighten to the proper specifications.

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5. Remove the 7518 mm (296 in) supply line (1) from the “in” port of the strainer (2). 6. Plug both ends of the 7518 mm (296 in) supply line using the plugs that are included in the case drain test kit and set in a clean area.

RAIL13SP05148AA

RAIL13SP05147AA

7. Remove the 7925 mm (312 in) return line (2) from the elbow at the “out” port of the flow meter (3) and remove the hook (1) from in between the fittings. 8. Plug both ends of the 7925 mm (312 in) return line with the plugs that are included in the case drain test kit. 9. Set the 7925 mm (312 in) return line in a clean area.

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RAIL13SP05090AA

Case drain testing kit Item 1 2 3 4 5 6 7 8 9 10 11 12 13

Part Number mlr09.74147 mlr21.00327 mlr21.00339 mlr21.00342 mlr21.20866 mlr21.21050 mlr21.52154 mlr21.52155 mlr21.52157 mlr21.52356 mlr21.52357 mlr21.52358 mlr44.02399

Description 3/4 in–16 union –08 ORB X –08 ORFS connector –12 ORFS cap (MW-24 motors only) 8 ORFS 90 ° elbow –8 ORFS cap 8 ORFS plug Case drain flowmeter Case drain kit strainer Case drain hanger hook 12 in case drain adaptor hose (MW-24 motors only) 296 in case drain supply hose 312 in case drain return hose 12 X 8 ORFS reducer (MW-24 motors only)

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10. Remove the connector (2) from the “in” port of the strainer (8). 11. Remove the “out” port of the strainer (8) from the union (1). 12. Remove the “in” port of the flow meter (7) from the union (1). 13. Remove the elbow (4) from the “out” port of the flow meter (7). NOTE: Keep all of the kit pieces together in a clean dry area to prevent the loss or damage of any of the case drain test kit components.

MW-24 motors: 1. Remove the hook (1) from the railing by the cab door and route the hose down from the railing to ground level.

RAIL13SP05147AA

RAIL13SP05146AA

2. Remove the 305 mm (12 in) adapter line (1) from the case drain line (2) that was removed from the tee fitting.

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3. Remove the 12 X 8 in reducer (1) from the tee fitting and install the case drain line to the open port on the tee fitting. 4. Tighten the fittings to the proper specifications.

RAIL13SP05156AA

RAIL13SP05151AA

RAIL13SP05148AA

5. Remove the 305 mm (12 in) case drain adapter line (2) from the 7518 mm (296 in) case drain supply line (1). 6. Plug both ends of the 305 mm (12 in) adapter line with the proper plugs that are included in the case drain test kit and set in a clean area.

7. Remove the 7518 mm (296 in) case drain supply line (1) from the â&#x20AC;&#x153;inâ&#x20AC;? port of the strainer (2). 8. Plug both ends of the 7518 mm (296 in) case drain supply hose with the proper plugs that are included in the case drain test kit and set the hose with the other test kit components.

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9. Remove the hanger (1) and the 7925 mm (312 in) case drain return line (2) from the â&#x20AC;&#x153;outâ&#x20AC;? port of the flow meter (3). 10. Plug both ends of the 7925 mm (312 in) case drain return line with the proper plugs that are included in the case drain test kit. 11. Place the hanger and the case drain return hose with the other case drain test kit components.

RAIL13SP05147AA

11. Repeat steps 10 through 13 in the previous section. NOTE: Keep all of the kit pieces together in a clean dry area to prevent the loss or damage of any of the case drain test kit components.

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Motor - Assemble - Case drain test kit WARNING Pressurized hydraulic fluid can penetrate the skin and cause severe injuries. Tighten all of the connections before starting the engine. If hydraulic fluid has penetrated the skin, seek medical assistance immediately. Failure to comply could result in death or serious injury. W0117A

NOTE: Case drain leak test may be performed using the following specified test kit or comparable components.

RAIL13SP05090AA

Case drain testing kit Item 1 2 3 4 5 6 7 8 9 10 11 12 13

Part Number mlr09.74147 mlr21.00327 mlr21.00339 mlr21.00342 mlr21.20866 mlr21.21050 mlr21.52154 mlr21.52155 mlr21.52157 mlr21.52356 mlr21.52357 mlr21.52358 mlr44.02399

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MW-14 and MS-18 motors: 1. Extend the wheel legs of the vehicle to the widest position. 2. Move the vehicle to a hard and level surface. 3. Apply the parking brake to ensure that the vehicle will not move during the installation and assembly of the case drain testing kit. 4. Shut the engine off and remove the key from the ignition. 5. Assemble the case drain strainer (8) to the case drain flow meter (7) using the union (1) and tighten. NOTE: Be sure that the “out” port on the strainer aligns with the “in” port on the case drain flow meter. 6. Assemble the connector (2) into the “in” port of the case drain strainer and tighten. 7. Assemble the elbow (4) into the “out” port of the drain flow meter and tighten. 8. Locate the case drain line (2) from the wheel motor that is connected to the tee fitting (1) on the side of the frame mounting plate. 9. Remove the case drain line from the tee fitting.

RAIL13SP05156AA

RAIL13SP05146AA

10. Assemble the male end of the of the 7518 mm (296 in) case drain supply line (2) to the female end of the case drain line (1) from the wheel motor. NOTE: The other end of the case drain supply line will be connected to the “in” port of the strainer.

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11. Route the other end of the 7518 mm (296 in) case drain supply line up to the operator platform into an area where it can be viewed through the sprayer cab door.

RAIL13SP05148AA

RAIL13SP05156AA

RAIL13SP05147AA

12. Connect the straight end of the 7925 mm (312 in) case drain return hose (1) to the open port of the tee fitting where the case drain line was removed. NOTE: The elbow of the 7925 mm (312 in) case drain return line will be connected along with the case drain hanger hook (1) to the â&#x20AC;&#x153;outâ&#x20AC;? port elbow of the flow meter.

13. Place the hanger (1) between the fittings of the 7925 mm (312 in) case drain return line (2) and the flow meter (3) and tighten. 14. Hang the hook on the railing in such a manner that it can be viewed from the cab.

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15. Connect the 7518 mm (296 in) case drain supply hose (1) to the â&#x20AC;&#x153;inâ&#x20AC;? port of the of the strainer (2) and tighten. NOTE: When the case drain kit is not being used, cap and plug the hose ends using the caps and plugs that are included in the case drain testing kit.

RAIL13SP05148AA

RAIL13SP05156AA

RAIL13SP05146AA

MW-24 motors: 1. Repeat steps 1 through 7. 2. Locate the case drain line from the wheel motor that is connected to the tee fitting on the side of the frame mounting plate. 3. Remove the case drain line from the tee fitting.

4. Assemble the male end of the 305 mm (12 in) case drain adapter hose (1) to the case drain line (2) from the wheel motor.

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5. Assemble the male end of the 7518 mm (296 in) case drain supply line (1) to the 305 mm (12 in) case drain adapter hose (2) from the wheel motor.

RAIL13SP05151AA

RAIL13SP05148AA

RAIL13SP05156AA

6. Route the 7518 mm (296 in) case drain supply line up to the operator platform into an area where it can be viewed from sprayer cab door.

7. Assemble the reducer (1) to the tee fitting where the case drain line was removed from the motor and tighten.

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8. Connect the straight end of the 7925 mm (312 in) case drain return hose (1) to the reducer on the tee fitting and tighten.

RAIL13SP05156AA

RAIL13SP05147AA

RAIL13SP05148AA

9. Place the hanger (1) between the fittings of the 7925 mm (312 in) case drain return hose (2) and the “out” port elbow of the flow meter (3) and tighten the fittings.

10. Hang the hook onto the railing by the cab door and connect the 7518 mm (296 in) hose (1) to the “in” port of the strainer (2). Tighten the fittings.

Next operation: Perform the case drain leak test Motor - Service instruction - Case drain leak test (29.218).

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Motor - Service instruction - Case drain leak test WARNING Escaping fluid! Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Make sure all components are in good condition and tighten all connections before pressurizing the system. DO NOT use your hand to check for leaks. Use a piece of cardboard or paper. Failure to comply could result in death or serious injury. W1140A

Prior operation: Install the case drain leak test kit. Refer to Motor - Assemble - Case drain test kit (29.218)

Case drain leak test - using test kit ATTENTION: All wheel motors, during normal operation will have a return flow of oil from the piston group, to the case and through the filter and return to tank. This case flow can assist in identifying excess leakage within the wheel motor indicating potential damage. The case flow amount will vary depending on the model. The wheel motors have one 1/2”(-8) case drain (return) hose with the exception of the MW24 which uses a 5/8 (-10) case return hose. The return flow, when measured under load, is approximately 0.95 - 3.79 L/min (0.25 - 1.00 US gpm) per motor measured during a static test. The combined case oil flow from the four motors returns to the tank through the case drain filter. If contamination is present in the closed loop the return hose may have material present. The case drain filter head is equipped with a sensor. If the filter becomes restricted and the internal pressure exceeds 22 psi, the case drain filter alarm will alert. If an alarm is active the case filter should be inspected for contamination. If contamination is present each of the case drain lines at the exit point from the motor will need to be inspected. 1. Clean the outside case of the hydraulic motor thoroughly. 2. Start the vehicle and allow the hydraulic oil temperature to warm to 38 °C (100 °F) . 3. Drive the vehicle in the first speed range at full throttle for no more than 10 minutes and no less than 5 minutes 4. Monitor the flow through the test kit flowmeter attached to the handrail. 5. The monitored flow through the flow meter should be BELOW 11.4 L/min (3.0 US gpm). 6. If the flow through the flow meter is ABOVE 11.4 L/min (3.0 US gpm), stop the vehicle. 7. Access the hydraulic motor being tested and inspect the hose to the hydraulic motor for leakage. Tighten the appropriate connections. 8. If no leaks of the hose connections are found, repeat step 1 through step 5. 9. If the flow through the flow meter is again ABOVE 11.4 L/min (3.0 US gpm), stop the vehicle. 10. Repair of the hydraulic motor may be necessary. Refer to the appropriate repair section of this manual.

Case drain leak test - no test kit 1. Park the unit on a level surface, be sure to position the hydrostat lever in neutral, apply park brake. Install wheel chocks on both front wheels capable to safely constrain the machine from moving forward. Perform the test with the aid of an assistant. 47691240 24/02/2015

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2. Unwrap the spiral cover from the hose in order to direct the hose into a container for the test. Use a 5 US gal sized bucket or container. 3. Remove the case drain hose from the steel hydraulic pipe of suspect motor. 4. Seal the pipe with an O-ring face seal cap. Drain the disconnected hose into the container. 5. Start the vehicle engine and Increase the engine rpm to 1500 to 1800, then shift the machine into the highest speed range, 3rd or 5th depending on model. 6. Slowly press the throttle lever forward about 1/2 to 3/4 of full throttle. At the same time, have the assistant time the flow of hydraulic oil into the container for one minute. 7. After one minute, throttle back the engine, remove the hose from the container and measure the mount of hydraulic oil in the container. A normal wheel motor case flow will be relatively light and would measure between 0.95 - 3.79 L/min (0.25 - 1.00 US gpm) 0.95 - 3.79 L (0.25 - 1.00 US gal). 8. Pull the throttle lever to neutral, release the park brake, and remove the chocks, allow the machine to roll forward 30 - 46 cm (12 - 18 in). Apply the park brake, and the wheel chocks. Perform step 4 through step 8 again. 9. Perform this test process a minimum of five times to assure pressure is applied to each piston in the motor. If the motor tests is acceptable reassemble hose in reverse order. Apply this test to the other suspect motors if required. If the measured case flow is excessive the motor will need to be removed for repair. NOTE: Charge Pressure on all models will be either 30 bar (435 psi) or 37 bar (540 psi) depending upon the model of hydraulic motor. If a systems charge pressure is operating at 620 psi (both pumps) , a flushing orifice will need to be installed into each of four wheel motors, as well as reducing the charge pressure to 540 psi with a charge pressure drop of 100 or 150 psi depending on model. See the following table for details. The hydrostat high pressure setting for all models of wheel motors is 448 bar (6500 psi). Wheel Motor Model Number MS11 MW14 MS18 MW24

30 bar 30 bar 37 bar 37 bar

Charge Pressure (435 psi) (435 psi) (540 psi) (540 psi)

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Charge Pressure Drop 6 bar (85 psi) 6 bar (85 psi) 10 bar (150 psi) 10 bar (150 psi)

Index Hydrostatic drive - 29 Pump and motor components - 218 Motor - Hydraulic schema - SP300F hydrostat Schematic (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Motor - Hydraulic schema - SP345F hydrostat Schematic (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Motor - Hydraulic schema - SP400F hydrostat Schematic (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Motor - Assemble - Case drain test kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Motor - Assemble - MS-18 Wheel motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Motor - Assemble - MW-14 Wheel motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Motor - Assemble - MW-24 Wheel motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Motor - Disassemble - Case drain test kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Motor - Disassemble - MS-18 Wheel motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Motor - Disassemble - MW-14 Wheel motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Motor - Disassemble - MW24 Wheel motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Motor - Hydraulic schema - SP295F hydrostat Schematic (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Motor - Identification - MS-18 Wheel motor trouble shooting and identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Motor - Identification - MW-14 Wheel motor trouble shooting and identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Motor - Identification - MW-24 Wheel motor trouble shooting and identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Motor - Install - Wheel motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Motor - Remove - Wheel motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Motor - Service instruction - Case drain leak test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Motor - Service instruction - Startup and air bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Pump - Adjust - 130cc H1 hydrostatic pump (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Pump - Adjust â&#x20AC;&#x201C; 75cc and 100cc hydrostatic pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Pump - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Pump - Install - 130cc H1 hydrostatic pump (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Pump - Install - 75cc and 100cc hydrostatic pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Pump - Remove - 130cc H1 hydrostatic pump (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Pump - Remove - 75cc and 100cc hydrostatic pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Pump and motor components - Overview - Ground drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Pump and motor components - Service instruction - Moving a downed SP.295F or SP.300F (*) . . . . . . . . . . . . . . 25 Pump and motor components - Service instruction - Moving a downed SP.345F (*) . . . . . . . . . . . . . . . . . . . . . . . . 27 Pump and motor components - Service instruction - Moving a downed SP.400F (*) . . . . . . . . . . . . . . . . . . . . . . . . 29

(*) See content for specific models 47691240 24/02/2015

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CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404 SERVICE - Technical Publications & Tools

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SERVICE MANUAL Brakes and controls SP.295F SP.300F SP.345F SP.400F

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Contents Brakes and controls - 33

[33.202] Hydraulic service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1

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SP.295F SP.300F SP.345F SP.400F

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Contents Brakes and controls - 33 Hydraulic service brakes - 202

FUNCTIONAL DATA Brakes Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Brake pedal control valve Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Hydraulic actuators Remove - Brake/shifting valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install - Brake/shifting valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Brakes - Overview The hydraulic service bake and the park brake are located internally of the hydraulic motors of the vehicle. The service brake is actuated through the use of the brake pedal (1) located in the cab.

RAIL12SP01077AA

The park brake is actuated by a switch (2) on the armrest console.

RAIL14SP00882AA

When the operator presses on the service brake pedal, hydraulic oil flow from the auxiliary pump flows to the brake valve and then to the XD port of the hydraulic motors. The park brake is activated when the park brake switch is engaged. Hydraulic oil flow from the bake over/under valve is directed to the X port of the hydraulic motor engaging the park brakes. There is an accumulator attached to the park brake circuit to deliver the proper pressure for park brake engagement. A park brake indicator light, mounted in the operator warning light panel will illuminate when the park is activated.

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Brake pedal control valve - Remove Prior operation: Apply a vacuum to the hydraulic tank to hold the hydraulic fluid Oil reservoir - Service instruction - Tank vacuum procedure (35.300) Prior operation: Remove the floor mat from the vehicle. 1. Relieve all hydraulic pressure from the system before disconnecting any lines or fittings. 2. At brake pedal/valve, tag and mark hydraulic and electrical lines. Cut securing cable ties as required. 3. Disconnect electrical connector (1). 4. Tag and mark hoses. Disconnect three hydraulic hoses (2) from brake pedal/valve assembly (3). 5. Cap and plug lines and fittings. NOTE: The locknuts securing the hex bolts are accessed underneath the vehicle; the bolts theyâ&#x20AC;&#x2122;re secured to will need to be removed from inside the cab.

RAIL13SP01119AA

6. Remove four locknuts (4) from hex bolts (5) protruding through floor mounting plate (6) to exterior of vehicle. 7. Remove four hex bolts (5) from brake pedal/valve assembly (3), and pull assembly up through opening in floor mounting plate (6).

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Brake pedal control valve - Install 1. Access the cab interior. Insert brake pedal/valve assembly (3) through opening in floor. Line up mounting plate (6) holes and insert four hex bolts (5) into pedal/valve assembly. NOTE: The hex bolts will need to be inserted through mounting plate holes from inside the cab; the locknuts are secured to the bolt studs from underneath the vehicle. 2. Access the underside exterior of the cab. Secure brake pedal/valve assembly by installing four locknuts (4) onto hex bolts (5) that protrude through floor mounting plate (6) to exterior of vehicle 3. Remove caps and plugs from lines and fittings.

RAIL13SP01119AA

4. Connect three tagged or marked hydraulic hoses (2) to brake pedal/valve assembly (3). 5. Connect electrical connector (1).

6. Remove tagging from hoses and wires. Secure hosing and electrical lines with cable ties as required. 7. Fill hydraulic tank with filtered hydraulic fluid. 8. Operate engine to check for leaks and proper function of all applicable systems.

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Hydraulic actuators - Remove - Brake/shifting valve NOTE: The following procedure applies to a 3-speed brake valve. A 5-speed brake valve will have 12 hydraulic lines. 1. Tag and mark all hydraulic and electrical lines. 2. Disconnect 10 hydraulic lines (1) from brake valve (2). 3. Cap and plug hydraulic lines and fittings. 4. Disconnect five electrical connectors (3) from brake valve (2). 5. Remove three bolts (4), six flat washers (5), and three locknuts (6) that secure brake valve (2) to bracket (7). 6. Remove brake valve (2).

RAIL13SP01118AA

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Hydraulic actuators - Install - Brake/shifting valve 1. Secure brake valve (2) to bracket (7) by installing three bolts (4), six flat washers (5), and three locknuts (6). 2. Connect five electrical connectors (3) to valve (2), and remove tags. 3. Remove caps and plugs from lines and fittings, and connect 10 hydraulic lines (1) to brake valve (2).Wipe up any hydraulic fluid spills. 4. Remove tags from hydraulic lines.

RAIL13SP01118AA

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Index Brakes and controls - 33 Hydraulic service brakes - 202 Brake pedal control valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Brake pedal control valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Brakes - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic actuators - Install - Brake/shifting valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Hydraulic actuators - Remove - Brake/shifting valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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SERVICE MANUAL Hydraulic systems SP.295F SP.300F SP.345F SP.400F

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Contents Hydraulic systems - 35

[35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 [35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2 [35.220] Auxiliary hydraulic pump and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3 [35.752] Hydraulic fan drive cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4 [35.610] Machine leveling control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5

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SP.295F SP.300F SP.345F SP.400F

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Contents Hydraulic systems - 35 Hydraulic systems - 000

TECHNICAL DATA Hydraulic systems Technical Data - SP.295F pressure settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Technical Data - SP.300F pressure settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Technical Data - SP.345F pressure settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Technical Data - SP.400F pressure settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Hydraulic systems Hydraulic schematic frame 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Hydraulic schematic frame 02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Hydraulic schematic frame 03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Hydraulic schematic frame 04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Hydraulic schematic frame 05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Hydraulic schematic frame 06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

SERVICE Hydraulic systems Service instruction - Accumulator charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Service instruction - Pressure testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

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Hydraulic systems - Technical Data - SP.295F pressure settings Component / System Priority pressure Auxiliary pump - running (high) Auxiliary pump - cranking (low) UltraFlo Auxiliary pump — running (high) UltraFlo Auxiliary pump — cranking (low) Charge pressure (charge pressures 1 and 2) High-pressure forward High-pressure reverse Charge pressure drop Air pressure Boom tilt accumulators 18.3 - 30.5 m (60.0 - 100.0 ft) Boom tilt accumulators 36.6 m (120.0 ft) Park brake accumulator Boom lift accumulator 27.4 m (90.0 ft) Boom lift accumulator 36.6 m (120.0 ft) Suspension accumulators Brake accumulator Shift accumulator Fan relief pressure Fan speed Air conditioning charge R134a

Minimum 2225 psi 2450 psi 175 psi N/A N/A 410 psi 6400 psi 6400 psi 70 psi 115 psi 1750 psi N/A 125 psi 625 psi N/A 225 psi 1375 psi 225 psi 2900 psi 1400 RPM —

Nominal 2300 psi 2500 psi 200 psi N/A N/A 435 psi 6500 psi 6500 psi 75 psi 120 psi 1800 psi N/A 150 psi 650 psi N/A 250 psi 1400 psi 250 psi 2950 psi 1450 RPM 6.0 lb

Maximum 2375 psi 2500 psi 225 psi N/A N/A 460 psi 6500 psi 6500 psi 80 psi 125 psi 1850 psi N/A 175 psi 675 psi N/A 250 psi 1425 psi 250 psi 3000 psi 1500 RPM —

Hydraulic systems - Technical Data - SP.300F pressure settings Component / System Priority pressure power steering Auxiliary pump - running (high) Auxiliary pump - cranking (low) UltraFlo Auxiliary pump — running (high) UltraFlo Auxiliary pump — cranking (low) Charge pressure (charge pressure 1 and 2) Tandem pump relief pressure (charge pressure 3) Brake relief pressure High-pressure forward High-pressure reverse Charge pressure drop Air pressure Boom tilt accumulators 18.3 - 30.5 m (60.0 - 100.0 ft) Boom tilt accumulators 36.6 m (120.0 ft) Park brake accumulator Boom lift accumulator 27.4 m (90.0 ft) Boom lift accumulator 36.6 m (120.0 ft) Suspension accumulators Brake accumulator Shift accumulator Fan relief pressure Fan speed Air conditioning charge R134a

Minimum 2225 psi 2450 psi 175 psi 2850 psi 175 psi 515 psi N/A N/A 6400 psi 6400 psi 85 psi 115 psi 1750 psi 2050 psi N/A 625 psi 1175 psi 225 psi 1375 psi N/A N/A 2900 RPM —

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Nominal 2300 psi 2500 psi 200 psi 2900 psi 200 psi 540 psi N/A N/A 6500 psi 6500 psi 90 psi 120 psi 1800 psi 2100 psi N/A 650 psi 1200 psi 250 psi 1400 psi N/A N/A 2950 RPM 6.0 lb

Maximum 2375 psi 2500 psi 225 psi 2950 psi 225 psi 565 psi N/A N/A 6500 psi 6500 psi 95 psi 125 psi 1850 psi 2150 psi N/A 675 psi 1225 psi 250 psi 1425 psi N/A N/A 3000 RPM —

Hydraulic systems - Hydraulic systems

Hydraulic systems - Technical Data - SP.345F pressure settings Component / System Priority pressure power steering Auxiliary pump - running (high) Auxiliary pump - cranking (low) UltraFlo Auxiliary pump — running (high) UltraFlo Auxiliary pump — cranking (low) Charge pressure (charge pressure 1 and 2) Charge pressure 3 Brake relief pressure High-pressure forward High-pressure reverse Charge pressure drop Air pressure Boom tilt accumulators 18.3 - 30.5 m (60.0 - 100.0 ft) Boom tilt accumulators 36.6 m (120.0 ft) Park brake accumulator Boom lift accumulator 27.4 m (90.0 ft) Boom lift accumulator 36.6 m (120.0 ft) Suspension accumulators Brake accumulator Shift accumulator Fan relief pressure Fan speed Air conditioning charge R134a Air conditioning oil PAG15

Minimum 2225 psi 2450 psi 175 psi N/A N/A 515 psi 625 psi 625 psi 6400 psi 6400 psi 125 psi 115 psi 1750 psi 2050 psi N/A 625 psi 1175 psi 225 psi 1375 psi N/A 2900 psi 1400 RPM —

Nominal 2300 psi 2500 psi 200 psi N/A N/A 540 psi 650 psi 650 psi 6500 psi 6500 psi 130 psi 120 psi 1800 psi 2100 psi N/A 650 psi 1200 psi 250 psi 1400 psi N/A 2950 psi 1450 RPM 7.0 lb 2.5 oz oil

Maximum 2375 psi 2500 psi 225 psi N/A N/A 565 psi 675 psi 675 psi 6500 psi 6500 psi 135 psi 125 psi 1850 psi 2150 psi N/A 675 psi 1225 psi 250 psi 1425 psi N/A 3000 psi 1500 RPM —

Hydraulic systems - Technical Data - SP.400F pressure settings Component / System Priority pressure power steering Auxiliary pump - running (high) Auxiliary pump - cranking (low) UltraFlo Auxiliary pump — running (high) UltraFlo Auxiliary pump — cranking (low) Charge pressure (Charge pressure 1 and 2) Tandem pump relief pressure (Charge pressure 3) Brake relief pressure High-pressure forward High-pressure reverse Charge pressure drop Air pressure Boom tilt accumulators 18.3 - 30.5 m (60.0 - 100.0 ft) Boom tilt accumulators 36.6 m (120.0 ft) Park brake accumulator Boom lift accumulator 27.4 m (90.0 ft) Boom lift accumulator 36.6 m (120.0 ft) Suspension accumulators Brake accumulator Shift accumulator Fan relief pressure Fan speed Air conditioning charge R134a Air conditioning oil PAG15

Minimum 2225 psi 2450 psi 175 psi N/A N/A 515 psi 625 psi 625 psi 6400 psi 6400 psi 125 psi 115 psi 1750 psi 2050 psi N/A 625 psi 1175 psi 225 psi 1375 psi 225 psi 2900 psi 1400 RPM —

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Nominal 2300 psi 2500 psi 200 psi N/A N/A 540 psi 650 psi 650 psi 6500 psi 6500 psi 130 psi 120 psi 1800 psi 2100 psi N/A 650 psi 1200 psi 250 psi 1400 psi 250 psi 2950 psi 1450 RPM 7.0 lb 2.5 oz oil

Maximum 2375 psi 2500 psi 225 psi N/A N/A 565 psi 675 psi 675 psi 6500 psi 6500 psi 135 psi 125 psi 1850 psi 2150 psi N/A 675 psi 1225 psi 250 psi 1425 psi 250 psi 3000 psi 1500 RPM —

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Hydraulic systems - Hydraulic schematic frame 01

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RAIL14SP01331JA

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Hydraulic systems - Hydraulic schematic frame 02

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RAIL14SP01332JA

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Hydraulic systems - Hydraulic schematic frame 03

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RAIL14SP01333JA

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Hydraulic systems - Hydraulic schematic frame 04

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RAIL14SP01334JA

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Hydraulic systems - Hydraulic schematic frame 05

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RAIL14SP01335JA

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Hydraulic systems - Hydraulic schematic frame 06

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RAIL14SP01336JA

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Hydraulic systems - Service instruction - Accumulator charging Boom lift accumulator 1. Using padded vice (1), securely clamp down accumulator (2).

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2. Remove red cap (3) on base of accumulator (2) and discard.

3. Insert 5.156 mm (0.203 in) orifice disk (4) into opening on base of accumulator (2).

4. Make sure orifice stays in place inside accumulator (2) and install two Tee fittings (5) (6).

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5. Remove metal protector cap (7) on opposite end of accumulator (2), exposing inflator nipple (8).

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6. Attach air line coupler (9) onto inflator nipple of accumulator (2) and turn core pusher (10) clockwise to open accumulator to nitrogen gas supply through gas supply hose.

7. Use the dry nitrogen gas manifold system (11) to fill the accumulator.

8. Slowly open appropriate bottle to fill accumulator. Deplete nitrogen in lower pressure bottles first, until flow of nitrogen slows or stops. Close that bottle and finish filling accumulator to appropriate pressure setting with another nitrogen bottle with higher psi content.

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9. Fill 37 m (120 ft) boom lift accumulator to 83 bar (1200 psi). Fill all other size boom lift accumulators to 45 bar (650 psi). NOTE: It will be necessary to slightly overfill the accumulator by approximately 3.4 bar (50.0 psi) over recommended pressure setting, because some loss of pressure will occur when fill hose coupler is removed. This is normal and to be expected.

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10. After proper pressure setting is acquired in accumulator (2) turn core pusher (10) counterclockwise to close accumulator off to nitrogen gas supply. 11. Remove air line coupler (9) from accumulator (2).

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12. Install the protector cap (7) over air inflator nipple on accumulator (2).

13. Add a label (12) to accumulator (2) with wording to alert others that accumulator is filled and to what applicable psi pressure it is charged.

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Boom tilt accumulator 1. Using padded vice (1), securely clamp down accumulator (2).

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2. Remove red cap (3) on base of accumulator (2) and discard.

3. Insert 5.156 mm (0.203 in) orifice disk (4) into opening on base of accumulator (2).

4. Ensure orifice stays in place inside accumulator (2) and install Tee fitting (5).

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5. Remove metal protector cap (7) on opposite end of accumulator (2), exposing inflator nipple (8).

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6. Attach air line coupler (9) onto inflator nipple of accumulator (2) and turn core pusher (10) clockwise to open accumulator to nitrogen gas supply through gas supply hose.

7. Use the dry nitrogen gas manifold system (11) to fill the accumulator.

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9. Fill 37 m (120 ft) boom tilt accumulator to 145 bar (2100 psi). Fill all other size boom tilt accumulators to 124 bar (1800 psi). NOTE: It will be necessary to slightly overfill the accumulator by approximately 3 bar (50 psi) over recommended pressure setting, because some loss of pressure will occur when fill hose coupler is removed. This is normal and to be expected.

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12. Install the protector cap (7) over air inflator nipple on accumulator (2).

13. Add a label (12) to accumulator (2) with wording to alert others that accumulator is filled and to what applicable psi pressure it is charged.

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Brake accumulator 1. In padded vice (1), securely clamp down accumulator (2).

RAIL13SP03458AA

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2. Remove metal protector cap (7) on opposite end of accumulator (2), exposing inflator nipple (8).

3. Attach air line coupler (9) onto inflator nipple of accumulator (2) and turn core pusher (10) clockwise to open accumulator to nitrogen gas supply through gas supply hose.

4. Use the dry nitrogen gas manifold system (11) to fill the accumulator.

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5. Slowly open appropriate bottle to fill accumulator. Deplete nitrogen in lower pressure bottles first, until flow of nitrogen slows or stops. Close that bottle and finish filling accumulator to appropriate pressure setting with another nitrogen bottle with higher psi content.

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6. Fill brake accumulator to 97 bar (1400 psi). Fill all other size boom tilt accumulators to 124 bar (1800 psi). NOTE: It will be necessary to slightly overfill the accumulator by approximately 3 bar (50 psi) over recommended pressure setting, because some loss of pressure will occur when fill hose coupler is removed. This is normal and to be expected.

7. After proper pressure setting is acquired in accumulator (2) turn core pusher (10) counterclockwise to close accumulator off to nitrogen gas supply. 8. Remove air line coupler (9) from accumulator.

9. Remove red plug on opposite end of accumulator and install two fittings (11). Discard plug.

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10. Add a label (12) to accumulator (2) with wording to alert others that accumulator is filled and to what applicable psi pressure it is charged.

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Suspension accumulators 1. Ensure suspension oil pressure is relieved (hold for several minutes) before measuring the pressure. Weight against the oil will magnify the actual pressure. 2. Using padded vice (1), securely clamp down accumulator (2).

3. Remove red cap on base of accumulator (2) and discard. Install three hydraulic fittings (3). Do not tighten Tee to accumulator at this time; it will be reorientated when accumulator is installed on unit.

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4. Close bleeder nipple (4) on end of fitting (3).

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5. Remove inflator guard (5) and valve stem cap (6).

6. Valve stem (7) is now exposed.

7. Install inflator supply hose (8) from nitrogen manifold system and turn core pusher (9) clockwise to open accumulator (2) to nitrogen gas supply through gas supply hose.

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8. Use the dry nitrogen gas manifold system (11) to fill the accumulator. A single bottle system can also be used to fill the accumulator.

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9. Slowly open appropriate bottle to fill accumulator. Deplete nitrogen in lower pressure bottles first, until flow of nitrogen slows or stops. Close that bottle and finish filling accumulator to appropriate pressure setting with another nitrogen bottle with higher psi content.

10. Pressure fill for suspension accumulators is 17 bar (250 psi). Slightly overfill the accumulator by approximately 3 bar (50 psi) over recommended pressure setting, because some loss of pressure will occur when fill hose coupler is removed. This is normal and to be expected.

11. After proper pressure setting is acquired in accumulator (2) turn core pusher (9) counterclockwise to close accumulator off to nitrogen gas supply.

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12. Fill all suspension accumulators to 17 bar (250 psi).

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13. Install valve stem cap (6) and reinstall inflator guard (5).

14. Add a label (12) to accumulator (2) with wording to alert others that accumulator is filled and to what applicable psi pressure it is charged.

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Hydraulic systems - Service instruction - Pressure testing Auxiliary Pump 1. Locate the auxiliary pump test port installed on the front side of the auxiliary valve. 2. Attach a 34474 kPa (5000 psi) digital pressure gauge on to the test port. 3. Start the engine of the vehicle and allow the hydraulic oil to reach temperature.

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4. Set the low pressure (normal cranking) by attaching an external 12 V power supply to the cold cranking solenoid. 5. Read the digital pressure gauge. The pressure rating should be 1207 - 1551 kPa (175 - 225 psi). 6. Adjust the pressure value. Turn the adjustment screw on the compensator clockwise to increase the pressure value. Turn the adjustment screw counter clockwise to decrease the pressure value.

Auxiliary pump cold cranking solenoid-51 GPM optional pump 1. Set the low pressure (normal cranking) by attaching an external 12 V power supply to the cold cranking solenoid. 2. Install a 34474 kPa (5000 psi) gauge on the Auxiliary Pump test port.

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3. Ensure the cold cranking solenoid is getting power. 4. Start the engine. Ensure the oil is warm. 5. Read the gauge. The compensator pressure should be 1207 - 1551 kPa (175 - 225 psi). 6. Adjust the pressure value. Turn the adjustment screw on the compensator clockwise to increase the pressure value. Turn the adjustment screw counter clockwise to decrease the pressure value.

RAIL14SP00233AA

7. Set the high pressure (normal cranking) by attaching an external 12 V power supply to the cold cranking solenoid. 8. Install a 34474 kPa (5000 psi) gauge on the Auxiliary Pump test port. 9. Start the engine. Ensure the oil is warm. 10. Read the gauge. The pressure reading should be 16892 - 17237 kPa (2450 - 2500 psi) . 11. Adjust as needed by loosening the set screw (1) of the cold cranking solenoid valve. Turn the high pressure adjuster (2) clockwise to increase pressure and counter clockwise decrease pressure. Tighten set screw.

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Steering relief pressure 1. Test the steering relief pressure by attaching a 34474 kPa (5000 psi) gauge on to the steering test port attached to the right hand hydraulic steering cylinder. 2. Start the engine. Allow the hydraulic oil to reach temperature. 3. Install a temporary cylinder stroke stop on the left hand side cylinder shaft (minimum length 1 m (3 ft)) to prevent the steering system from going into the phasing mode. Turn the wheel to the right and continue turning while viewing the gauge. 4. Read the gauge. The pressure reading should be 15341 - 16375 kPa (2225 - 2375 psi). RAIL14SP00229AA

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5. Adjust as needed by removing the cap from the pressure adjuster (RV2 on the auxiliary valve) , loosening jam nut, and turning the adjuster clockwise to increase pressure, or turning the adjuster counter clockwise to decrease pressure.

Boom raise/lower rate 1. Adjust the lift arm lower rate by loosening the lock nut on the FC1 adjuster (1). Turn the adjuster screw clockwise to decrease the lowering speed. Turn the adjuster screw counter clockwise to increase the lowering speed. 2. Adjust the lift arm raise rate by loosening the lock nut on the NV1 adjuster (2). Turn the adjuster screw clockwise to decrease the lift raise rate. Turn the adjuster screw counter clockwise to increase the lift rate. 3. Tighten lock nut on the adjusters when the desired raise / lower rate in achieved.

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Product pump flow adjustment NOTE: If product flow rates are not acceptable it may be necessary to adjust the hydraulic oil flow through the NV2 valve. Make sure you have investigated all possible problems with the product delivery system before adjusting. 1. Open the tank sump of the product tank. Verify that all other valves to the tank are closed. 2. Verify that the master boom switch and all the boom switches OFF.

RAIL14SP00234AA

NOTE: If by pass is installed on the vehicle then turn the master switch ON, but turn the boom switches are OFF. 3. Turn on the product pump, increase the engine 2200 RPM . The boom pressure gauge should read 896 - 965 kPa (130 - 140 psi) on standard product pumps. The boom pressure gauge should read 758 - 827 kPa (110 - 120 psi) on high flow product pumps. 4. Increase NV2 flow rate by turning adjustment screw counter clockwise if needed. NOTE: Do not over speed the product pump. To determine flow. install an in—line flow meter. Flow at maximum should be 61 - 64 L/min (16 - 17 US gpm) on both standard and high flow pumps.

Boom Cylinder Speed Adjustment 1. Adjust according to customer preference. Loosen the adjuster lock nut and turn the adjuster to either increase or decrease boom cylinder speeds.

RAIL14SP00268FA

Item 1 2 3 4 5 6 7 8 9 10

Description F1 Up — Left side fold cylinder up F1 Dn — Left side fold cylinder down F2 In — Left side swing cylinder in F2 Out — Left side swing cylinder out F3 Dn (top of valve) — Left side tilt cylinder down F3 Up (bottom of valve) — Left side tilt cylinder up F4 Dn (top of valve) — Right side tilt cylinder down F4 Up (bottom of valve) — Right side tilt cylinder up F5 Out — Right side swing cylinder out F5 In — Right side swing cylinder in 47691240 24/02/2015

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Item 11 12

Description F6 Dn — Right side fold cylinder down F6 Up — Right side fold cylinder up

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Index Hydraulic systems - 35 Hydraulic systems - 000 Hydraulic systems - Hydraulic schematic frame 02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Hydraulic systems - Hydraulic schematic frame 03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Hydraulic systems - Hydraulic schematic frame 04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Hydraulic systems - Hydraulic schematic frame 05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Hydraulic systems - Hydraulic schematic frame 06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Hydraulic systems - Hydraulic schematic frame 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Hydraulic systems - Service instruction - Accumulator charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Hydraulic systems - Service instruction - Pressure testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Hydraulic systems - Technical Data - SP.295F pressure settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic systems - Technical Data - SP.300F pressure settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic systems - Technical Data - SP.345F pressure settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Hydraulic systems - Technical Data - SP.400F pressure settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Hydraulic systems - 35 Reservoir, cooler, and filters - 300

SP.295F SP.300F SP.345F SP.400F

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Contents Hydraulic systems - 35 Reservoir, cooler, and filters - 300

FUNCTIONAL DATA Reservoir, cooler, and filters Overview - Hydraulic oil reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Thermal bypass valve Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SERVICE Reservoir, cooler, and filters Remove Hydraulic reservoir filter and strainer element removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Install Hydraulic reservoir filter and strainer element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Oil reservoir Service instruction - Tank vacuum procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Thermal bypass valve Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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Reservoir, cooler, and filters - Overview - Hydraulic oil reservoir The hydraulic reservoir contains the hydraulic oil used by the hydraulic system of the vehicle. The reservoir is located at the rear of the vehicle inside the engine enclosure, at the right hand side . Access to the reservoir is made through the sliding engine enclosure doors. The hydraulic reservoir is a square container constructed of welded steel sheet and has a capacity of approximately 132 L (35 US gal) of hydraulic oil. Hydraulic oil contained in the hydraulic reservoir is used to operate the hydrostatic pumps, the cooling fan pump and motor, the auxiliary pump, the product pump, and the integrated valve which directs hydraulic oil to the steering, suspension, boom, and brakes. Additionally, the reservoir receives return hydraulic oil from the hydraulic oil cooler and the wheel motors.

RAIL14SP00811AA

Hydraulic reservoir sensors Attached the hydraulic reservoir are two pressure sensors, a hydraulic oil level sensor, and a hydraulic oil temperature probe. The sensors have SAE style threads for attachment to the reservoir. The sensors activate warnings and alarms, as well as display conditions of the hydraulic oil when issues arise with the hydraulic oil in the reservoir. The sensors send signals to the overhead side display to indicate warnings, and signals to the chassis monitor to display condition status. The overhead side display in the vehicle cab will alert the operator as to critical conditions of the hydraulic oil pressure, level, and temperature. The hydraulic icon (1) of the overhead side display panel will illuminate red, and an audible alarm will sound, when the hydraulic oil temperature has gone above the normal operating range. Shut the vehicle down as soon as safely possible and check for the cause of the problem.

RAIL12SP01126AA

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The chassis monitor displays the hydraulic oil condition. Access the hydraulic system operating conditions is made by selecting the Hydraulics button on the chassis monitor home screen. This will display the hydraulics screen. The hydraulic screen is a monitoring screen only and has no selectable features. The displayed conditions present on the screen are the hydraulic case drain filter status (1) , the main hydraulic oil filter status (2), the hydraulic oil temperature (3), and the hydraulic oil level (4).

RAIL14SP00813AA

The hydraulic oil case drain filter status and the main hydraulic oil filter status will read normal if the filters are clean. If the filters become obstructed with debris, the hydraulic oil pressure within the filters boxes of the reservoir will increase above the specified pressure rating of the senor. This will cause the monitor to display a “Not Normal” status. Replace the appropriate filter to bring the status back to “Normal” condition. The hydraulic oil temperature status will display the hydraulic oil temperature within the tank. If the hydraulic oil temperature exceeds the specified value, the temperature value will be displayed on the chassis monitor screen. The hydraulic oil level status will display the oil level within the reservoir. If the hydraulic oil level is below the specified level required for the system, the monitor to display a “Not Normal” status. Fill the reservoir to the proper level to bring the status back to “Normal” condition. Additionally, viewing the hydraulic oil level sight glass, mounted to the front of the reservoir will also give an indication as to the hydraulic oil level within the reservoir.

Hydraulic oil filters and strainer Two filters and a strainer are attached to the hydraulic reservoir. The case drain filter (1) provides filtering of the wheel motor case drain oil, shifting valve, cooling fan motor, and the product pump motor case drain oil. The main filter (2) provides filtering of hydraulic oil from the oil cooler, manifold valve, and the hydrostatic pumps. The strainer (3) provides for straining of hydraulic oil that is filled into the reservoir through the fill port located on the top of the reservoir.

RAIL15SP00195GA

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The following illustration identifies the hydraulic reservoir attachments points and components.

RAIL15SP00187GA

Item A B C D E F G H J K L M N P Q R S T U

Description Pressure sensor â&#x20AC;&#x201D; 22 psi Pressure sensor â&#x20AC;&#x201D; 35 psi Hydraulic oil level sensor Hydraulic reservoir breather Hydraulic reservoir Main hydraulic filter (located under cover plate) Fill port strainer (located under cap) Integrated valve connection point Product pump connection point Hydraulic oil level sight glass Wheel motor connection points Cooling fan connection point Case drain hydraulic filter (located under cover plate) Hydraulic oil temperature probe Cooling fan pump connection point Auxiliary pump connection point Hydrostatic pump connection points Wheel motor connection points Hydraulic oil cooler connection point

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Thermal bypass valve - Overview A thermal bypass valve (1) is attached to the hydraulic oil cooler of the vehicle. The bypass valve handles input hydraulic oil from the cooling fan motor, the cooling fan relief hydraulic oil, and the shuttle valve. The bypass valve body is not removable, but the internal cartridge (2) can be removed for replacement or repair. The thermal bypass valve is a dual purpose valve containing both the thermal bypass and the relief valve functions in one.

RAIL15SP00135FA

The thermal bypass valve is normally open. The normally open valve function allows the hydraulic oil of the hydraulic system to circulate through, and past the hydraulic oil cooler by way of the hydraulic oil cooler bypass hose, when the hydraulic oil temperature is below 54 °C (130 °F). This function allows cool hydraulic oil to operate the within the system to provide hydraulic pressure for the initial demand of the system.

RAIL15SP00140FA

Item 1 2 3 4

Description Hydraulic oil cooler Thermal bypass valve Relief valve Input — Cooling fan relief valve

Item 5 6 7 8

Description Input — Shuttle valve Input — Fan motor Hydraulic oil cooler bypass line Hydraulic oil cooler output to hydraulic reservoir

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When the hydraulic oil temperature is between 54 - 66 °C (130 - 150 °F) on the hydraulic oil cooler output flow, the thermal bypass valve begins to close and more hydraulic oil is forced through the hydraulic oil cooler (1) and the hydraulic oil cooler bypass line (2). The closing of the thermal bypass valve is proportional to the hydraulic oil cooler outlet temperature. At 54 °C (130 °F) the valve starts to close. At 66 °C (150 °F) the valve is fully closed.

RAIL15SP00138FA

When the hydraulic oil temperature becomes greater than 66 °C (150 °F) for the hydraulic oil cooler output flow, the thermal bypass valve becomes fully closed (1). All the hydraulic oil is then forced through the hydraulic oil cooler and no hydraulic oil will bypass around the hydraulic oil cooler. The thermal bypass valve also has a relief function (2) when it is fully closed. If the hydraulic oil cooler becomes blocked or has some restriction, the thermal bypass valve will start to open at 3.5 Kg/cm² (50.0 psi), This will allow hydraulic oil to bypass around the hydraulic oil cooler and prevent over pressurization of the hydraulic oil cooler.

RAIL15SP00141FA

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Reservoir, cooler, and filters - Remove Hydraulic reservoir filter and strainer element removal Return filter element removal 1. Remove the four bolts and flat washers (1) attaching the cover (2) to the large filter box mounting flange (3). 2. Remove the O-ring (4) and the filter element (5) from the filter box. 3. Dispose of the O-ring and the filter element properly.

RAIL15SP00142AA

RAIL15SP00143AA

Strainer element removal 4. Remove the cap (1) from the hydraulic reservoir fill port by turning the cap one half turn. 5. Lift the strainer element (2) from the hydraulic reservoir. Dispose of the strainer element properly.

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Top filter element removal 6. Remove the four bolts, flat washers, and lock washers (1) attaching the cover plate (2) to the small filter box mounting flange (3). 7. Remove the O-ring (4) and the filter element (5) from the small filter box. Dispose of the O-ring and the filter element properly.

RAIL14SP00144AA

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Reservoir, cooler, and filters - Install Hydraulic reservoir filter and strainer element Top filter element installation 1. Install the top filter element (1) in to the small filter box. ensure that the filter element is seated properly into the mounting area. 2. Install the O-ring (2) into the recess of the small filter box mounting flange. Ensure that the O-ring is seated properly. 3. Attach the cover plate (3) to the mounting flange using the four flat washers, lock washers, and bolts (4). Tighten the bolts securely.

RAIL14SP00144AA

RAIL15SP00143AA

Strainer element installation 4. Install the strainer element (1) into the fill port neck Ensure that the strainer is seated properly 5. Attach the fill cap (2) to the fill port neck. Turn the cap one half turn to lock in place.

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Return filter element installation 6. Install the return filter element (1) into the large filter box mounting area. Ensure that the filter element is properly seated. 7. Install the O-ring (2) into the O-ring mounting area. Ensure that the O-ring is properly seated. 8. Attach the large filter box cap (3) to the large filter box using the four bolts and flat washer (4). Tighten the bolts securely.

RAIL15SP00142AA

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Oil reservoir - Service instruction - Tank vacuum procedure 1. Open the upper engine compartment door to access hydraulic oil tank. 2. Clean top of hydraulic oil tank to prevent contamination from entering tank. 3. Remove hydraulic oil tank oil fill cap and attach shop vacuum hose or other vacuum device hose to fill spout using duct tape or other sealing material to seal the connection. 4. Remove vent filter from top of hydraulic oil tank. Using duct tape, seal the tube so as to create an air tight seal on oil tank. 5. Shop vac or vacuum device can now be turned on to create a vacuum inside hydraulic oil tank, preventing oil from escaping out of large hydraulic suction hoses when removed from hydrostatic and auxiliary pumps. Observe or perform the following as necessary, while executing this vacuum task: â&#x20AC;˘ Watch oil level in sight gauge, making sure oil is not sucked into vacuum and creating potential for tank to collapse. â&#x20AC;˘ Strength of suction on the tank can be controlled by cutting a slit in duct tape to allow air to enter. Cut slit only large enough to allow oil to be held in tank and hoses. 6. Once set up as outlined above, applicable hydraulic hoses can be removed. Once hose ends are removed and capped, vacuum device can be shut off until reassembly. 7. If using a specially designed vacuum pump, adjust vacuum as required to prevent excess vacuum on tank. 8. When reassembling hydraulic hoses to hydrostatic and auxiliary pumps, turn on shop vac or vacuum device again until all applicable hoses are assembled and tightened. 9. Remove all duct tape securing shop vac or vacuum device to hydraulic oil spout and vent filter. 10. Reassemble vent filter to tube on oil tank and install hydraulic oil tank oil fill cap. 11. Wipe up any hydraulic oil drips or spills.

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Thermal bypass valve - Remove 1. Move the vehicle to a hard level surface. 2. Turn the ignition key to the off position. Remove the key from the ignition. 3. Drain the hydraulic fluid from the system, following all applicable warnings and cautions. Remove the drain plug (1) from the bottom of the hydraulic tank (2) and allow the hydraulic oil to drain into a suitable container.

RAIL14SP01765AA

RAIL14SP01912AA

4. Access the cooling package at the rear of the vehicle. Locate the thermal bypass valve (1) attached to the side of the hydraulic oil cooler (2) .

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5. Remove the hydraulic oil lines (1) attached to the bypass valve (2). Cap or plug the hydraulic oil lines.

RAIL14SP01769AA

RAIL15SP00135FA

6. Remove the thermal bypass valve cartridge from the valve body.

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Thermal bypass valve - Install 1. Inspect the interior of the thermal bypass valve for debris. Clean as required. 2. Install the thermal bypass valve cartridge (1) into the thermal bypass valve body. Tighten the cartridge securely.

RAIL15SP00135FA

RAIL14SP01769AA

RAIL14SP01765AA

3. Attach the hydraulic oil lines (1) to the bypass valve (2). Tighten the connections securely.

4. Install the drain plug (1) into the hydraulic reservoir (2). Fill the hydraulic reservoir with specified hydraulic oil.

5. Start the engine of the vehicle. Check the hydraulic oil level. Bring the level up to the proper capacity if needed. Verify operation of the hydraulic component of the system.

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Index Hydraulic systems - 35 Reservoir, cooler, and filters - 300 Oil reservoir - Service instruction - Tank vacuum procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Reservoir, cooler, and filters - Install Hydraulic reservoir filter and strainer element . . . . . . . . . . . . . . . . . . . . . . . . . 10 Reservoir, cooler, and filters - Overview - Hydraulic oil reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Reservoir, cooler, and filters - Remove Hydraulic reservoir filter and strainer element removal . . . . . . . . . . . . . . . . 8 Thermal bypass valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Thermal bypass valve - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Thermal bypass valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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Hydraulic systems - 35 Auxiliary hydraulic pump and lines - 220

SP.295F SP.300F SP.345F SP.400F

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Contents Hydraulic systems - 35 Auxiliary hydraulic pump and lines - 220

SERVICE Auxiliary hydraulic pump Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Hydraulic systems - Auxiliary hydraulic pump and lines

Auxiliary hydraulic pump - Remove Prior operation: Apply a vacuum on the hydraulic tank to hold the oil. Oil reservoir - Service instruction - Tank vacuum procedure (35.300) 1. Move the vehicle to a hard level surface. 2. Turn the ignition key to the â&#x20AC;&#x153;OFFâ&#x20AC;? position. Remove the key from the ignition. 3. Access the auxiliary pump by opening the right hand side lower access door. The pump is attached to the end of the tandem hydrostat pump assembly. 4. Tag and mark the hydraulic lines connected to the auxiliary pump. 5. Disconnect the upper and lower hydraulic lines (1) from auxiliary hydraulic pump (2) by removing the flange clamps (3). 6. Cap and plug the hydraulic lines and fittings. 7. Remove the hydraulic lines (4) connected to the tee fitting (5) attached to the auxiliary pump (2). 8. Cap and plug the hydraulic lines and fittings. 9. Disconnect the wire harness connection to the auxiliary pump valve solenoid (6) .

RAIL14SP01908AA

RAIL14SP01909AA

10. Remove the two bolts and flat washers. (1) attaching the auxiliary pump to the hydrostat pump assembly. 11. Remove the pump and the O-ring (2) from the vehicle. Discard the O-ring.

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Auxiliary hydraulic pump - Install 1. Attach the O-ring (1) to the auxiliary pump. 2. Attach the auxiliary pump to the tandem hydrostat pump assembly using the two bolts and washers (2). Tighten securely.

RAIL14SP01909AA

RAIL14SP01908AA

3. Connect the wire harness connection to the auxiliary pump valve solenoid (1). 4. Attach the hydraulic lines (2) to the tee fitting (3) attached to the auxiliary pump. 5. Attach the upper and lower hydraulic lines (4) to the auxiliary hydraulic pump using the flange clamps (5). Tighten securely.

6. Fill the hydraulic tank to the required level. 7. Start the vehicle and allow the hydraulic system to fully charge the system. Inspect for leaks at the pump hydraulic line connection points.

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Index Hydraulic systems - 35 Auxiliary hydraulic pump and lines - 220 Auxiliary hydraulic pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Auxiliary hydraulic pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Hydraulic systems - 35 Hydraulic fan drive cooling system - 752

SP.295F SP.300F SP.345F SP.400F

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Contents Hydraulic systems - 35 Hydraulic fan drive cooling system - 752

SERVICE Fan pump Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Fan motor Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Fan pump - Remove 1. Move the vehicle to a hard level surface. 2. Turn the ignition key to the â&#x20AC;&#x153;OFFâ&#x20AC;? position. Remove the key from the ignition. 3. Tag and mark all lines, fittings, and hoses, prior to removal. 4. Access the fan pump by opening the engine enclosure bottom door. The pump is mounted to the rear side of the engine. 5. Remove the tee fitting (1) attached to the fan pump (2). The fan pump pressure relief valve (3) and the feed hoses (4) are attached to the tee fitting. Cap or plug the tee fitting. Move the hose and valve assembly out of the way when disconnected.

RAIL15SP00070AA

RAIL14SP01830AA

6. Remove the common feed hose (1) connected to the fan pump. Cap or plug the feed line.

7. Remove the fan pump and gasket (1) from the engine by removing the bolts and washers (2).

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Fan pump - Install 1. Attach the fan pump and gasket (1) to the engine using the bolts and washers (2).

RAIL14SP01830AA

RAIL15SP00070AA

2. Attach the common feed hose (1) to the fan pump. Tighten securely.

3. Attach the tee fitting (1) to the fan pump. Attach the fan pump relief valve (2) to the tee fitting. Attach the fan motor feed line to the fan pump (3) .

4. Fill the hydraulic tank to the required level. 5. Start the vehicle and allow the hydraulic system to fully charge the system. Inspect for leaks at the fan pump connection points and related attachments.

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Fan motor - Remove Prior operation: Remove the engine enclosure panels and doors. Refer to Engine hood and panels - Remove (90.100) 1. Move the vehicle to a hard level surface. 2. Turn the ignition key to the â&#x20AC;&#x153;OFFâ&#x20AC;? position. Remove the key from the ignition. 3. Tag and mark all lines, vents, and hoses, prior to removal. 4. Remove the fan blades (1) from the fan motor by removing the nut and washer (2) .

RAIL14SP01827AA

RAIL15SP00067AA

5. Disconnect the hydraulic lines (1) attached to the fan motor (2). Cap or plug the lines.

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6. Remove the fan mount weldment (1) from the mounting plates (2) of the cooling package by removing the bolts, washers, and nuts (3). Remove the fan mount with fan motor attached from the vehicle.

RAIL14SP01828AA

RAIL14SP01829AA

7. Remove the fan motor (1) from the fan mount (2) by removing the bolt, washers, and nuts (3) .

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Fan motor - Install 1. Attach the fan motor (1) to the fan mount (2) using the bolts, washers, and nuts (3) .

RAIL14SP01829AA

RAIL14SP01828AA

2. Attach the fan mount weldment with fan motor (1) to the mounting plates (2) of the cooling package using the bolts, washers, and nuts (3).

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3. Attach the hydraulic lines (1) to the fan motor (2). Tighten the connection s securely.

RAIL15SP00067AA

RAIL14SP01827AA

4. Attach the fan blades (1) to the fan motor using the nut and washer (2) . Tighten securely.

5. Start the vehicle and check for leaks at the connection points on the fan motor. Verify that the cooling fan is operating properly.

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Index Hydraulic systems - 35 Hydraulic fan drive cooling system - 752 Fan motor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Fan motor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Fan pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Fan pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Hydraulic systems - 35 Machine leveling control system - 610

SP.295F SP.300F SP.345F SP.400F

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Contents Hydraulic systems - 35 Machine leveling control system - 610

FUNCTIONAL DATA Machine leveling control system Overview - Suspension system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Machine leveling control system Check - Suspension system leakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Adjust - Suspension cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Service instruction - Suspension system, air bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Overhaul - Suspension cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Machine leveling control system - Overview - Suspension system If the hydraulic suspension system is settling after shutdown, a test will be required to confirm the cause. Refer to Machine leveling control system - Check - Suspension system leakdown (35.610) Location of the check valve spring (1). Single acting valve, (2) controls the flow of oil as needed. Linkage (3) must be disconnected and lowered for transport.

RAIL13SP00994AA

Only two leak paths exist for the oil other than an external hose leak. The first path to confirm is the load holding check valve in the suspension valve. Examine the condition of the ball, spring, cover, and internal seat for the valve. The suspension valve is a double acting valve utilized as a single acting valve which means a duplicate check valve is on the opposite side of the valve not being used. The duplicate ball and spring can be used to replace a damaged or questionable ball and spring, to check the oil from returning to the tank. Load holding suspension check (1). Disconnect the linkage (2) allowing the control levers (3) to return to neutral. The linkage is anchored and spring loaded. Pivot points of the linkage must work freely without binding.

RAIL13SP00995AA

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Machine leveling control system - Check - Suspension system leakdown Suspension system check 1. Park the vehicle on a level surface. 2. Allow the vehicle to run with the park brakes off. 3. Disconnect the suspension linkage and lower the suspension all the way down. Hold the lever an extra 60 seconds to make sure all the oil is released. 4. Shut the engine off. 5. Locate the suspension valves under the vehicle. NOTE: There are two -10 tees (MLR2142114NIT) located on the inside frame rail just inside from the suspension valves. One end of the tee has a short hose (MLR2141762NL) attached to it that connects to a larger tee, then to the accumulator. That short hose is not removed for this procedure. The other end of the tee has a longer hose (MLR2142365NL) that crosses over to the diagonally located suspension cylinder. This long hose is the one that will be disconnected from the tee for this procedure. 6. Remove any cable ties as needed. Remove all four longer hoses from the -10 tees and cap the tees. 7. Allow the free end of the hoses to drain into the four containers.

Suspension System Leak Down Check NOTE: Before proceeding with the Suspension System Leak Down Check steps , be sure to inspect the condition of the ball, spring, and seat 8. Start the engine and operate the suspension valves to raise the vehicle slowly to a height so that four inches of chrome rod is showing on all four cylinders. This will allow more fluid to drain from the hoses placed in the containers. 9. Turn the vehicle off and empty the containers. 10. Place the containers back under the drain hoses. 11. Let the vehicle sit for two hours and note whether the vehicle settles. 12. If a corner of the vehicle settles and oil has drained into the container, that is an indication of a leaking cylinder piston seal. 13. If the container on one corner of vehicle has oil in it, then the cylinder which is directly across is leaking, i.e, if right front has oil in the container, left front cylinder is leaking down, or if left rear has oil in the container, right rear cylinder is leaking down, etc. 14. Replace or reseal the worn cylinder. 15. Replace the hoses that were removed and bleed any trapped air in the suspension system. Refer to Machine leveling control system - Service instruction - Suspension system, air bleed (35.610)

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16. Replace any cable ties that were removed. 17. Connect the suspension linkage. 18. Fill the hydraulic system. 19. Adjust suspension cylinders so vehicle is level. Refer to Machine leveling control system - Adjust - Suspension cylinders (35.610)

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Machine leveling control system - Adjust - Suspension cylinders 1. Park the vehicle on level ground. NOTE: The adjustment procedure requires two people, one person to remain in the operators cab and the second person to adjust the suspension. 2. Start the engine. 3. Reduce the engine speed to idle. 4. Release the parking brake. 5. Have the person on the ground loosen the jam nut (1) at each linkage rod (2). Detach the two right and two left side suspension valve linkage rods from the valve arms (3). Allow the rods to rest in the bottom of the guide slots.

RAIL13SP00997AA

RAIL13SP00998AA

RAIL13SP00997AA

6. Actuate each valve arm manually fore or aft until 101.6 mm (4.0 in) of unpainted suspension cylinder rod is exposed on each of the four suspension cylinders. NOTE: Actuating a given cylinder may affect the exposed rod length of the opposite (diagonal) cylinder. 7. After setting all four cylinders to 101.6 mm (4.0 in) , recheck the other cylinders. 8. Repeat as required until the exposed rod on all four cylinders remains at 101.6 mm (4.0 in).

9. Reattach the linkage rods (1) to the valve arms, adjusting the length of each linkage rod by turning the clevis on each rod. Each rod should be adjusted until the retainer pin can be reinserted through the clevis and valve arm ball without shifting either the valve arm ball or the linkage (valve arm ball and clevis are aligned). 10. Insert the retainer pin through the clevis and valve arm ball and secure in place. 11. Tighten the jam nuts (2) against each clevis to hold it in place.

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Machine leveling control system - Service instruction - Suspension system, air bleed If the hydraulic suspension system has been opened, it will be necessary to make sure any air which may have entered the system is purged. 1. Installed on the end of the bleed fitting. 2. Turn counterclockwise and while cycling the suspension valve, from the bottom upward, monitor the line until it is free of air bubbles and the oil runs clear. 3. Close the bleeder fitting and repeat the process on the other three accumulators.

RAIL13SP00996AA

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Machine leveling control system - Overhaul - Suspension cylinders 1. Clean any accumulated dirt or debris from the port openings and rod guide area. NOTE: The cylinder should be disassembled in a clean environment to prevent dirt or other contamination from entering the interior of the cylinder. 2. Remove the port plugs and drain any oil from the cylinder. Do not reinstall the port plugs at this time. 3. Pull out the rod until the piston is approximately at midstroke. Secure the cylinder in a vise, clamping at the base mount. Do not tighten the vise excessively or the cylinder wall may be permanently distorted. RAIL13SP01006AA

4. Loosen the rod guide with a spanner wrench or pipe wrench by turning it counterclockwise when viewing the rod end of the cylinder. NOTE: The rod guide is assembled at the factory with liquid thread locker and the rod guide may be difficult to unscrew. Heating the rod guide and barrel to about 93.3 °C (200.0 °F) will soften the thread locker and ease removal of the rod guide. 5. Unscrew the rod guide and pull it from the cylinder wall. 6. Pull the rod assembly from the cylinder bore. If there is high resistance to movement at the piston, the vise may be clamped too tightly. Loosen the vise or reclamp at the base. Be careful to not mar the chromed surface of the rod. 7. Inspect the cylinder bore for scoring. Following are problem areas you may find, and how to proceed: • The cylinder bore should be smooth all around on the full length of the bore. • A score or scratch that can be felt when drawing one’s fingernail across it indicates that the blemish has the potential to cause piston seal damage. • If shallow score marks are present, the bore should be honed smooth, if possible. However, the bore should not be honed more than 0.076 mm (0.003 in) oversize to clean up any blemishes. • If the cylinder wall assembly and rod/piston assembly both need to be replaced, a new cylinder should be ordered. 8. Inspect the piston rod chromed surface for score marks or pitting in the stroke zone that travels under the rod wiper. If the chromed surface is scored or pitted, the rod should be replaced.

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9. Note the position and orientation of the seals on the piston and rod guide before replacing them. Be careful to not scratch the seal grooves when removing the old seals. The seals can be removed with a sharp tool, like an awl, by carefully pushing the point partially into the seal and prying the seal from the groove. Hard seals can be removed by carefully cutting the seal apart with a utility knife or an x-acto knife. 10. Inspect the seal grooves and clean away any contamination. Apply a light coating of clean oil to the new seals and into the seal grooves to ease installation and prevent scuffing of the sealing surfaces. 11. Loop the wire tie through the inside diameter of the unseated portion of the Teflon ring, placing the smooth side of the wire tie toward the Teflon ring, then gently pull and lift the ring over the land. Apply only enough effort to force the ring over the land and do not stretch the ring excessively. Pull the wire tie free when the Teflon ring is in place.

RAIL13SP00999AA

RAIL13SP00956AA

RAIL13SP01003AA

NOTE: Use hot water or oil to make the fit up easier. 12. Care must be taken with installation of the four-piece piston seal. Install the Nitrile energizer ring first (1). 13. Next install the Teflon seal (2). The Teflon seal ring (bronze colored) must be installed on the piston from the mount end of the rod. The Teflon seal can be installed in the groove in a similar manner as mounting a tire on a rim. Extreme care must be taken to prevent undue stretching or scoring of the Teflon ring. Working around the circumference of the piston, maneuver the Teflon ring into the groove until the ring begins to tighten. The balance of the ring can be nudged into the groove by using a nylon wire tie that is at least 304.8 mm (12.0 in) long. 14. Once the Teflon seal is in place, install the backup rings (3) on each side. The one side of the backup ring is rounded along the inside diameter. Be sure that the rounded side is installed toward the Teflon ring.

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15. The Teflon ring probably will have stretched slightly from installation and will require resizing in order to fit into the cylinder bore. A piston ring compressor can be used to squeeze the Teflon ring to size. Take care to prevent any damage to the surface of the Teflon ring during the resizing process. The outside diameter surface must be smooth.

RAIL13SP01010AA

16. Install the resealed rod guide onto the rod. 17. Apply a light coating of clean oil to the piston outside diameter and to the static seal on the rod guide. Carefully clean away any oil that is on the rod guide and cylinder barrel threads. 18. Apply removable (blue) Loctite to the second innermost rod guide thread groove in sufficient quantity that the fluid effectively fills the thread groove for at least half the circumference. 19. Carefully position the piston so that it is centered and square with the cylinder wall mouth. Once started, push firmly until the piston is about half way down the length of the cylinder bore. 20. Carefully push the rod guide into the cylinder bore until the threads engage. 21. Screw the rod guide into the barrel and tighten to approximately 169.5 NÂˇm (125.0 lb ft). Be careful to not mar the chromed rod surface. Allow the Loctite to cure for at least one hour before pressurizing the cylinder with oil. 22. Check cylinder for external leaks using rated hydraulic pressure in both extend and retract modes. Any leaks should be evident after the cylinder has been pressurized for one minute. Remove pressure from cylinder. If the seals are oil tight, the cylinder is ready for service.

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Index Hydraulic systems - 35 Machine leveling control system - 610 Machine leveling control system - Adjust - Suspension cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Machine leveling control system - Check - Suspension system leakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Machine leveling control system - Overhaul - Suspension cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Machine leveling control system - Overview - Suspension system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Machine leveling control system - Service instruction - Suspension system, air bleed . . . . . . . . . . . . . . . . . . . . . . . . 7

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CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404 SERVICE - Technical Publications & Tools

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SERVICE MANUAL Pneumatic system SP.295F SP.300F SP.345F SP.400F

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Contents Pneumatic system - 36

[36.100] Pneumatic system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36.1 [36.908] Pneumatic suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36.2

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Contents Pneumatic system - 36 Pneumatic system - 100

FUNCTIONAL DATA Pneumatic compressor Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Pneumatic system Remove - Air governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install - Air governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Adjust - Air governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Pneumatic system tank Remove - Air tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install - Air tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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Pneumatic system - Pneumatic system

Pneumatic compressor - Overview The air compressor of the vehicle is used for the foam marker system, boom blow out option, and the cab air suspension. The air compressor of the vehicle is attached to , and driven by, the engine. The air compressor is cooled by engine coolant. The operating pressure range for the air compressor is 8 - 9 Kg/cmÂ˛ (115 - 125 psi). The location and style of the air compressor for the vehicle is different depending upon the engine of the vehicle. For QSB engines the air compressor is located nearer the fan belt end of the engine. For QSL engines the air compressor is located further from the fan belt of the engine

RAIL15SP00249FA

Air compressor location QSB engine

RAIL15SP00248FA

Air compressor location QSL engine The air compressor has a small amount of lubricating oil carry over, which lubricates the piston rings and moving parts of the compressor. When the lubricating oil is exposed to normal air compressor operating temperatures over a period of time, the lubricating oil will form carbon deposits. The carbon deposits will cause the air compressor piston rings to be affected by high operating temperatures and pressures, resulting in improper ring seal. Inspect the inside diameter of the air discharge line for carbon deposits exceeding 1.52 mm (0.06 in). If the total carbon deposit exceeds 1.52 mm (0.06 in), clean and inspect the air compressor cylinder head, the valve assembly, and the discharge line. Replace any items if necessary.

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Pneumatic system - Pneumatic system

Pneumatic system - Remove - Air governor 1. Open the engine belly doors. Drain the air from the air system. 2. Disconnect air line (1) from air governor (2). 3. Remove two bolts (3), lockwashers (4), washers (5), and gasket, and remove governor (2) from air compressor (6).

RAIL13SP03445AA

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Pneumatic system - Pneumatic system

Pneumatic system - Install - Air governor 1. Clean the mounting area on the compressor and governor. Also, ensure that the air line is clean before reinstalling. 2. Install the air governor (2) to the air compressor (6) with a new gasket, two bolts (3), lockwashers (4), and washers (5). 3. Install the air line (1) to the air governor (2). 4. Operate the engine and check for air leaks and proper function of the system. RAIL13SP03445AA

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Pneumatic system - Pneumatic system

Pneumatic system - Adjust - Air governor 1. Remove the plastic cap (1) from the air governor (2) that is mounted to the air compressor. 2. Access the adjustment screw of the air governor to adjust the pressure. Air pressure setting range is: 8.1 - 8.8 Kg/cmÂ˛ (115.0 125.0 psi) 3. Turn the adjusting screw inward to increase pressure. Turn the adjustment outward to decrease pressure. 4. Replace the plastic cap onto the air governor after proper adjustment is obtained. RAIL13SP03445AA

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Pneumatic system - Pneumatic system

Pneumatic system tank - Remove - Air tank Prior operation: Remove the upper right hand engine enclosure panel and the lower right hand engine enclosure door. Refer to Engine hood and panels - Remove (90.100) 1. Move the machine on to a hard level surface. 2. Turn the ignition key to the â&#x20AC;&#x153;OFFâ&#x20AC;? position and remove the key from the ignition. 3. Locate the air tank (1) . The air tank is located at the rear of the vehicle next to the cooling package.

RAIL14SP01768AA

RAIL14SP00817AA

RAIL15SP00096AA

4. Drain the condensation from the air tank by opening the remote bulkhead drain (1) and allowing the condensation to drain completely.

5. Evacuate any remaining air from the air tank by pulling up the ring on the relief valve (1) attached to the top of the tank.

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6. Disconnect the lines (1) attached to the air tank.

RAIL15SP00097AA

RAIL15SP00098AA

7. Remove the air line fittings (1) and pressure gauge (2) from the air tank.

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8. Remove the bolts (1) securing the mounting bands to the air tank. 9. Remove the air tank from the vehicle by dropping the tank downward through its mounting area.

RAIL15SP00099AA

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Pneumatic system tank - Install - Air tank 1. Install the air tank (1) into the mounting bands (2). 2. Secure the air tank into the mounting bands using the bolts (3). Tighten the bolts securely.

RAIL15SP00099AA

RAIL15SP00098AA

3. Install the air line fittings (1), and the pressure gauge (2) into the air tank. Tighten securely.

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4. Attach the lines (1) to the fittings of the air tank. 5. Install the relief valve (2) into the top of the air tank.

RAIL15SP00097AA

RAIL14SP00817AA

RAIL14SP01768AA

6. Close the remote bulkhead drain (1).

7. Operate the engine and check for leaks and proper function of system. Read the air tank pressure gauge (1) and verify that the tank is charged to 8.1 - 8.8 Kg/ cmÂ˛ (115.0 - 125.0 psi).

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Index Pneumatic system - 36 Pneumatic system - 100 Pneumatic compressor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Pneumatic system - Adjust - Air governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Pneumatic system - Install - Air governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Pneumatic system - Remove - Air governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Pneumatic system tank - Install - Air tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Pneumatic system tank - Remove - Air tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Pneumatic system - 36 Pneumatic suspension - 908

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Contents Pneumatic system - 36 Pneumatic suspension - 908

SERVICE Cab pneumatic suspension Service instruction - Cab suspension lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Remove - Cab air bags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install - Cab air bags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Pneumatic system - Pneumatic suspension

Cab pneumatic suspension - Service instruction - Cab suspension lowering The cab suspension must be lowered once the sprayer is on the trailer. Proceed as follows to lower the cab suspension. 1. Turn off the engine. 2. Open the rear belly pan door. 3. Locate the petcock on the bottom of the air tank. Open the petcock and drain all the air from the air tank. Close the petcock when finished. 4. Locate the suspension valve linkage (1) at the rear of the cab. RAIL12SP01152AA

5. Remove the lower disconnect (2) from the mounting ball. Do not remove from the linkage rod (1). 6. Pull down on the linkage rod and allow the cab to lower completely. 7. After the cab is completely lowered, reassemble the lower disconnect (2) to the mounting ball and lock in place.

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Pneumatic system - Pneumatic suspension

Cab pneumatic suspension - Remove - Cab air bags Prior operation: Position an appropriate sized block or spacer between the bottom of the cab and the frame of the machine to maintain a suitable work area. The air bag will compress once depressurization occurs, preventing removal of hardware. Prior operation: Lower the cab suspension, refer to Cab pneumatic suspension - Service instruction - Cab suspension lowering (36.908). 1. Disconnect the airline (1) from the cab air bag assembly (2). 2. Remove the hardware (3) on top of the cab air bag assembly.

RAIL13SP00953AA

RAIL13SP01071AA

3. Remove the hex bolt, flat washer and lockwasher (1) that secures the cab air bag assembly (2) to the bottom bracket. Remove the cab air bag assembly.

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Pneumatic system - Pneumatic suspension

Cab pneumatic suspension - Install - Cab air bags 1. Position the cab air bag assembly in the bottom bracket. 2. Secure in place with one hex bolt, one flat washer and lockwasher (1).

RAIL13SP01071AA

RAIL13SP00953AA

3. Connect the airline (1) to the cab air bag assembly (2). 4. Install the hardware (3) to the top of the cab air bag assembly. 5. Remove the block or spacer from in between the cab and the frame. 6. Operate the engine to check for proper function of the cab air bag system.

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Index Pneumatic system - 36 Pneumatic suspension - 908 Cab pneumatic suspension - Install - Cab air bags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Cab pneumatic suspension - Remove - Cab air bags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Cab pneumatic suspension - Service instruction - Cab suspension lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404 SERVICE - Technical Publications & Tools

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SERVICE MANUAL Steering SP.295F SP.300F SP.345F SP.400F

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Contents Steering - 41

[41.101] Steering control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1 [41.216] Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2

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SP.295F SP.300F SP.345F SP.400F

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Contents Steering - 41 Steering control - 101

FUNCTIONAL DATA Steering control Dynamic description - Four wheel steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Overview - Steering diagnostics-Four wheel steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Hydraulic schema - Four wheel steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Electrical schema - Four wheel steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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Steering control - Dynamic description - Four wheel steer The Four Wheel Steer (4WS) function is available on the Guardian Front boom sprayers. The system allows for steering of the two rear wheels in conjunction with the steering of the two front wheels. Steering of all four wheels gives the vehicle the ability to have the rear wheels track with the front wheels, resulting in less crop damage when turning and also the ability to â&#x20AC;&#x153;crabâ&#x20AC;? steer in order to help hold on side hills or to climb out of trouble spots

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The system includes two hydraulic steering cylinders, two hydraulic lock cylinders, a counterbalance valve, a directional control valve, and a cylinder lock valve. Electrically, the system includes three wheel position sensors, two lock proximity switches, an IQAN X IO 2 controller, and a steering mode selection switch. Additionally, system functioning is controlled by the MC2 master controller. Other components related to the 4WS system are common wheel leg assemblies (front left / right rear, and front right / left rear), remote grease lines, and a raised operator walkway System operation may be monitored and controlled through the use of the in cab display panel mounted on the right hand console. In order to activate the 4WS steering mode, the operator selects the 4WS mode from the selector switch. The switch also allows for the selection of the two wheel steer (normal), and CAL (manual steering) functions. In order to utilize 4WS, the vehicle must be moving and have ground speed. If the cab display panel does not show a vehicle ground speed the 4WS function will not operate. When 4WS is activated, a signal travels to the MC2 controller (1) to activate the system. From the MC2 controller, signals are sent to the directional control valve of the 4WS system and to the IQAN X IO 2 controller. The signal to the directional control valve activates the valve to allow hydraulic fluid to flow to the system components. The signal to the IQAN X IO 2 controller is distributed from the controller and sent to the cylinder lock valves, the lock proximity switches, the wheel position sensors, and any third party steering controller input. Feedback signals are sent back from the lock proximity switches and the wheel position sensors to the cab display panel to show cylinder lock status and the wheel positions

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Hydraulically, when the 4WS system is activated, the fluid flows from the directional control valve to the lock cylinders and unlocks the rear wheels for steering. Fluid also flows to the steering cylinders, passing through a counterbalance valve which balances the fluid flow supplying both rear steering cylinders. 47691240 24/02/2015

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The steering selector switch also has a CAL (manual) mode selection and two wheel steer mode (2WS) selection. When CAL is selected, the 4WS system is activated but the steering control of the rear wheels is controlled by using the soft keys on the cab display panel. This function allows for the vehicle to be crab steered. The CAL mode also allows the operator to phase all four steering cylinders. The 2WS function places the vehicle into normal two wheel steering mode and locks the two rear wheel legs preventing four wheel steering.

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Hydraulic components The hydraulic components of the 4WS system are located in the following locations on the vehicle. The directional control valve, the counterbalance valve, and the cylinder lock valve (1) are all located in a recessed opening in the raised walkway (2). The opening is accessed by removing the opening cover panel.

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The steering cylinders and the lock cylinders are located at the top surface of the rear wheel legs, mounted to the top plate. All hydraulic components are easily accessible for servicing and maintenance.

Steering Cylinder The steering cylinders (1) are attached to the front and rear wheel legs and control left and right movement of the wheels when 4WS is activated. The steering cylinders are common for the front and rear wheel legs on 4WS model vehicles, but are different than the steering cylinders used on 2WS model vehicles.

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Lock cylinder The lock cylinders (1) are mounted adjacent to the rear steering cylinders only. When 4WS is activated, hydraulic fluid flow is directed to unlock the lock cylinders, allowing for free travel of the rear wheel legs.

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Counterbalance valve The counterbalance valve (1) checks oil in the rear steering cylinders. The rear steering cylinders are plumbed in series, and the hydraulic oil is trapped in the cylinders by the counterbalance valve. These rear cylinders will require phasing occasionally. Refer to Steering cylinder - Service instruction - Four wheel steer, cylinder phasing (41.216) for cylinder phasing procedure.

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Directional control valve The directional valve (1) controls the direction of hydraulic fluid flow to the counterbalance valve and to the lock valve. The valve is located in the recessed opening of the raised walkway. The valve is operated electrically by a pulse width modulation (PWM) signal sent from the MC2 master control to the PWM coils (2) of the directional control valve.

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Cylinder lock valve The cylinder lock valve (1) directs the flow of the hydraulic fluid to the lock cylinders in order to either lock or unlock the lock cylinders. The valve will lock the rear wheel legs into the straight on position when 2WS is active. When 4WS is activated the cylinders unlock allowing for wheel leg movement. The valve is located in the recessed opening of the raised walkway.

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Electrical components The electrical components of the 4WS system are located at various points of the vehicle, as noted in the following electrical component descriptions.

Wheel position sensor The wheel position sensor are mounted next to the right and left rear steering cylinders and also next to left front steering cylinder. The front left and the rear left sensors coordinate the wheel leg positions when the vehicle is in 4WS mode. The right rear position sensor monitors the wheel leg position for phasing of the rear wheels. If the right rear position sensor detects the wheel position as being too far out of phase, the vehicle operator will receive a warning on the cab control display.

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Lock proximity switch The lock proximity switch is mounted next to each lock cylinder. The switches are normally open and close when the pick up of the switch sees bare metal on the lock cylinder shaft. The switches will send a signal to the cab display panel and indicate locked or opened rear wheel lock status.

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IQAN X IO 2 Controller The IQAN X IO 2 Controller directs signals from the MC2 controller to the cylinder lock valves, the lock proximity switches, the wheel position sensors, and any third party steering controller input. The controller (1) is mounted under the rear deck above the rear fender.

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Steering mode selection switch The steering selector switch provides for the selection of the three steering modes: 4WS (1) , 2WS (2) , and CAL (3). The switch in mounted in the right hand console or the armrest assembly.

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You can view and calibrate the four wheel steer system from the display screen. From the home screen, press the steering icon (1).

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From the four wheel steer screen you can steer the rear wheels either right or left by touching the appropriate icon or calibrate the rear wheels.

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Steering control - Overview - Steering diagnostics-Four wheel steer A steering diagnostics page for the four wheel steer (4WS) is available on the chassis display panel.

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To access the steering diagnostics page from the home screen, touch the navigation icon. The List screen displays. From the List screen touch the “4 Wheel Steer (FWS)” button (1), or 4WS icon (2). This function is only present if the vehicle is equipped with 4WS.

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The 4WS steering page displays. Touch the Steering Diagnostics (1) button to access the diagnostics page.

The diagnostics page displays. The reported values on the screen include: Millivolt output — Front wheel position Millivolt output — Right rear wheel position Millivolt output — Left rear wheel position Milliampere output — Rear steer valve current Rear steer status Steer mode Rear steer reduction percentage

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The 4WS rule is as follows: Vehicle speed under 7 mph you have full speed reaction and no percent reduction. Vehicle speed between 7 mph and 15 mph you have up to a 30% reduction in reaction. Vehicle speed above 15 mph the maximum 30% reduction is applied. 4WS is locked out in the 4th and 5th range on 5 speed models, and 3rd range on 3 speed models.

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Steering control - Hydraulic schema - Four wheel steer

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Steering control - Electrical schema - Four wheel steer

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Index Steering - 41 Steering control - 101 Steering control - Electrical schema - Four wheel steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Steering control - Dynamic description - Four wheel steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Steering control - Hydraulic schema - Four wheel steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Steering control - Overview - Steering diagnostics-Four wheel steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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Steering - 41 Cylinders - 216

SP.295F SP.300F SP.345F SP.400F

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Contents Steering - 41 Cylinders - 216

SERVICE Steering cylinder Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Service instruction - Steering cylinder toe in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Service instruction - Four wheel steer, cylinder phasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Remove - Four wheel steer hydraulic control components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Install - Four wheel steer hydraulic control components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Remove - Four wheel steer cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Install - Four wheel steer cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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Steering cylinder - Remove Prior operation: Remove the steering cover Fender - Remove - Front steering cover (90.116) 1. Tag and mark all hydraulic lines. 2. Cut all cable ties. 3. Disconnect, plug, and cap hydraulic lines. 4. Disconnect, plug, and cap grease lines. 5. Remove shoulder bolt (1). 6. Remove roll pin (2). 7. Remove steering cylinder pin (3). 8. Remove the bushings (4) if they are worn.

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9. Remove five locknuts (5), eight washers (6), and five bolts (7).

10.

WARNING Crushing hazard! Before disconnecting the cylinders or equipment, make sure you adequately support and secure the equipment or implement. Failure to comply could result in death or serious injury. W0243A

Lift upper steering weldment (8), steering cylinder (9), and lower steering weldment (10) from A-frame weldment using suitable lifting device. 11. Remove steering cylinder (9) from upper steering weldment (8) and lower steering weldment (10).

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Steering cylinder - Install 1. Position steering cylinder (9) into upper steering weldment (8) and lower steering weldment (10).

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Lift upper steering weldment (8), steering cylinder (9) and lower steering weldment (10) onto A-frame weldment (11) using suitable lifting device.

3. Install steering cylinder (9) and steering weldments (8) (10) to A-frame (11) using five bolts (7), eight washers (6), and five locknuts (5). Tighten the bolts securely to the proper torque specifications.

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4. If removed, press fit bushings (4) into clevis. 5. Install steering cylinder pin (3). 6. Install roll pin (2). 7. Install shoulder bolt (1). Tighten the bolt to the proper torque specifications.

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8. Connect grease lines. 9. Connect hydraulic lines following all applicable cautions and warnings. 10. Install cable ties as needed. 11. Remove tags from hydraulic lines. 12. Check hydraulic oil level and add as needed. 13. Perform hydraulic fluid level checks and pressure tests. 14. Grease fittings on steering cylinder. 15. Check steering cylinder phasing. 16. Check steering toe in.

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Steering cylinder - Service instruction - Steering cylinder toe in 1. Perform the steering cylinder phasing procedure Steering cylinder - Service instruction - Four wheel steer, cylinder phasing (41.216). 2. Start the vehicle engine. Ensure that the vehicle is on level ground and that the tires are facing forward. Reduce vehicle engine speed to low idle. Have someone at ground level check that the tread width cylinders are fully retracted. 3. Detach the two right and two left side suspension valve linkages (1).

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4. Actuate each linkage fore or aft until there is 102 mm (4 in) of unpainted suspension cylinder rod exposed on each of the four suspension cylinders (1) (2). 5. After setting all four cylinders to the 102 mm (4 in) value, recheck all the cylinders again. 6. Repeat Step 4 as required until the exposed rod on all four cylinders is at 102 mm (4 in). 7. Reconnect the suspension valve linkages.

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Toe in adjustment 1. Turn off the engine and access the underside of the vehicle. Measure the unpainted area of each steering cylinder rod (1). The measurement should be 150.813 mm (5.938 in).

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2. Measure the differences between the front and rear tires. • Loop a string around the center mounting bolt of the front right wheel motor (1) . • Wrap the string around the center of the front tire and back along the center of the front tire to the rear tire. • Draw the string tight. Move the string towards the rear tire until the string just barely touches the front tire at point (C) • Measure point (A) at the front edge of the rear tire. • Repeat the process on the left side of the machine and measure point (B). • The point (A) and (B) measurements should be the same, and should be between 12.7 - 25.4 mm (0.5 1.0 in).

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3. If the measurements of the unpainted area of each steering cylinder rod are not equal, or if the point (A) and point (B) measurements are out of the 12.7 25.4 mm (0.5 - 1.0 in) range, you will need to adjust the steering cylinder clevis. 4. Adjust the steering cylinder clevis by loosening the jam nut (1) and then loosening the retaining pin screw (2) in the clevis (3). 5. Turn the cylinder rod out of the clevis. Each full turn of the cylinder rod will change the dimension of points (A) or (B) approximately 25.4 mm (1.0 in). NOTE: Under NO circumstances should the clevis be rotated out more than 5 full turns from the point where the inside base of the clevis is flush with the end of the cylinder shaft. If the clevis is turned out 5 full turns and the 12.7 - 25.4 mm (0.5 - 1.0 in) range has not been reached, bring the range dimensions as close as possible to the specified value. The extended length of the steering cylinder rods must be of equal value. 6. Tighten the jam nuts and retighten the pin retaining screws.

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Steering - Cylinders

Steering cylinder - Service instruction - Four wheel steer, cylinder phasing Four wheel steer cylinder phasing using four wheel steer mode: 1. Start the vehicle and move to flat, level ground. 2. Select four wheel steer (4WS) from the steering selector switch (1).

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3. Turn the steering wheel, right or left, to completely turn the front wheels to the lock position. The 4WS controller will turn the rear wheels to their lock position. 4. Continue to turn the steering wheel in one direction after the wheels have hit the steering stops. 5. This will phase the front cylinder and the controller will phase the rear cylinders by pushing them completely to the end of the cylinderâ&#x20AC;&#x2122;s travel. In this position, the cylinders will bleed oil from the rod to the ram end to phase the cylinders.

Phasing using the CAL mode: 1. Start the vehicle and move to flat, level ground. 2. Select CAL using the steering selector switch (1).

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3. Access the steering diagnostics page. 4. Press the steer left/steer right soft keys of the steering diagnostics page and manually push the rear wheels completely to the end of the stroke. Perform manual steer in each direction. Hold the steer left/steer right button for a period of time after the cylinders have stopped moving in order to phase the cylinders.

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Four wheel steer calibration NOTE: Calibration of the 4WS system has been performed at the factory. Calibration of the system must be performed if a wheel position sensor has been replaced. 5. Immediately after setting the toe, turn on key, Do not start engine 6. From the home screen touch the navigation button. The List screen displays. From the List screen touch the “4 Wheel Steer (FWS)” button (1) in the list, or touch the 4 wheel steer icon (1) on the top of the screen if so equipped. The 4WS page displays.

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7. From the 4WS screen you can calibrate the rear wheels by touching the “Steering Diagnostics” button (1) . The 4 wheel steer calibrate screen displays.

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8. After the wheels are all calibrated, touch the Calibrate Wheels button (1) . This screen will give you the values for the wheel sensors. After touching the calibrate wheels icon, a screen asking â&#x20AC;&#x153;Are you sure you want to calibrate wheels? will come up. Touch yes if you are sure the wheels are square and inline. Touch no if you need to adjust more.

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NOTE: Do not answer yes unless you are sure the wheels are straight (by measurement) and you donâ&#x20AC;&#x2122;t want the current calibration. 9. The system will now look at the wheels as being set to straight front to back. Calibrating of the rear wheels should only be required after a steering system repair. Once the calibration is locked in, there should be no more operator intervention unless a repair has been made. For future reference record the calibration numbers (mv) for the three wheel position sensors. Once the toe for the front wheels is checked and set, reassemble the steer cylinder covers and reconnect the harness to the lights. Reconnect the suspension linkage rods to the suspension valves.

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Steering cylinder - Remove - Four wheel steer hydraulic control components Directional control valve WARNING Electrical shock hazard! Before working on any part of the electrical system, disconnect the battery ground cable. Complete all electrical work before connecting the cable. Failure to comply could result in death or serious injury. W0129A

CAUTION Escaping fluid! Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Before applying pressure, make sure all connections are tight and all components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in minor or moderate injury. C0104A

1. Move the machine to a hard and level surface. 2. Turn the machine key to the “OFF” position. 3. Turn the power to the batteries off by turning the switch attached to the engine panel to the “OFF” position.

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4. Remove the bolts (1) securing the panel to the walkway in order to gain access to the hydraulic control components.

5. Place a clean drain pan underneath the hydraulic fittings on the directional control valve where the lines are to be removed. 47691240 24/02/2015

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6. Tag and mark the electrical connections (1) attached to the solenoids on the directional control valve.

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7. Tag and mark all of the hydraulic hoses (1) attached to the directional control valve.

8. Slowly open and remove all of the hydraulic hoses (1) attached to the directional control valve. 9. Cap and plug all of the hydraulic lines and fittings that were removed from the directional control valve.

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10. Unhook all of the electrical connections (2) attached to the directional control valve.

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11. Remove the mounting bolts, nuts and washers (not shown) securing the directional control valve to the machine and remove the valve from the machine.

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Counterbalance valve 1. Tag and mark all of the hydraulic lines that are connected to the counterbalance valve. 2. Place a clean drain pan underneath the hydraulic fittings on the counterbalance valve where the lines are to be removed. 3. Bottom out the relief. NOTE: The relief should be 211 Kg/cmÂ˛ (3000 psi). 4. Slowly open and remove the four hydraulic lines. (1) from the counterbalance valve being sure to collect all of the residual fluid from the lines and fittings. 5. Cap and plug all of the hydraulic lines and fittings that were removed from the counterbalance valve.

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6. Remove the bolts (1), nuts (2) and washers (3) securing the counterbalance valve and remove the valve from the machine.

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Lock valve 1. Tag and mark the four hydraulic lines attached to the lock valve. 2. Place a clean drain pan underneath the hydraulic fittings on the lock valve where the lines are to be removed. 3. Slowly open and remove the hydraulic lines attached to the lock valve being sure to catch any residual fluid in the remaining in the lines being sure to collect all of the residual fluid in the lines and fittings.

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4. Unhook the electrical connection (1) attached to the solenoid on the lock valve.

5. Remove the bolts (1), nuts (2) and washers (3) securing the lock valve and remove the valve from the machine.

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Steering cylinder - Install - Four wheel steer hydraulic control components WARNING Electrical shock hazard! Before working on any part of the electrical system, disconnect the battery ground cable. Complete all electrical work before connecting the cable. Failure to comply could result in death or serious injury. W0129A

WARNING Escaping fluid! Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Before applying pressure, make sure all connections are tight and all components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in death or serious injury. W0178A

Directional control valve 1. Install the directional control valve (1) into the proper position on the machine.

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2. Install the directional control valve mounting bolts (not shown) securing the directional control valve into position and tighten to the proper specifications.

3. Remove all of the caps and plugs from the hydraulic lines and fittings.

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4. Install the hydraulic lines (1) to the proper fittings on the directional control valve and tighten the fittings to the proper specifications. NOTICE: Do not overtighten the fittings as it could cause a leak or component damage.

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5. Clip the electrical connections (2) into the proper positions on the directional control valve.

6. Remove all of the tagging on the hydraulic hoses and the electrical connections that was applied during removal.

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Counterbalance valve 1. Install the counterbalance valve (1) into the proper position on the machine.

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2. Install the counterbalance valve mounting bolts (1), nuts (2) and washers (3) securing the valve and tighten to the proper specifications.

3. Remove all of the caps and plugs on the hydraulic lines and the fittings on the counterbalance valve. 4. Install the four hydraulic lines (1) into the proper fittings on the valve and tighten the fittings to the proper specifications. NOTICE: Do not overtighten the fittings as it could cause a leak or component damage.

5. Remove all of the tagging on the hydraulic lines that was applied during removal.

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Lock valve 1. Install the lock valve (1) into the proper position on the machine.

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2. Install the lock valve mounting bolts (1), nuts (2) and washers (3) securing the lock valve to the machine and tighten to the proper specifications.

3. Remove all of the caps and plugs on the hydraulic lines and fittings on the valve. 4. Install the hydraulic lines (1) onto the proper fittings on the lock valve and tighten the fittings to the proper specifications. NOTICE: Do not overtighten the fittings as it could cause a leak or component damage.

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5. Install the electrical connection (1) to the proper position on the lock valve.

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6. Remove all of the tagging on the hydraulic lines and the electrical connections that was applied during removal. 7. Install the access panel into the proper position on the walkway and secure tightly with the access panel mounting bolts (1).

8. Turn the power to the batteries on by turning the switch attached to the engine panel to the â&#x20AC;&#x153;ONâ&#x20AC;? position.

9. Start the machine and cycle the hydraulic system multiple times to ensure the proper component functionality.

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Steering cylinder - Remove - Four wheel steer cylinders WARNING Escaping fluid! Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Before applying pressure, make sure all connections are tight and all components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in death or serious injury. W0178A

1. Move the machine to a hard and level surface. 2. Turn the machine key to the “OFF” position. 3. Place the machine into the neutral or float position in order to relieve the pressure within the hydraulic system. 4. Turn the power to the batteries off by turning the switch attached to the engine panel to the “OFF” position.

RAIL14SP00818AA

RAIL13SP05041AA

5. Block the wheels to prevent the machine from rolling during the service of the cylinders. 6. Mark and tag the hydraulic lines (1) on both ends of the cylinder to ensure proper placement of the lines during installation.

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Steering - Cylinders

7. Slowly open and remove the hydraulic line from the fitting (1) on the rod end of the steering cylinder. 8. Cap and plug the hydraulic line and the fitting.

RAIL13SP05041AA

RAIL13SP04983AA

9. Slowly open and remove the hydraulic line from the fitting (2) on the base end of the steering cylinder. 10. Cap and plug the hydraulic line and the fitting.

11. Remove and discard the roll pins (1) from the clevis pin on the base end of the steering cylinder.

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Steering - Cylinders

12. Remove the clevis pin (2) and the washers (1) from the base end of the steering cylinder.

RAIL13SP04983AA

13. Remove the bushing (1) from the mounting plate on the base end of the steering cylinder. NOTE: If the bushing is damaged, discard the bushing.

14. Remove the bolt (not shown), nut (2) and washer (1) securing the clevis pin to the rod end of the steering cylinder.

15. Remove and discard the roll pin (1) securing the other side of the clevis pin on the rod end of the steering cylinder.

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Steering - Cylinders

16. Remove the clevis pin and weldment (1) from the rod end of the steering cylinder.

RAIL13SP04983AA

17. Remove the washer (1) from the rod end of the steering cylinder.

18. Remove the bushing from the mounting plate on the rod end of the steering cylinder. NOTE: If the bushing is damaged, discard the bushing. 19. Remove both ends of the cylinder from the mounting plates and remove the cylinder from the machine.

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Steering - Cylinders

Stop cylinder 1. Mark and tag the hydraulic lines (1) on both ends of the stop cylinder to ensure proper placement during installation.

RAIL13SP05059AA

RAIL13SP04984AA

2. Slowly open and remove the hydraulic line from the fitting (1) on the base end of the stop cylinder.

3. Slowly open and remove the hydraulic line from the fitting (2) on the rod end of the stop cylinder.

4. Remove and discard the cotter pin (1) securing the clevis pin into the base end of the stop cylinder.

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Steering - Cylinders

5. Remove the clevis pin (1) securing the base end of the stop cylinder to the mounting bracket.

RAIL13SP04984AA

6. Remove the washer (1) from the base end of the stop cylinder.

7. Remove and discard the cotter pin (1) securing the clevis pin on the rod end of the stop cylinder.

8. Remove the clevis pin (1) securing the steering block on the rod end of the stop cylinder.

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Steering - Cylinders

9. Push the steering block out (2) of the mounting bracket (1) and remove the stop cylinder from the machine.

RAIL13SP04984AA

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Steering - Cylinders

Steering cylinder - Install - Four wheel steer cylinders CAUTION Escaping fluid! Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Before applying pressure, make sure all connections are tight and all components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in minor or moderate injury. C0104A

1. If necessary, install new bushings (1) into the mounting brackets on both ends of the cylinder.

RAIL13SP04983AA

2. Install the steering cylinder into the proper position on the machine. 3. Install the clevis pin and weldment (1) into the rod end of the cylinder securing the rod end of the steering cylinder onto the mounting plate.

4. Install the washer (1) into place on the clevis pin and weldment already installed into the rod end of the cylinder.

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Steering - Cylinders

5. Install the roll pin (1) into the clevis pin securing the clevis pin into the rod end of the cylinder.

RAIL13SP04983AA

6. Install the bolt (not shown), nut (2) and washer (1) securing the weldment and clevis pin into the rod end of the steering cylinder.

7. Install the clevis pin (1) into the yoke of the base end of the cylinder securing the base end of the cylinder to the mounting bracket.

8. Install the washers (1) into place on the clevis pin on the base end of the cylinder.

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Steering - Cylinders

9. Install the new roll pins (1) into the base end of the steering cylinder securing the clevis pin, washer and base end of the steering cylinder onto the mounting plate.

RAIL13SP04983AA

10. Install the proper hydraulic hose into the fitting (1) on the base end of the steering cylinder. 11. Tighten the fitting to the proper specifications. NOTICE: Do not overtighten the fitting as it could cause a leak or component damage.

12. Install the proper hydraulic line onto the fitting (1) on the rod end of the steering cylinder. 13. Tighten the fitting to the proper specifications. NOTE: Do not overtighten the fitting as it could cause a leak or component damage.

RAIL13SP04983AA

14. Remove all of the tagging that was applied to the hydraulic lines during removal.

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Steering - Cylinders

Stop cylinder 1. Install the stop cylinder into the proper mounting brackets (1) on the machine.

RAIL13SP04984AA

2. Install the clevis pin (1) into the mounting bracket and through the steering block on the rod end of the stop cylinder.

3. Install the new cotter pin (1) into the clevis pin securing the base pin on the rod end of the stop cylinder.

4. Install the clevis (1) pin into the mounting bracket and through the base end of the stop cylinder securing the base end of the cylinder to the mounting bracket.

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Steering - Cylinders

5. Install the washer (1) into place on the clevis pin on the base end of the cylinder.

RAIL13SP04984AA

RAIL13SP05059AA

6. Install the new cotter pin (1) into the clevis pin securing the clevis pin and base end of the stop cylinder to the mounting bracket.

7. Install the proper hydraulic line onto the fitting (1) on the rod end of the stop cylinder. 8. Tighten the fitting to the proper specifications. NOTE: Do not overtighten the fitting as it could cause a leak or component damage.

9. Install the proper hydraulic line onto the fitting (1) on the base end of the cylinder. 10. Tighten the fitting to the proper specifications. NOTE: Do not overtighten the fitting as it could cause a leak or component damage.

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Steering - Cylinders

11. Remove all of the tagging from the hydraulic lines that was applied during removal. 12. Turn the power to the batteries on by turning the switch attached to the engine panel to the â&#x20AC;&#x153;ONâ&#x20AC;? position.

RAIL14SP00818AA

12. Start the machine and cycle both the steering cylinder and the stop cylinder multiple times to ensure the proper functionality of the cylinders. 13. Check the hydraulic system for leaks.

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Index Steering - 41 Cylinders - 216 Steering cylinder - Install - Four wheel steer cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Steering cylinder - Install - Four wheel steer hydraulic control components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Steering cylinder - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Steering cylinder - Remove - Four wheel steer cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Steering cylinder - Remove - Four wheel steer hydraulic control components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Steering cylinder - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Steering cylinder - Service instruction - Four wheel steer, cylinder phasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Steering cylinder - Service instruction - Steering cylinder toe in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404 SERVICE - Technical Publications & Tools

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SERVICE MANUAL Wheels SP.295F SP.300F SP.345F SP.400F

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Contents Wheels - 44

[44.511] Front wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.1 [44.520] Rear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.2

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SP.295F SP.300F SP.345F SP.400F

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Contents Wheels - 44 Front wheels - 511

SERVICE Front wheels Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Wheels - Front wheels

Front wheels - Remove Prior operation: Remove the fenders. Fender - Remove - Front and rear fenders (90.116) 1.

WARNING Heavy object! The following instruction requires two people. Failure to comply could result in death or serious injury. W1270A

WARNING Explosion hazard! Never weld on a wheel. Welding can cause stresses that will cause a wheel to crack or break unexpectedly. Tires can separate explosively during welding. Always have a qualified tire mechanic service wheels and tires. Failure to comply could result in death or serious injury. W0124A

Lift vehicle with a suitable lifting device, following all safety precautions for device. 2. Loosen eight lug nuts (1) and remove.

RAIL13SP03403AA

RAIL13SP03401AA

3. Maneuver tire (2) off wheel studs (3). 4. Set tire aside and secure.

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Wheels - Front wheels

5. Position adequately rated jackstand(s) (4) under edge of leg assembly (5) and release tension on lifting device, lowering leg assembly onto jackstand(s).

RAIL13SP03409AA

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Wheels - Front wheels

Front wheels - Install 1.

WARNING Avoid injury! The component is heavy. Removal/installation requires two persons or a lifting device. Failure to comply could result in death or serious injury. W1141A

Lift the vehicle with suitable lifting device, following all safety precautions for device. Then remove jackstand( s) from under edge of leg assembly. 2. Position new tire (2).

RAIL13SP03378AA

RAIL13SP03405AA

3. Maintain tire in straight up and down position. Install tire onto wheel studs (3) with eight lug nuts (1) or lug bolts.

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Wheels - Front wheels

4. Using appropriate torque wrench, starting with lug nut or lug bolt at 12 o’clock position (6), torque lug nut or lug bolt to 610 N·m (450 lb ft). Torque remaining seven lug nuts or lug bolts in similar fashion, progressing in star-patterned sequence. 5. Re-torque wheel lug nuts or lug bolts to 610 N·m (450 lb ft) after 1 hour of use.

RAIL13SP03408AA

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Index Wheels - 44 Front wheels - 511 Front wheels - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Front wheels - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Wheels - 44 Rear wheels - 520

SP.295F SP.300F SP.345F SP.400F

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Contents Wheels - 44 Rear wheels - 520

SERVICE Rear wheels Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Wheels - Rear wheels

Rear wheels - Remove Prior operation: Remove the fenders. Fender - Remove - Front and rear fenders (90.116) 1.

WARNING Heavy object! The following instruction requires two people. Failure to comply could result in death or serious injury. W1270A

Lift vehicle with a suitable lifting device, following all safety precautions for device. 2. Loosen eight lug nuts (1) and remove.

RAIL13SP03403AA

RAIL13SP03401AA

3. Maneuver tire (2) off wheel studs (3). 4. Set tire aside and secure.

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Wheels - Rear wheels

5. Position adequately rated jackstand(s) (4) under edge of leg assembly (5) and release tension on lifting device, lowering leg assembly onto jackstand(s).

RAIL13SP03409AA

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Wheels - Rear wheels

Rear wheels - Install 1.

WARNING Avoid injury! The component is heavy. Removal/installation requires two persons or a lifting device. Failure to comply could result in death or serious injury. W1141A

Lift the vehicle with suitable lifting device, following all safety precautions for device. Then remove jackstand( s) from under edge of leg assembly. 2. Position new tire (2).

RAIL13SP03378AA

RAIL13SP03405AA

3. Maintain tire in straight up and down position. Install tire onto wheel studs (3) with eight lug nuts (1) or lug bolts.

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Wheels - Rear wheels

RAIL13SP03408AA

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Index Wheels - 44 Rear wheels - 520 Rear wheels - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Rear wheels - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404 SERVICE - Technical Publications & Tools

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SERVICE MANUAL Cab climate control SP.295F SP.300F SP.345F SP.400F

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Contents Cab climate control - 50

[50.100] Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.1 [50.104] Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.2 [50.200] Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.3

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SP.295F SP.300F SP.345F SP.400F

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Contents Cab climate control - 50 Heating - 100

SERVICE Heater control valve Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Cab climate control - Heating

Heater control valve - Remove 1. Move the machine to a hard and level surface. 2. Turn the ignition key to the “OFF” position. 3. Turn off the power to the batteries by turning the switch attached to the engine panel to the “OFF” position.

RAIL14SP00818AA

RAIL13SP04730AA

RAIL13SP04724AA

4. Remove the instructors seat (1) from the interior of the cab in order to access the back panel mounting bolts.

5. Remove the operators seat (1) from the interior of the cab in order to access the back panel mounting bolts.

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Cab climate control - Heating

6. Remove the upper rear panel mounting bolts (1) securing the upper rear panels to the back panel.

RAIL13SP04736AA

RAIL13SP04971AA

7. Remove the left upper rear panel (1).

8. Turn the right rear panel (2) over to access the electrical connections (1). 9. Tag, mark and remove the electrical connections and remove the right rear panel.

10. Remove the floor mat from the interior of the cab.

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Cab climate control - Heating

11. Remove the back panel mounting bolts (1).

RAIL13SP04732AA

RAIL13SP04734AA

RAIL13SP04731AA

12. Remove the back panel (1) from the interior of the cab.

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Cab climate control - Heating

13. Remove the four screws attaching the plenum duct (1) to the evaporator housing. Remove the two screws attaching the inner duct (2) to the plenum duct. 14. Remove the plenum duct from the interior of the cab.

RAIL13SP04975AA

RAIL13SP04977AA

RAIL13SP04978AA

15. Unhook the electrical connection on the front of the water valve.

16. Slide the two hose clamps (1) off of the fitting on the top of the water valve. 17. Remove the heater hose from the fitting on the top of the water valve.

18. Slide the hose clamp (1) off of the fitting on the bottom of the water valve. 19. Remove the heater hose from the fitting on the bottom of the water valve.

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Cab climate control - Heating

20. Remove the screws (1) attaching the water valve (2) to the housing and remove the water valve from the machine.

RAIL13SP04982AA

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Cab climate control - Heating

Heater control valve - Install 1. Install the water valve (1) into the proper position on the evaporator/heater housing (2). 2. Attach the water valve to the housing using the screws.

RAIL13SP04982AA

RAIL13SP04977AA

RAIL13SP04978AA

3. Install the heater hose (1) onto the fitting on the top of the water valve.

4. Slide the hose clamps (1) into position securing the heater hose to the fitting on the top of the water valve.

5. Install the heater hose (1) onto the fitting on the bottom of the water valve.

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Cab climate control - Heating

6. Slide the hose clamp (1) into place on the heater hose securing the heater hose to the fitting on the bottom of the water valve.

RAIL13SP04978AA

RAIL13SP04977AA

RAIL13SP04975AA

7. Reconnect the electrical connection on the front of the water valve.

8. Attach the plenum duct (1) to the top of the evaporator housing and to the inner duct using the screws.

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Cab climate control - Heating

9. Install the back panel (1) into the proper position and secure with the back panel mounting screws (2).

RAIL13SP04731AA

RAIL13SP04732AA

RAIL13SP04734AA

10. Install the floor mat.

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Cab climate control - Heating

11. Install the operators seat (1) in the proper position inside of the machine cab.

RAIL13SP04724AA

RAIL13SP04730AA

RAIL13SP04736AA

12. Install the instructors seat (1) in the proper position inside of the machine cab.

13. Install the left rear panel (1) and secure with the rear panel mounting bolts.

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Cab climate control - Heating

14. Install the electrical connections (1) on the back side of the right rear panel (2).

RAIL13SP04971AA

RAIL13SP04736AA

RAIL14SP00818AA

15. Install the right rear panel (1) and secure with the rear panel mounting bolts.

16. Turn the power to the batteries on by turning the switch attached to the engine panel to the â&#x20AC;&#x153;ONâ&#x20AC;? position.

17. Start the machine and cycle the heater system multiple times to ensure the proper functionality of the water valve.

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Index Cab climate control - 50 Heating - 100 Heater control valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Heater control valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Cab climate control - 50 Ventilation - 104

SP.295F SP.300F SP.345F SP.400F

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Contents Cab climate control - 50 Ventilation - 104

SERVICE Air filter Replace - Charcoal filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Cab climate control - Ventilation

Air filter - Replace - Charcoal filter NOTE: The cab charcoal filter requires changing annually, but can be changed more often if needed. NOTE: The cab charcoal filter is located under the cover panel at the rear left hand side of the cab. 1. Remove the screw knob (1) attaching the cover panel to the cab. Remove the cover panel (2).

RAIL12SP01103AA

RAIL12SP01104AA

2. Remove the screw knob (1) that secures the charcoal filter (2) to the cab. Remove the charcoal filter. 3. Install the new charcoal filter to the cab. Secure in place using the screw knob.

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Index Cab climate control - 50 Ventilation - 104 Air filter - Replace - Charcoal filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Cab climate control - 50 Air conditioning - 200

SP.295F SP.300F SP.345F SP.400F

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Contents Cab climate control - 50 Air conditioning - 200

TECHNICAL DATA Air conditioning General specification - Pressure temperature chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Air conditioning Overview - Troubleshooting using Automatic Temperature Control (ATC) . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Electrical schematic sheet 01 - Manual control schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Electrical schematic sheet 02 - Automatic Temperature Control (ATC) schematic . . . . . . . . . . . . . . . . . . 18

SERVICE Air conditioning Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Air-conditioning compressor Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Compressor drive belt Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Air-conditioning compressor lines Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Receiver/Dryer Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Air-conditioning evaporator Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

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Air conditioning - General specification - Pressure temperature chart 째F -60 -55 -50 -45 -40 -35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35 40 45 50

째C -51.1 -48.3 -45.6 -42.8 -40 -37.2 34.4 31.7 28.9 -26.1 -23.3 -20.6 -17.8 -15 -12.2 -9.4 -6.7 -3.9 -1.1 1.7 4.4 7.2 10

HFC 134a 21.8 20.4 18.7 16.9 14.8 12.5 9.8 6.9 3.7 0.0 1.9 4.1 6.5 9.1 12.0 15.0 18.4 22.1 26.1 30.4 35.0 40.0 45.3

째F 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165

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째C 2.8 15.6 18.3 21.1 23.9 26.7 29.4 32.2 35.0 37.8 40.6 43.3 46.1 48.9 51.7 54.4 57.2 60.0 62.8 65.6 68.3 71.1 73.9

HFC 134a 51.1 57.3 63.9 70.9 78.4 86.4 94.9 103.9 113.5 123.6 134.3 145.6 157.6 170.3 183.6 197.6 212.4 227.9 244.3 261.4 279.5 298.4 318.3

Cab climate control - Air conditioning

Air conditioning - Overview - Troubleshooting using Automatic Temperature Control (ATC) Troubleshooting of the air conditioning system may be performed using the automatic temperature control display. The following procedure details the steps necessary for display of error codes associated with the system. Use the ATC control to access the error code in order to troubleshoot the HVAC system. The control is mounted in the headliner at the upper right hand side of the cab interior.

RAIL12SP01141AA

ATC key descriptions Item 1 2 3 4 5 6 7 8 9

Description Fan speed (increase/decrease) Economy Mode Power Key Display Mode Key Defrost Key Automatic Mode Key Fresh Key (not used) Temperature Key (increase/decrease)

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Error Code Mode 1. With the system turned on, press the PWR and AUTO keys at the same time in order to enter the error code mode. Errors will be displayed on the control panel display. 2. Scroll through any multiple errors by repeatedly pressing the PWR key. 3. The system will exit the error code mode after five seconds and return to normal operation. 4. Refer to the following table for a listing of error codes. Code E0 E1 E2 E3 E4 E5 E6 E11 E12 E13 E14 E15 E16 E17 E18 E19 E20 E21 E22 E23

Description No faults Cab sensor shorted Cab sensor open Evap probe shorted Evap probe open Duct sensor shorted Duct sensor open Pressure transducer open Pressure transducer shorted Water valve actuator error Fresh / Recirc actuator error Charge sensor shorted Charge sensor open Electronics or Comm. error Clutch open Clutch shorted No refrigerant Low refrigerant High pressure Low voltage error

Notes

Not used Not used Not used Not used Not used

Not used Not used Not used

Advanced Diagnostics The advanced diagnostics control panel allows a technician to see real time system information on the control panel display that will assist in air conditioning and heater servicing. The following procedure details the steps necessary for display of advanced error codes associated with the system. 1. From the error code mode, press PWR and AUTO keys at the same time in order to enter the advanced diagnostics mode. The text CAB will be displayed on the control panel. 2. After a few seconds, the cab temperature measurement will be displayed in degrees F or degrees C, depending on which units have been previously selected. 3. Press the PWR key repeatedly to cycle through the available real time diagnostics. 4. Refer to the following table for a listing of advanced diagnostics available. Displayed Code CAB DUCT EVAP HEAT A-C FAN DEF HI-P FRSH COND REF CLUT VOLT

Description Cab air temperature (degrees F or C) Duct air temperature (degrees F or C) Evaporator core temperature (degrees F or C) Water valve command (% of valve open) A-C clutch request (On/Off) Blower fan speed (% of maximum fan speed) Defrost request (On/Off) NOT USED — High side pressure (psig/bar) NOT USED — Fresh/Recirculation door position (% fresh air) Condenser fan request status (On/Off) Not Used — Refrigerant charge level (DC reading: 0 to 255) Compressor clutch current (Amps) System voltage (DC volts) 47691240 24/02/2015

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NOTE: The system may be operated normally while in the advanced diagnostics mode, including changing the temperature set point or changing the blower fan speed, in order to evaluate the response of the system to different settings.

Firmware version 1. To display the firmware version of the control panel and the ECU, from the advanced diagnostics mode press the PWR and AUTO keys at the same time. The text CTRL will be displayed and shortly after the control panel firmware version number will be displayed. 2. Press the PWR key to toggle to the ECU firmware version. 3. The following firmware version information is available: CTRL â&#x20AC;&#x201D; Control panel version. ECU â&#x20AC;&#x201D; ECU version

Exiting the diagnostics mode 1. Press the PWR and AUTO keys at the same time to cycle through the various diagnostics modes and the normal operation mode. Continue pressing the PWR and AUTO keys until the normal set point temperature is displayed to exit the diagnostic mode.

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Additional Troubleshooting The following table lists additional troubleshooting which can be performed for both the heating and cooling systems of the machine. Action Connect power to the Control Panel and verify that all display segments illuminate briefly. Verify that the Control Panel is plugged into the wire harness and press the PWR key. Check to see if wire harness is wired into the vehicle properly. No fan Turn up fan with the Fan UP key. Make sure fan is plugged into wire harness, verify all wiring connections. Verify that the circuit breakers or fuses are intact. If all other functions work properly, replace Electronic Control Unit (ECU). No heat Turn up heat with the Temperature UP key. Use the advanced diagnostics to verify that the water valve is commanded open. Inspect and verify all wiring connections. Verify that any coolant shut off valves on the engine are open Verify that warm coolant is flowing into the heater core by testing the heater hoses. Verify that the valve can shut off completely by setting the controls to the coldest temperature and checking the heater hoses. Inspect and replace the electronic water valve if necessary. Inspect and replace ECU if necessary. No cooling Turn down heat with the Temperature DOWN key and enable the defrost mode. Use the advanced diagnostics to verify that the A/C clutch is requested ON. Verify that the system is fully charged with refrigerant. Verify that voltage is present at the compressor clutch Verify that the correct voltage is present at the clutch relay on the wire harness. Inspect and verify all wiring connections. Inspect the expansion valve, evaporator probe and/or refrigerant pressure switch. Inspect compressor and clutch assembly and replace clutch if necessary. Inspect and replace the ECU if necessary. The system is not controlling Inspect the Cab and Duct Air Temperature sensors. the cab temperature properly Verify that the recirculation vent inlet is not obstructed. Inspect and replace recirculation vent air filter if necessary. Change the setpoint temperature in small increments. Verify that the water valve is working properly (see No Heat) Verify that the flow through the water valve is going in the correct direction. Verify that the compressor clutch is working properly (see No Cooling) The evaporator core is icing up Inspect the Evaporator Temperature Probe. and restricting airflow Verify that the probe is making good contact with the evaporator fins and is not loosely inserted. Reposition the probe and check the core temperature during operation using the advanced diagnostics. Replace the evaporator core if necessary. Symptom No display

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Air conditioning - Dynamic description The air conditioning system equipped on the Guardian sprayer is an orifice tube type system. In the system, the refrigerant is divided into a high pressure side and a low pressure side. The dividing points are the compressor and the orifice tube. In an orifice tube system, the high side begins at the compressor, continues through the condenser, through the receiver/dryer, and ends at the orifice tube. The low side begins where the high side left off at the orifice tube. From there the low side continues through the evaporator, through the accumulator, and ends at the compressor. The following illustration identifies the components of the air conditioning system. The operator controls heating and cooling through the use of either one of two types of control systems: manual control, or Automatic Temperature Control (ATC).

RAIL14SP00043AA

Item 1 2 3 4 5 6 7

Description Compressor Binary switch Condenser Receiver/Dryer Orifice tube Evaporator Accumulator

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System components Compressor The compressor (1) in the system operates as a gas pump. The compressor moves the refrigerant through the system. When restricted, the refrigerant flow creates the pressure differential in the system. The compressor is mounted on the engine, and a drive belt from the engine turns the compressor driveshaft, working the compressor pistons. The movement of the pistons draws the refrigerant in on the low side and pumps it out on the high side. When the compressor runs, it pushes all of the refrigerant in the system at high pressure toward the condenser. At the same time, it pulls all available refrigerant from the evaporator side of the orifice tube. The cycling clutch binary switch, a pressure cycling switch, turns the compressor on and off. The intermittent compressor operation controls the refrigerant flow and pressure.

RAIL13SP05028AA

Compressor

Condenser The condenser (1) is a heat exchanger that is connected to the vehicle cooling package. Refrigerant enters the condenser as hot compressor gas. The compressed gas is much hotter than the outside air and the refrigerant releases its heat to the air rushing past the condenser fins. As the latent heat is released, the refrigerant changes back to a liquid state. The temperature of the refrigerant may remain almost the same, but it is released all of its latent heat and has changed states, back to being a high-pressure liquid.

RAIL13SP00990GA

Condenser

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Receiver / Dryer The receiver/drier (1) contains a desiccant to remove excess moisture away from the refrigerant. Refrigerant flows from the condenser to the receiver/drier. The receiver/drier also stores additional refrigerant until it is needed later when the heat loads increase. The heat load is the amount of heat to be removed from the air. A number of variables affect heat load: ambient temperature, vehicle load, hydraulic component heat, solar heat, and/or engine heat. As heat loads increase, the need for extra refrigerant increases with it. That extra refrigerant is stored in the receiver/drier. From the receiver/drier, the high-pressure liquid refrigerant flows to the orifice tube. When the air conditioning system is opened for servicing, the receiver / dryer must be replaced. The receiver dryer is usually located on the underside of the vehicle frame.

RAIL13SP05025AA

Receiver/Dryer

Orifice tube The orifice tube is a fixed size restricting orifice and is positioned between the high side and the low side of the refrigerant system. The orifice tube creates the pressure differential between the two sides of the system. The orifice tube must flood the evaporator to work properly under all conditions, so it meters a steady flow of refrigerant while the compressor is operating. The orifice tube consists of a filter screen to remove contaminants, and a calibrated tube to meter refrigerant flow. The orifice tube is mounted in the refrigerant line coming from the receiver / dryer and running to the evaporator.

RAIL13SP04974AA

Orifice Tube

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Evaporator The evaporator (1) is located in the evaporator housing (2) , mounted behind the operators seat. The evaporator is a finned, internal core unit that changes warm air to cool air. As the refrigerant passes through the evaporator, most of it changes to a vapor. Warm air flow from the blower motor (3) flows into the evaporator fins, and from there into the cold refrigerant. The refrigerant carries the heat away from the evaporator, cooling the evaporator so it can cool more air. From the evaporator, the refrigerant flows into the accumulator.

RAIL13SP04979AA

Evaporator

Accumulator The accumulator (1) separates the liquid refrigerant from the refrigerant vapor. This prevents liquid refrigerant from getting back to the compressor. The additional liquid remains on hand, for times when the heat load is high. From the accumulator, the low pressure vapor returns to the compressor. Frost build up on the exterior of the accumulator may indicate a problem with the orifice tube.

RAIL13SP05026AA

Accumulator

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Air conditioning control Two styles of control are available for operator control of the air conditioning system: manual control and Automatic Temperature Control (ATC). The two style of controls also control the heating function of the HVAC system.

Manual control The manual control use a simple three switch control panel to direct control of the air conditioning and heating system. The three switches control, fan speed (1) , AC/Heat selection (2) , and temperature control (3).Turning the fan speed control switch increases the fan speed of the blower motors. The AC/Heat selector switch allows for either heating or cooling functioning. The temperature control switch allows temperature setting for the cab interior.

RAIL12SP01140AA

When air conditioning is selected using the manual control, the system is activated. A thermostat (1) , mounted in the evaporator housing (2) , receives a signal from the temperature control switch in order to regulate the AC system for the desired cab temperature. The temperature control switch also controls the operation of the water valve for cab heating.

RAIL13SP04976AA

Thermostat

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Automatic Temperature Control (ATC) The Automatic Temperature Control (ATC) allows the operator to control the HVAC system through the use of an electronic control . Fan speed, temperature, air intake, defrost / defogging, AC and heating and mode are all selectable on the display panel.

RAIL12SP01141AA

Automatic Temperature Control (ATC) panel The ATC system uses an ECU control (1) mounted to the front of the evaporator housing to control cooling and heating operation. When air conditioning is selected and the desired cab temperature is set, the ATC activates and regulates the system using inputs from the air temperature sensor (2) mounted inside the evaporator housing. An evaporator probe (3), also mounted inside the evaporator housing, controls the AC system by monitoring ice formation in the evaporator core. If the probe detects a temperature of 34 Â°F or lower, the ECU sends a signal to disengage the compressor clutch. If a temperature above 37 Â°F is detected than the compressor clutch is engaged. Additionally, the ECU also controls the operation of the water valve (4) for the heating function.

RAIL13SP04979AA

ATC control components

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Binary Switch The Binary switch works in the AC system by sensing pressure on the air conditioning line. The purpose of the binary switch is to send an electrical signal to turn the compressor clutch off when the refrigerant pressure gets too high, to prevent damage to components and catastrophic failure. The binary switch will also keep the compressor from coming on when then the pressure is too low, as when the outside temp is too cold, or if the system has lost its charge. The switch is attached to a tee in the AC line coming from the compressor and running to the condenser.

RAIL14SP00040AA

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Air conditioning - Electrical schematic sheet 01 - Manual control schematic

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RAIL14SP00042AA

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Air conditioning - Electrical schematic sheet 02 - Automatic Temperature Control (ATC) schematic

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RAIL14SP00041AA

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Air conditioning - Charging Field charging 1. Insure all fittings are tight and components installed correctly. 2. Attach manifold gauge set to high and low side service ports. The blue coupler attaches to low pressure charge port and red coupler attaches to high pressure charge port.

RAIL13SP03377AA

3. Attach yellow (center) hose from manifold gauge set to vacuum pump. 4. Attach Thermistor Vacuum Gauge to AC system not at the vacuum pump. The reading at the vacuum pump may not give an accurate indiction of the true vacuum in the AC system. 5. Start vacuum pump. 6. Open both red and blue (high and low side) valves on manifold gauge set. 7. Let vacuum pump run until thermistor vacuum gauge reads 1000 microns. Then run an additional 15 minutes. 8. Close red and blue valves on manifold gauge set. 9. Monitor pressure reading on thermistor vacuum gauge for 10 minutes with vacuum pump off and manifold gauge valves closed. Reading should be between 1000 and 400 microns and should not climb above 1000 microns. 10. If pressure in AC system rises above 1000 microns, the system has a leak and needs to be repaired prior to charging the system. 11. After verifying the system has no leaks, remove thermistor vacuum gauge. 12. Attach yellow hose from manifold gauge set to refrigerant. 13. Place refrigerant tank upside down on charging scale. Yellow hose should be attached and tank valve open. 14. Zero charging scale measurement.

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15. Open red (high side) valve on manifold gauge set and add the factory recommended charge amount 3.40 kg (7.50 lb). Close red valve on manifold gauge set. Charging is complete. Verify proper AC operation. Document total refrigerant added to system and apply appropriate label near compressor stating refrigerant charge amount. 16. If the proper refrigerant charge amount is not known, add one to two pounds of liquid refrigerant to the system through the high side port (red). The amount of refrigerant added depends on the estimated full charge amount. It is typically 1/2 to 3/4 of the estimated full charge. Close red valve on manifold gauge set. This type of refrigerant charging should be done at an ambient temperature of 32째C (90째F) or greater with machine doors open to provide a load on the evaporator. 17. Turn refrigerant tank right side up on charging scale (vapor charge position). 18. Start machine engine and turn on AC system. 19. Record ambient temperature, evaporator inlet temperature, evaporator air outlet temperature, suction pressure, and discharge pressure. 20. If suction pressure is 0.3 bar (5.0 psi) or less, keep engine speed at idle until additional refrigerant has been added and suction pressure exceeds 0.34 bar (5.00 psi). 21. Slowly open blue valve on manifold gauge set and bleed vapor refrigerant into low side of system in small increments of 0.05 - 0.09 kg (0.10 - 0.20 lb). Suction pressure should not exceed 3.4 bar (50.0 psi) while charging vapor into the low side of the system or the compressor can be damaged. 22. Continue to add refrigerant in this manner in small increments until optimum AC performance is achieved. 23. Document total amount of refrigerant added to system and apply appropriate label near compressor stating refrigerant charge amount.

Alternate charging technique 1. Perform Step 1 through Step 20 of the AC field charging procedure. 2. With an infrared thermometer, measure condenser tube temperatures from refrigerant inlet to refrigerant outlet (typically from top to bottom). 3. The temperature will be highest at the refrigerant inlet (superheated region). Then the temperature will decrease to the saturation temperature of the refrigerant at the operating discharge pressure (saturation or condensing temperature). Near the outlet of the condenser, the temperature should once again decrease by roughly 6 - 8 째C ( 10 - 14 째F) below the saturation temperature (sub-cooled region).

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4. If the refrigerant at the out of the condenser is not subcooled by 6 - 8 째C ( 10 - 14 째F) below the saturation temperature, continue to add vapor refrigerant in small increments through the blue (low side) charge port. 5. When 6 - 8 째C ( 10 - 14 째F) of condenser outlet subcooling is reached, verify proper AC operation. 6. Document total refrigerant amount added to system and apply appropriate label near compressor stating refrigerant charge amount.

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Air-conditioning compressor - Remove 1. Move the machine to a hard and level surface. 2. Turn the ignition key to the “OFF” position. 3. Turn the power to the batteries off by turning the switch attached to the engine panel to the “OFF” position. 4. Slide the engine access doors open.

RAIL14SP00818AA

RAIL13SP05028AA

5. Evacuate the air conditioning system. This task should be performed by a trained technician. 6. Remove the air conditioning compressor belt. Refer to Compressor drive belt - Remove (50.200). 7. Tag, mark and remove the two air conditioning lines (1). 8. Cap the two lines that were removed and the two fittings on the compressor.

9. Tag, mark and disconnect the clutch electrical connection (1).

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10. Remove the left-hand nut (1) and bolt (2) securing the compressor to the engine.

RAIL13SP03418AA

11. Remove the right-hand nut (1) and bolt (2) securing the compressor to the engine.

12. Remove the compressor from the engine.

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Air-conditioning compressor - Install 1. Install the air conditioning compressor (1) into the proper position on the engine.

RAIL13SP05028AA

RAIL13SP03418AA

2. Install the left-hand nut (1) and bolt (2) securing the compressor to the engine. 3. Tighten the nut and bolt to the proper specifications.

4. Install the right-hand nut (1) and bolt (2) securing the compressor to the engine. 5. Tighten the nut and bolt to the proper specifications.

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6. Connect the clutch electrical connector (1).

RAIL13SP05028AA

RAIL14SP00818AA

7. Remove the caps and plugs from the air conditioning lines and the compressor fittings. 8. Connect the air conditioning lines (1) to the proper fittings on the compressor. NOTE: Lubricate the O-ring connections for the air conditioning condenser with vacuum pump oil.

9. Any time the air conditioning system is opened the receiver/dryer needs to be replaced. Refer to Receiver/ Dryer - Remove (50.200) and Receiver/Dryer - Install (50.200). 10. Charge the air conditioning system. Refer to Air conditioning - Charging (50.200). 11. Install the compressor drive belt. Refer to Compressor drive belt - Install (50.200). 12. Slide the engine access doors closed. 13. Turn the power to the batteries on by turning the switch attached to the engine panel to the â&#x20AC;&#x153;ONâ&#x20AC;? position.

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14. Operate the air conditioning to ensure the proper functionality of the system.

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Compressor drive belt - Remove 1. Move the machine to a hard and level surface. 2. Turn the machine off and remove the key from the ignition. 3. Turn the power to the batteries off by turning the switch attached to the engine panel to the â&#x20AC;&#x153;OFFâ&#x20AC;? position.

RAIL14SP00818AA

RAIL13SP03413AA

4. Slide the engine access doors open in order to access the air conditioning compressor. 5. Loosen the jam nut (1) on the stud (2).

6. Rotate the stud (2) counterclockwise in order to release the tension on the compressor drive belt (1).

7. Remove the compressor drive belt from the air conditioning compressor. 47691240 24/02/2015

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Compressor drive belt - Install 1. Install the new compressor drive belt into the proper position on the air conditioning compressor.

RAIL13SP03413AA

2. Rotate the stud (1) clockwise to add tension to the belt securing the belt in position. NOTE: There should be little to no play in the belt once the proper tension has been achieved.

3. Tighten the jam nut (1) on the stud securing the stud into the proper position.

4. Close the engine access doors and lock the doors into place using the door locking straps.

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5. Turn the power to the batteries on by turning the switch attached to the engine panel to the â&#x20AC;&#x153;ONâ&#x20AC;? position.

RAIL14SP00818AA

6. Start the machine and check for the proper functionality of the compressor drive belt. NOTE: The belt should be rotating smoothly and quietly within the pulleys.

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Air-conditioning compressor lines - Remove

RAIL13SP04981AA

The illustration above is a reference for the different components of the air conditioning system. It is meant to be used as a guide for service of the air conditioning system but not for component location. Air conditioning reference table: Ref. 1 2 3 4 5 6

Description Compressor High pressure air conditioning line Condenser High pressure air conditioning line Receiver/dryer High pressure air conditioning line

Ref. 7 8 9 10 11

Description Orifice tube location Evaporator Low pressure air conditioning line Low pressure air conditioning line Accumulator

1. Turn the power to the batteries off by turning the switch attached to the engine panel to the â&#x20AC;&#x153;OFFâ&#x20AC;? position. 2. Slide the engine access doors open.

RAIL14SP00818AA

3. Discharge the air conditioning system. This task should be performed by a certified technician.

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4. Anytime the air conditioning system is opened, the receiver/dryer should be replaced. Refer to Receiver/ Dryer - Remove (50.200) and Receiver/Dryer - Install (50.200). 5. Tag and mark all of the air conditioning lines. 6. Cut the cable ties as necessary to gain access to the air conditioning lines. 7. Remove the high pressure air conditioning line (1) running from the compressor located in the engine compartment to the condenser connected to the cooling package.

RAIL13SP05028AA

RAIL13SP05025AA

RAIL13SP04738AA

8. Remove the high pressure air conditioning line running from the condenser to the receiver/dryer (1) located on the underside of the sprayer.

9. Remove the high pressure air conditioning line running from the receiver/dryer to the orifice tube connection (1) located in the cab. Remove the orifice tube with a pair of angled needle nose pliers if necessary. NOTE: To access this fitting the left rear panel will need to be removed.

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10. Remove the low pressure air conditioning line (1) running from the evaporator, located in the cab, to the accumulator, located on the under side of the sprayer.

RAIL13SP05026AA

RAIL13SP05028AA

11. Remove the low pressure air conditioning line (1) running from the accumulator to the compressor.

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Air-conditioning compressor lines - Install

RAIL13SP04981AA

The illustration above is a reference for the different components of the air conditioning system. It is meant to be used as a guide for service of the air conditioning system, not for component location. Air conditioning reference table: Ref. 1 2 3 4 5 6

Description Compressor High pressure air conditioning line Condenser High pressure air conditioning line Receiver/dryer High pressure air conditioning line

Ref. 7 8 9 10 11

Description Orifice tube location Evaporator Low pressure air conditioning line Low pressure air conditioning line Accumulator

1. Install the low pressure air conditioning line (1) running from the compressor in the engine compartment to the accumulator on the under side of the machine.

RAIL13SP05028AA

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2. Install the low pressure air conditioning line (1) running from the accumulator to the evaporator located in the cab.

RAIL13SP05026AA

RAIL13SP04738AA

RAIL13SP05025AA

3. If necessary, install the orifice tube in the proper position inside of the connection (1) between the evaporator and the high pressure line running to the receiver/dryer.

4. Install the high pressure air conditioning line running from the receiver/dryer (1) to the condenser that is connected to the cooling package.

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5. Install the high pressure air conditioning line (1) running from the condenser to the compressor located in the engine compartment.

RAIL13SP05028AA

RAIL14SP00818AA

6. Replace all of the cable ties that were cut during the removal of the air conditioning lines. 7. Charge the air conditioning system to 2.5 kg (5.5 lb). This task should be performed by a certified technician. 8. Slide the engine access doors closed and lock the doors using the door locking straps. 9. Turn the power to the batteries on by turning the switch attached to the engine panel to the â&#x20AC;&#x153;ONâ&#x20AC;? position. 10. Operate the engine to check for the proper functionality of the air conditioning system.

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Receiver/Dryer - Remove 1. Move the machine to a hard and level surface. 2. Shut the machine off and remove the key from the ignition. 3. Turn the power to the batteries off by turning the switch attached to the engine panel to the â&#x20AC;&#x153;OFFâ&#x20AC;? position.

RAIL14SP00818AA

RAIL13SP05025AA

4. Evacuate the air conditioning system. This task should be performed by a trained technician. 5. Locate the receiver/dryer on the underside of the machine.

6. Loosen the fittings and remove the two air conditioning lines (1) running to either side of the receiver/dryer. 7. Plug the two lines that were removed from either side of the receiver/dryer.

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8. Loosen the two hose clamps (1) securing the receiver/ dryer to the machine. 9. Remove the receiver/dryer from the hose clamps and remove from the machine.

RAIL13SP05025AA

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Receiver/Dryer - Install 1. Install the receiver/dryer into the proper location within the hose clamps on the under side of the machine.

RAIL13SP05025AA

2. Tighten the hose clamps (1) securing the receiver/dryer to the machine.

3. Remove the plugs from the two air conditioning lines that were installed during removal. 4. Install the two air conditioning lines to the proper fittings on the receiver/dryer. 5. Tighten the fittings to the proper specifications.

6. Charge the air conditioning. This task should be performed by a trained technician.

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7. Turn the power to the batteries on by turning the switch attached to the engine panel to the â&#x20AC;&#x153;ONâ&#x20AC;? position.

RAIL14SP00818AA

8. Cycle the air conditioning system multiple times to ensure the proper component functionality.

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Air-conditioning evaporator - Remove 1. Move the machine to a hard and level surface. 2. Turn the ignition key to the “OFF” position. 3. Turn off the power to the batteries by turning the switch attached to the engine panel to the “OFF” position.

RAIL14SP00818AA

RAIL13SP04730AA

RAIL13SP04724AA

4. Evacuate the air conditioning system. This task should be performed by a trained technician. 5. Remove the instructors seat (1) from the interior of the cab in order to access the back panel mounting bolts.

6. Remove the operators seat (1) from the interior of the cab in order to access the back panel mounting bolts.

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7. Remove the upper rear panel mounting bolts (1) securing the upper rear panels to the back panel.

RAIL13SP04736AA

RAIL13SP04971AA

8. Remove the left upper rear panel (1).

9. Turn the right rear panel (2) over to access the electrical connections (1). 10. Tag, mark and remove the electrical connections and remove the right rear panel.

11. Remove the floor mat from the interior of the cab.

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12. Remove the back panel mounting bolts (1).

RAIL13SP04732AA

RAIL13SP04734AA

RAIL13SP04731AA

13. Remove the back panel (1) from the interior of the cab.

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14. Remove the four screws attaching the plenum duct (1) to the evaporator housing. Remove the two screws attaching the inner duct (2) to the plenum duct. 15. Remove the plenum duct from the interior of the cab.

RAIL13SP04975AA

RAIL13SP04968AA

RAIL13SP04976AA

RAIL13SP04978AA

16. Remove the front cover mounting bolts securing the front cover (2) to the blower/evaporator housing (1) and remove the front cover.

17. Disconnect the electrical harness connection attached to the evaporator housing. Disconnect the electrical connection attached to the thermostat. Remove the thermostat (1) from the housing.

18. Disconnect the hose connections attached to the evaporator and the heater core.

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19. Loosen the fitting (1) on the supply line containing the orifice tube. 20. Gently separate the supply line at the fitting pushing the two ends apart.

RAIL13SP04738AA

RAIL13SP04974AA

RAIL13SP04977AA

21. With a pair of angled needle-nose pliers, slide the orifice tube out of the supply line. NOTE: Be sure to note the orientation of the orifice tube to ensure proper installation.

22. Disconnect the hose connections and the electrical harness connections attached to the water valve (1).

NOTE: When removing the hoses from the fittings, residual fluid may drain out. 23. Remove the screws attaching the water valve to the evaporator housing. 24. Remove the evaporator from the evaporator housing.

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Cab climate control - Air conditioning

HVAC components â&#x20AC;&#x201D; Premium SprayView Cab 1. The Premium SprayView cab has additional components attached to the evaporator housing. The components are an evaporator probe (1), an air temperature probe thermistor (2), and an AC ECU module (3) 2. Remove the evaporator probe at the electrical connection and remove from the evaporator housing.

RAIL13SP04979AA

RAIL13SP04980AA

RAIL13SP05026AA

3. Remove the air temperature probe (2) by disconnecting the electrical connection from the front of the probe. 4. Remove the mounting clip (1) from the back of the air temperature sensor and remove the probe from the mounting bracket (3).

5. Remove the AC ECU from the front panel of the evaporator housing by removing the screws attaching the ECU to the panel.

Accumulator removal: 1. Locate the accumulator on the under side of the machine along the frame rail.

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2. Tag, mark and remove the two air conditioning lines attached to either side of the accumulator.

RAIL13SP05026AA

RAIL13SP05027AA

3. Loosen the two hose clamps (1) securing the accumulator in position on the frame rail. 4. Slide the accumulator out of the loosened hose clamps and remove the accumulator from the machine.

Binary switch removal 5. Open the engine belly door and access the binary switch (1) located near the electrical power junction (2). 6. Disconnect the electrical connector attached to the binary switch. 7. Cut the cable ties securing the binary switch in place. Remove the switch from the line.

Next operation: Install the air conditioning evaporator Air-conditioning evaporator - Install (50.200).

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Air-conditioning evaporator - Install 1. Place the air conditioning evaporator (1) into the proper position in the lower housing.

RAIL13SP04979AA

RAIL13SP04977AA

RAIL13SP04974AA

2. Attach the water valve (1) to the evaporator using the screws and tighten securely.

3. Connect the hose connections (1) and the electrical harness connections to the water valve.

4. Install the orifice tube into the supply line. Ensure the proper orientation of the orifice into he line. Tighten the connection.

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5. Tighten the connection of the lines.

RAIL13SP04738AA

RAIL13SP04978AA

RAIL13SP04976AA

6. Install the return and supply lines to the evaporator/ heater core. Tighten the connections.

7. Install the thermostat into the evaporator housing. Connect the electrical connector to the thermostat.

8. If the machine is equipped with a SprayView cab, proceed to step 4.

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HVAC components â&#x20AC;&#x201D; Premium SprayView Cab 1. Install the air temperature probe (1) into the mounting bracket and secure into position using the mounting clip (2). 2. Connect the electrical connection to the air temperature probe.

RAIL13SP04980AA

RAIL13SP04979AA

3. Install the evaporator probe (1) into the evaporator housing by connecting the probe to the electrical connector.

3. Attach the front cover (1) onto the evaporator housing using the screws. 4. Connect the electrical harness to the AC ECU (2) mounted on the front of the front panel.

RAIL13SP04968AA

RAIL13SP04975AA

Evaporator install â&#x20AC;&#x201D; SprayView and Premium and cabs 1. Attach the plenum duct (1) to the top of the evaporator housing and to the inner duct using the screws.

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2. Install the back panel (1) into the proper position and secure with the back panel mounting screws (2).

3. Install the floor mat.

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RAIL13SP04731AA

RAIL13SP04732AA

RAIL13SP04734AA

Cab climate control - Air conditioning

4. Install the operators seat (1) in the proper position inside of the machine cab.

RAIL13SP04724AA

RAIL13SP04730AA

RAIL13SP04736AA

5. Install the instructors seat (1) in the proper position inside of the machine cab.

6. Install the left rear panel (1) and secure with the rear panel mounting bolts.

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7. Install the electrical connections (1) on the back side of the right rear panel (2).

RAIL13SP04971AA

RAIL13SP04736AA

RAIL13SP05027AA

8. Install the right rear panel (1) and secure with the rear panel mounting bolts.

Binary switch installation 9. Install the binary switch (1) in to the high pressure line of the system. The switch location is near the electrical junction area (2) 10. Secure the switch in place using cable ties located on either side of the switch. 11. Connect the electrical connector to the binary switch.

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Accumulator installation: 1. Slide the accumulator (1) into the proper position inside of the loosened hose clamps (2).

RAIL13SP05026AA

2. Tighten the hose clamps (1) around the accumulator to secure it in place along the frame rail.

3. Install the two air conditioning lines (1) into the proper fittings on the accumulator and tighten the fittings. 4. Remove all tagging from the air conditioning lines.

5. Charge the air conditioning system. This task should be performed by a certified technician. Refer to Air conditioning - Charging (50.200). 6. Any time the air conditioning system is evacuated, the receiver/dryer should be replaced by a certified technician prior to charging the system. Refer to Receiver/ Dryer - Remove (50.200) and Receiver/Dryer - Install (50.200).

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7. Turn the power to the batteries on by turning the switch attached to the engine panel to the â&#x20AC;&#x153;ONâ&#x20AC;? position.

RAIL14SP00818AA

8. Operate the air conditioning to ensure the proper functionality of the system.

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Index Cab climate control - 50 Air conditioning - 200 Air conditioning - Electrical schematic sheet 02 - Automatic Temperature Control (ATC) schematic . . . . . . . . . . . 18 Air conditioning - Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Air conditioning - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Air conditioning - Electrical schematic sheet 01 - Manual control schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Air conditioning - General specification - Pressure temperature chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Air conditioning - Overview - Troubleshooting using Automatic Temperature Control (ATC) . . . . . . . . . . . . . . . . . . . 4 Air-conditioning compressor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Air-conditioning compressor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Air-conditioning compressor lines - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Air-conditioning compressor lines - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Air-conditioning evaporator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Air-conditioning evaporator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Compressor drive belt - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Compressor drive belt - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Receiver/Dryer - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Receiver/Dryer - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

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CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404 SERVICE - Technical Publications & Tools

47691240 24/02/2015 EN

SERVICE MANUAL Electrical systems SP.295F SP.300F SP.345F SP.400F

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Contents Electrical systems - 55

[55.000] Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 [55.015] Engine control system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 [55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 [55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 [55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6 [55.640] Electronic modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7 [55.050] Heating, Ventilation, and Air-Conditioning (HVAC) control system. . . . . . . . . . . . . . . . . . . 55.8 [55.047] Steering control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.9

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Electrical systems - 55 Electrical system - 000

SP.295F SP.300F SP.345F SP.400F

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Contents Electrical systems - 55 Electrical system - 000

FUNCTIONAL DATA Electrical system Overview - Electrical power distribution, fuses and relays, sensing systems . . . . . . . . . . . . . . . . . . . . . . . . 3 Overview - Onboard control system diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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Electrical system - Overview - Electrical power distribution, fuses and relays, sensing systems The electrical power distribution system includes the system batteries, fuses, relays, resistors, and dongles, grounding, starting system, and system sensing. Electrical power distribution begins at the batteries and is routed to the positive (+) jumper post, and to the starter motor. From the jumper post, power is routed to the battery disconnect switch. From the disconnect switch the battery power is branched off to each of the 200 Amp relays, the auxiliary fuse panel, and to the positive (+) remote battery terminal. From the starter the battery power is routed to the alternator excitation cable connected to the alternator.

RAIL15SP00357FA

Item 1 2 3 4 5 6 7 8 9

Description Relay — 200 Amp Relay — 200 Amp DEF Fuse panel Module — MVEC, front Auxiliary fuse panel Module — XIO2 Module — MVEC, rear Module — MC2 Module — XS2

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Batteries Three batteries supply power to the vehicle. Two batteries are for the primary starting circuit, one battery is for the vehicle electronics. The batteries are hybrid style with high temperature flooded epoxy bonded plates. Battery rating is 12 volts at 1000 cold cranking amps. The batteries are connected in parallel.

RAIL15SP00341FA

Battery combiner The battery combiner is utilized to separate the electrical power used for the electronics on the vehicle from the cranking power needed to start the vehicle.

RAIL15SP00358AA

A benefit of the battery combiner is all of the electronic power is fed from battery one and the other two engine cranking batteries are isolated. There is also no voltage to the electronic circuits when the engine is starting. There should never be a dead battery due to the built-in jump starting feature of the switch. Additionally, the vehicle will have full use of all three batteries, both feeds and charging. The battery combiner opens its contacts when voltage drops below 12.7 V (Engine is turned off). The combiner closes when it senses voltage above 13.1 V engine running and (alternator charging) all 3 batteries. Combiner opens contacts during the engine start sequence (from relay 4 in engine panel) to pin 3 of plug #EN732 using battery # 2 and # 3 to crank. Combiner closes contacts when manual switch is engaged to assist in starting should a battery drain down occur (Dome light, console, etc. left on).

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Jumper posts The battery jumper terminals are located on the bottom side of the rear frame, next to the batteries. The positive jumper terminal (1) is connected to the positive post on the second battery, and the to the battery combiner switch. The negative jumper post (2) is connected to the negative post on the second battery and to the negative post on the third battery.

RAIL14SP01018AA

FUSES, RELAYS, RESISTORS, and DONGLES The fuse and relays of the power distribution system include two 200 Amp relays, one 100 Amp relay, two multiplexing vehicle electrical centers (MVEC) modules, in-line fuse links, auxiliary fuse panel, lighting relays and resistors, grid heater resistor, and dongles.

100 and 200 amp relays There are two 200 amp relays connected to the power distribution system. One 200 amp relay feeds power from the battery disconnect switch to the cab harness, the lower MVEC and the upper MVEC. The other 200 amp relay feeds power from the 100 amp starter relay of the starter motor to the engine grid heater.

RAIL15SP00342AA

Multiplexing Vehicle Electrical Center (MVEC) Each of the MVEC’s contain relays and fuses for various circuit paths leading to system components. Each of the MVEC’s contain 16 fuses and 8 relays. Eight of the fuses feed relays, while the other 8 fuses go straight through The relays are CAN Bus controlled and diagnostics are available for the fuses and relays on the chassis panel display. The MVEC’s are each unique and cannot be interchanged.

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RAIL14SP00099JA

The lower / rear MVEC fuse panel (1) is located in the electrical enclosure just below the engine.

RAIL14SP00809AA

The upper / front MVEC (1) is located at the left rear corner of the cab behind a removable panel.

RAIL14SP00078AA

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Fuse configurations for the upper and lower MVECâ&#x20AC;&#x2122;s are shown in the following illustrations.

RAIL14SP00097JA

Front/Upper Multiplexing Vehicle Electrical Center (MVEC) configuration

RAIL14SP00098JA

Rear/Lower Multiplexing Vehicle Electrical Center (MVEC) 47691240 24/02/2015

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Electrical systems - Electrical system

In-Line Fuses A number of in-line replaceable fuses (1) are present in the electrical power distribution circuit. The fuses are located in line of the designated cable. The following illustration and table identify the fuse sizes and locations of the in-line fuses.

Item 1 2 3 4 5 6

Fuse Size 100 Amp 125 Amp 50 Amp 80 Amp 80 Amp 200 Amp

200 200 200 200 200 200

RAIL14SP00070AA

RAIL15SP00340FA

Cable connection amp relay to Remote Battery Terminal Amp Relay to Front/Upper MVEC Amp Relay to Rear/Lower MVEC Amp Relay to cab harness connector Amp Relay to cab harness connector Amp Relay to Engine Grid Heater

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Auxiliary fuse panel The auxiliary fuse panel (1) is mounted next to the rear MVEC inside the electrical enclosure. One side of the fuse panel functions battery powered circuits, the other side functions keyed power circuits. Diagnostics are not available for the fuses on the chassis panel display.

RAIL14SP00809AA

The following illustration and table describes fuse function, fuse size, and battery or keyed power indications of the auxiliary fuse panel.

RAIL14SP00100JA

Fuse position A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 C1 C2 C3 C4 C5 C6

Power source Battery Power Battery Power Battery Power Battery Power Battery Power Battery Power Battery Power Battery Power Battery Power Battery Power Keyed Power Keyed Power Keyed Power Keyed Power Keyed Power Keyed Power

Fuse size 10 Amp 10 Amp 10 Amp 25 Amp 10 Amp 10 Amp 10 Amp 10 Amp 10 Amp 10 Amp 30 Amp 30 Amp 10 Amp 10 Amp 10 Amp 10 Amp

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Function Constant Power 1 & 2 Constant Power 3 & 4 Radio Power Head/Dome Light Stalk Power 12 volt Ignition 12 volt feed Constant Power â&#x20AC;&#x201D; Computer ECU/Clock Power Display Constant Power Station Light HC Power 1 HC Power 2 Product Valve 12 volt Boom Valve 12 volt Foamer Motor Power Indicator Light +

Electrical systems - Electrical system

Engine fuse and relay panel There is a fuse and relay panel associated with the Def system and engine starting. A fuses / relay panel (1) is mounted adjacent to the DEF pump module (2) . The panel includes four relays and four fuses. The function of the DEF relays and fuses is to provide control and power for the DEF pump and heated lines as related to engine starting.

RAIL15SP00356AA

RAIL15SP00355BA

DEF Fuse/Relay Panel Item Relay 1 Relay 2 Relay 3 Relay 4 Fuse 1 Fuse 2 Fuse 3 Fuse 4

Description Ignition and exhaust senders DEF supply module DEF heaters Starter lock out, Neutral start switch 5 AMP, Ignition key 10 AMP, Exhaust sensors 15 Amp, DEF Supply module 15 AMP, DEF Line heaters

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Lighting Relays and Resistors Front boom sprayers use two, dual element bulbs for high beam and low beam headlights.

RAIL14SP00095JA

To control the high and low beam lights, there are two relays (1) outside the cab under the cover in the right rear corner.

RAIL14SP00067AA

When low beams are selected by the operator using the stalk switch on the steering column, the low beam relay will supply 12 volts to pin number 1 of the connector CM116. high beams are selected, the high beam relay will provide 12 volts to pin number 2 of connector CM116.

RAIL14SP00103JA

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Attached to the upper frame rail, just forward of the engine bay, is a resistor pack (1) . The resistor pack is used to prevent the overhead warning lamp panel from flickering the lamps. When the resistors are not attached, the lamps can flicker, giving the operator the impression that something is wrong. With the resistor pack installed, the lamps have to be fully on before they will illuminate. These are referred to as current bleed resistors.

RAIL14SP00074AA

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Electrical systems - Electrical system

Egress lighting module The egress lighting module (1) controls the egress lighting connections and timing. The module is located at the rear left hand side of the vehicle, adjacent to the battery combiner switch. The egress lighting is activated by the push button switch located below the battery disconnect switch. Egress lights are located on the exterior of the vehicle at the side of the fuel tank, and at the left rear exterior corner of the vehicle cab. An additional egress light is mounted to the boarding ladder. To activate the egress lighting on the platform and the ladder, the dome light switch must be in the auto position. Egress lighting will activate after the door is closed and will stay lit for 3 minutes.

RAIL14SP01093AA

Grid Heater Resistor A ceramic resistor (1) is included in the grid heater relay circuit. The rating of the resistor is 33 ÎŠ, 5 W. The resistor is located just froward of the engine bay, above and to the left of the XI02 module. The resistor prevents the uncontrolled activation of the grid heater.

RAIL14SP00065AA

Dongles A dongle is a diode pack. Diodes are semi-conductors, they consume some voltage to open the gate to allow current to pass through the circuit. Diodes only pass current in one direction. A dongle (1) is attached to the vehicle along the right frame rail under the cab near the super node connector CM105 . The dongle has been added to the vehicle to aid third party control of the fence row function.

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Electrical systems - Electrical system

RAIL14SP00059AA

The dongle near connector CM105 is a six pin diode pack which actually has five diodes and a common pin C. If power is fed in on pins A, B, D, E, or F it will pass out through C.

RAIL14SP00110AA

Sprayers equipped with third party control have 3 additional dongles on the boom harness. The dongles are located along the right boom arm.

RAIL14SP00111AA

Pump Dump Dongle A pump dump dongle (1) is attached to the vehicle near the XI02 module. The pump dump dongle prevents the uncontrolled activation of the pump dump.

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Electrical systems - Electrical system

RAIL14SP00057AA

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Electrical systems - Electrical system

GROUNDING SYSTEM Electrical grounding for the vehicle starts at the grounding distribution point grounding stud located inside the frame tube directly under the left hand rear cab corner.

RAIL15SP00343FA

Item 1 2 3 4 5

Description Starter motor ground Rear frame grounding Engine ground Front frame grounding Cab ground harness

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Electrical systems - Electrical system

The starter ground runs from the battery to the starter (1)

RAIL14SP00077AA

The grounding distribution point grounding stud (1) is located inside the frame tube directly under the left hand rear cab corner.

RAIL14SP00049AA

The engine ground (1) is attached to the engine and runs to the rear grounding stud.

RAIL14SP00061AA

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Electrical systems - Electrical system

The front frame ground (1) is a ground stud located below the left hand rear corner of the cab, inside of the main frame â&#x20AC;&#x153;Câ&#x20AC;? channel. A ground cable runs from the rear ground stud to the front stud. The cab ground harness is attached to the front frame ground stud.

RAIL14SP00066AA

The cab ground harness is attached to the cab ground mounting panel (1) which is located in the compartment at the left rear of the cab, under the removable panel. The ground mounting panel is a solid copper rectangle. The harness is then attached to the cab right rear corner harness connection panel.

RAIL14SP00051AA

The Cab ground harness is attached to the cab right hand rear harness connection panel. The ground connector (1) is labeled CB276 on the electrical schematic.

RAIL14SP00050AA

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Electrical systems - Electrical system

There is a ring terminal ground on the front side of the shuttle valve. To locate the ground wire, lift the rubber curtain on the front side of the engine bay.

RAIL14SP00076AA

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Electrical systems - Electrical system

STARTING CIRCUIT The start system begins with a 12 volt feed into the ignition switch. When the key is turned, the 12 volt signal runs from the cab harness to the neutral start switch and the neutral start relay. From the relay the 12 volt signal runs to the auxiliary fuse panel. From the fuse panel the 12 volts runs to the battery combiner switch and to the starter relay to initiate engine cranking.

RAIL14SP00107AA

Item 1 2 3

Description Starter Motor Power cable from 100 Amp Relay Ground Cable

Refer to the following illustration for circuit path of the starting system.

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Electrical systems - Electrical system

RAIL15SP00319HA

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Electrical systems - Electrical system

There is a neutral start switch (1) attached to the hydrostatic pump of the vehicle.

RAIL14SP00072AA

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Electrical systems - Electrical system

SYSTEM SENSING The sensing system of the vehicle includes fuel level, intake air restriction, brake light pressure, flow meter, and grid heater. Additionally, hydraulic charge pressures, oil temperature, case drain and main filter pressures are also monitored through the sensing system.

Fuel Level A fuel level float attached to the fuel tank monitors the level of fuel in the tank. The fuel level float has a range of 30 Ω when full to 240 Ω when the tank is empty.

RAIL14SP00102JA

A 5 volt feed coming from the MC2 controller enters a 120 Ω, 0.4 W resistor, which in turn sends the fuel level signal from the fuel level sensor back to the MC2 to be displayed on the chassis monitor. The fuel level resistor (1) is located along the left frame rail, just under the cab.

RAIL14SP00064AA

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Electrical systems - Electrical system

Air Filter Restriction Indicator An air filter restriction indicator (1) is attached to the air filter housing. The restriction indicator senses the air flow through the air intake of the filter housing. When the air filter becomes dirty air flow through the air cleaner drops. This drop in air flow causes the indicator to send a signal to the chassis display alerting the operator to change the filter or to look for any obstruction in the housing. When a restriction has been cleared from the system the restriction indicator must be reset by pressing in the yellow button on the indicator.

RAIL14SP00062AA

Brake light pressure switches There are two brake light pressure switches on the vehicle. One of the brake light pressure switches is located on the shuttle valve (1) . This switch has a rating of 12 volts, 750 PSI. This switch turns on the brake lights when the vehicle is slowing down.

RAIL14SP00052AA

A second brake light pressure switch (2) is attached to the service brake valve outlet. The switch has a rating of 12 volts and is normally open. When the operator uses the service brake, the switch closes, with the increase of pressure, causing the brake lights to turn on.

RAIL14SP00075AA

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Electrical systems - Electrical system

Flow Meter Product flow through the system is monitored by two sensors, one sensor on the product flow control valve, and the other on the flow meter (2) . The signal sent from these sensors display the product flow on the chassis display.

RAIL14SP00073AA

RAIL14SP00063AA

In order to attach Raven system monitor, there are four harness adapters available for conversion of both the flow meter and the flow control valve. The flow meter harness adaptors either convert a round 3 pin Connexall connector to a rectangular Deutsch connector to allow an older flow meter to be installed on a newer machine, or converts a rectangular Deutsch to a 3 pin round Connexall connector allowing a new flow meter to be installed onto an older vehicle. The flow control valve harness adaptors either converts a 2 position bullet connector to a rectangular Deutsch connector allowing an older flow control valve to be installed on a newer series vehicle, or converts a rectangular Deutsch connector to a 2 position bullet connector to allow for a new control valve to be installed into an older vehicle.

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Electrical systems - Electrical system

Hydraulic System Sensing The hydraulic sensing system includes the case drain filter sensor, the main hydraulic filter sensor, the hydraulic oil level sensor, the hydraulic oil temperature sensor, Charge Pressure sensors, and the brake pressure switches.

Case filter, Main hydraulic filter, and Hydraulic oil level and temperature sensors A case drain return filter sensor (1) is attached to the hydraulic oil tank case drain filter assembly housing. The sensor has a rating of 1.52 bar (22.00 psi) at 12 V. When flow through the sensor reaches the close set point, a signal is sent to the chassis display monitor to activate a filter status alarm. The main hydraulic filter sensor (2) is attached to the tank return filter assembly housing. the sensor has a rating of 2.41 bar (35.00 psi) at 12 V. When flow through the sensor reaches the close set point, a signal is sent to the chassis display monitor to activate a filter status alarm. The hydraulic oil level sensor (3) is attached to the hydraulic oil tank. The sensor has a rating of 12 V. When the sensor reaches the close set point, a signal is sent to the chassis display monitor to activate a low oil level alarm. The hydraulic oil temperature sender (4) is located on the back of the hydraulic reservoir. The sensor has a rating of 5 V. When the sensor detects an out of ranges temperature of the hydraulic oil, a signal is sent to the chassis display monitor to activate a high oil temperature alarm.

RAIL15SP00344FA

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Electrical systems - Electrical system

Charge pressure sensor There are three hydraulic charge pressure sensors attached to the vehicle. Two charge pressure sensors are attached, one each, to the hydrostatic pump filter heads. The third sensor is mounted to the shifting valve. Charge pressure sensors 1 (1) and 2 (2) are mounted to the front and rear hydrostatic pumps. These two sensors each have a rating of 5 V. A range of 0.5 - 4.5 V is displayed on the chassis monitor. The two sensor report the Charge Pressure 1 and 2 of the system on the chassis monitor.

RAIL15SP00073AA

The third charge pressure sensor (3) is attached to the shifting valve. The sensor has a rating of 5 V. A range of 0.5 - 4.5 V. The charge pressure reading is displayed on the chassis monitor. The sensor reports the Charge Pressure 3 of the system.

RAIL14SP00055AA

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Electrical systems - Electrical system

Park brake pressure switch The park brake pressure switch attached to the shifting valve. Two different switches are used depending upon the vehicle model number. On model numbers SP.295F and SP.300F the brake pressure switch (1) has a rating of 180 psi at 12 V.

RAIL14SP00055AA

On model numbers SP.345F and SP.400F the brake pressure switch (2) has a rating of 20 bar (287 psi) at 12 V

RAIL14SP00054AA

The park brake pressure switch sends a signal to the overhead side display panel indicating park brake status.

RAIL12SP01126AA

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Electrical systems - Electrical system

Electrical system - Overview - Onboard control system diagnostics An onboard control systems diagnostics package is present in the Guardian sprayers. The diagnostic can be accessed through the use of the chassis display monitor. To access the diagnostics information for a particular system, press the navigation icon (1) on the Home screen of the chassis display monitor. The List screen will display (2) . From the List screen, select the appropriate system item to display the specific values related to system diagnostics.

RAIL14SP00780AA

RAIL14SP00802AA

The following list screen selections, related to system diagnostics, are described.

Hydraulics screen From the home screen touch the navigation icon. The List screen displays. From the list screen touch the â&#x20AC;&#x153;Hydraulicsâ&#x20AC;? button (1), or touch the hydraulics icon (2) in the upper right corner of the screen. The Hydraulics screen displays.

RAIL14SP00802AA

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Electrical systems - Electrical system

The hydraulic system operating conditions are displayed. The Hydraulics screen is a monitoring screen only and has no selectable features.

RAIL14SP00813AA

RAIL14SP00802AA

RAIL14SP00797AA

Engine screen From the home screen touch the navigation icon. From the list screen touch the â&#x20AC;&#x153;Engineâ&#x20AC;? button (1), or touch the engine icon (2) on the left side of the screen. The engine screen displays.

The engine screen will display the operating conditions of the engine. Additionally, the engine screen contains the Active Faults (1) button, Inactive Faults (2) button, and the Set Service Timer (3) button.

If a engine fault has been detected, the engine icon will flash (1). Touch the flashing icon, or touch the Active Fault button (2) to display the engine fault codes. The Service Fault Number screen displays.

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The Service Fault Number screen will display any engine fault code present on the vehicle. The fault number will be presented as an SPN number (1) , and as an FMI number (2) .

RAIL14SP00799AA

RAIL14SP00797AA

Set the service timer interval by touching the Set Service Timer (1) button from the Engine screen. The Service Interval Setting screen displays.

Set the service timer interval by touching the Set Service Reminder button (1). The up and down arrow keys display (2) . Use the up or down arrows keys to set the desired service time interval.

RAIL14SP00843AA

RAIL14SP00844AA

If the service time interval has expired, the Service Reminder Expired screen will display. Address any service issues and reset the service time.

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Electrical systems - Electrical system

Electrical screen From the home screen touch the navigation icon. The List screen displays. From the list screen touch the “Electrical” button (1) in the list. The Electrical screen displays.

RAIL14SP00802AA

RAIL14SP00845AA

RAIL14SP00846AA

RAIL14SP00847AA

The Electrical screen is a monitoring screen for the fuse blocks. From the electrical screen you can select the appropriate fuse block to be monitored by touching the selectable fuse block buttons (1) in the left hand column. The appropriate Fuse Block Description screen is displayed.

From the Fuse Block Description screen you have the capability of turning the fuse descriptions on or off. Touch the “Toggle ON/OFF” button (1) to turn the descriptions on (2) or off (3). Additionally, if a fuse has failed within the system, the failed fuse will display in RED on the description page.

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Electrical systems - Electrical system

The following illustrations show the fuse block descriptions screens that are available. Fuse block description screen

RAIL14SP00846AA

Description Upper electrical fuse block fuse descriptions

Lower electrical fuse block fuse descriptions

RAIL14SP00848AA

Auxiliary fuse block fuse descriptions

RAIL14SP00850AA

Engine fuse block fuse descriptions

RAIL14SP00851AA

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Electrical systems - Electrical system

Diesel Exhaust Fluid (DEF) screen From the home screen touch the navigation icon. The List screen displays From the list screen touch the “DEF” (diesel exhaust fluid) button (1) , or touch the DEF icon (2) in the lower right corner of the screen. The DEF screen displays.

RAIL14SP00802AA

RAIL14SP01057AA

RAIL14SP00802AA

RAIL14SP00784AA

The DEF screen is a monitoring screen only and has no selectable features.

Fuel screen From the home screen touch the navigation icon. The List screen displays. Touch the “Fuel” button (2), or touch the fuel icon (2) in the lower left corner of the screen. The Fuel Monitoring screen displays.

The Fuel Monitoring screen is a monitoring screen only and has no selectable features.

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Electrical systems - Electrical system

4 Wheel Steer (FWS) screen From the home screen touch the navigation icon. The List screen displays. From the List screen touch the “4 Wheel Steer (FWS)” button (1), or touch the 4 wheel steer icon (2) on the top of the screen. This function is only present if the vehicle is equipped with 4WS.

RAIL14SP00802AA

RAIL14SP00825AA

RAIL14SP00826AA

Touch the Rear Steer Left (1), or the Rear Steer Right (2) buttons to steer the rear wheels either right or left.

Touch the Steering Diagnostics (1) button to calibrate the rear wheels. The 4 Wheel Steer Calibrate Rear Wheels screen displays.

Wheel calibration is a manual operation and the yes button should only be pressed if the operator is sure that all four wheels are currently in the straight ahead positions. After the wheels are all calibrated, touch the Calibrate Wheels button (1) . This screen will display the values for the wheel sensors.

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Electrical systems - Electrical system

After touching the Calibrate Wheels button, a screen asking “Are you sure you want to calibrate wheels? will display. See the Calibration section before pressing yes. Touch yes if you are sure the wheels are square, in-line, and in a straight ahead position. Touch no if more adjustment is needed.

RAIL14SP00827AA

RAIL14SP00825AA

RAIL14SP00839AA

To place the four wheel steer system in the “Auto” mode touch the Auto Mode button (1). The steering of the rear wheels will now follow the sensitivity zone set up for the front wheels. This means the rear wheels will not steer unless the front wheels are turned out of the sensitivity zone. Once the front wheels are turned beyond this point the rear wheels will turn to follow the front wheels.

Touch the Sensitivity button (1) to set the sensitivity of the rear wheels reacting to the movement of the front wheels

The up and down arrow keys (1) will display. Use the arrow keys to adjust the values for the rear wheel sensitivity. Setting the value higher will widen the zone that the front wheels can be steered in without the rear wheels steering. Setting the value lower will narrow the zone that the front wheels can be steered in without the rear wheels steering. Set this value for personal preference.

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Electrical systems - Electrical system

Error codes, messages and actions If one of the following errors is detected, a message will be presented on the display together with an error code on the module. In some cases, the module will turn off or at least shut down the outputs, to increase safety. Errors with the modules are indicated with flashing or steady on LED lights on the module. The yellow LED (1) and a green LED (2) indicator on the MC2 and XS2 modules will flash in certain sequences. See the following illustrations for LED indicators.

RAIL14SP00296AA

RAIL14SP00297FA

The XIO2 module has LED indicators which flash indicating functioning. The Power (blue) LED is steady on indicating that the module is powered up (1) . The CAN (green) LED can be steady on indicating J1939 is okay, or flashing indicating J1939 fault (2) . The Status (red) LED can be flashing indicating microprocessor is okay, or steady on indicating microprocessor fault (3) . The RS-485 (yellow) LED can be steady on indicating RS-485 is okay, or flashing indicating RS-485 fault (4) .

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Electrical systems - Electrical system

RAIL14SP00300BA

The XIO2 (Hourglass) module has LED indicators which flash indicating functioning. The Power (blue) LED is steady on indicating that the module is powered up (1) . The CAN (green) LED can be steady on indicating J1939 is okay, or flashing indicating J1939 fault (2) . The Status (red) LED can be flashing indicating microprocessor is okay, or steady on indicating microprocessor fault (3) . The RS-485 (yellow) LED is off (4)

RAIL14SP00301BA

The super node and Autoboom nodes have LED lights along the left edge for diagnostics. The lights indicate: Logic Power, HC Power, Micro 1HZ, CAN Rx, and Can Tx. There are also two more lights: Diagnostic 1 light which covers AutoBoom and Super node, and the diagnostic 2 light which covers AutoBoom and 3rd Party control. The Logic Power and HC Power LEDâ&#x20AC;&#x2122;s light up when 12 volts are seen for logic power. Micro 1Hz LED flashes once per second if the processor is working correctly. The CAN Rx and Tx LED lights flash intermittently when CAN communication is present going away from the node. The diagnostic 1 and 2 AutoBoom LED lights will light up when a second ultrasonic sensor is installed on one boom. The diagnostic super node LED lights up when reception of CAN 2 is received. The diagnostic 3rd party node LED light will light up when reception of CAN 2 is transmitted back out on the CAN bus from the node.

RAIL14SP00302BA

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Index Electrical systems - 55 Electrical system - 000 Electrical system - Overview - Electrical power distribution, fuses and relays, sensing systems . . . . . . . . . . . . . . . 3 Electrical system - Overview - Onboard control system diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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Electrical systems - 55 Harnesses and connectors - 100

SP.295F SP.300F SP.345F SP.400F

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Contents Electrical systems - 55 Harnesses and connectors - 100

FUNCTIONAL DATA Harnesses and connectors Electrical schematic sheet 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Electrical schematic sheet 02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Electrical schematic sheet 03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Electrical schematic sheet 04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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Electrical systems - Harnesses and connectors

Harnesses and connectors - Electrical schematic sheet 01

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Electrical systems - Harnesses and connectors

RAIL14SP01327JA

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Electrical systems - Harnesses and connectors

Harnesses and connectors - Electrical schematic sheet 02

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Electrical systems - Harnesses and connectors

RAIL14SP01328JA

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Electrical systems - Harnesses and connectors

Harnesses and connectors - Electrical schematic sheet 03

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Electrical systems - Harnesses and connectors

RAIL14SP01329JA

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Electrical systems - Harnesses and connectors

Harnesses and connectors - Electrical schematic sheet 04

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Electrical systems - Harnesses and connectors

RAIL14SP01330JA

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Electrical systems - Harnesses and connectors

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Index Electrical systems - 55 Harnesses and connectors - 100 Harnesses and connectors - Electrical schematic sheet 02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Harnesses and connectors - Electrical schematic sheet 03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Harnesses and connectors - Electrical schematic sheet 04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Harnesses and connectors - Electrical schematic sheet 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Electrical systems - 55 Engine control system - 015

SP.295F SP.300F SP.345F SP.400F

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Contents Electrical systems - 55 Engine control system - 015

SERVICE Engine Control Unit (ECU) HB - Display stored fault codes - Code retrieval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 View - Engine diagnostic fault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Electrical systems - Engine control system

Engine Control Unit (ECU) - HB - Display stored fault codes - Code retrieval When an engine fault has occurred and is currently being detected, an engine icon will light on the overhead side display panel and an alarm will sound. The monitor panel will also display active fault codes as they occur with an acknowledgement screen. Pressing the acknowledgement screen will cancel the alarm however the engine light icon will remain on in the overhead display until the condition is cleared. To review the active engine faults, perform the following: 1. With the ignition key in the On position, press the engine icon from the home screen of the display. RAIL14SP00780AA

RAIL14SP00797AA

RAIL14SP00799AA

2. From the engine screen, press the Active Faults button.

3. The engine fault number screen will display and any active engine fault code present on the vehicle will be shown. 4. Refer to Engine diagnostic fault code list Engine Control Unit (ECU) - View - Engine diagnostic fault codes (55.015) and perform the required action. One this corrective action has been performed and the condition has been cleared, the engine icon light in the overhead side display panel will go off. The engine fault will be removed from the Active Faults list and placed in the Inactive Faults list. NOTE: Only a Cummins service technician can clear the history from the Inactive Faults list.

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Electrical systems - Engine control system

Engine Control Unit (ECU) - View - Engine diagnostic fault codes Code

SPN

FMI

Lamp color

111

629

red

115

612

red

122

102

amber

123

102

amber

124

102

amber

135

100

amber

141

100

amber

143

100

amber

144

110

amber

145

110

amber

146

110

amber

151

153

154

110

105

red

amber

Reason for fault Error internal to the Engine Control Module (ECM) related to memory hardware malfunctions or internal ECM voltage supply circuits The ECM has detected the primary and backup speed sensor signals are connected backwards High signal voltage detected at the intake manifold pressure circuit Low signal voltage or open circuit at the intake manifold pressure circuit Intake manifold pressure has exceeded the maximum limit for the given engine rating High signal voltage detected at the engine oil pressure circuit Low signal voltage or open circuit at the engine oil pressure circuit Engine oil pressure signal indicates engine oil pressure is below the engine protection warning limit High signal voltage or open circuit detected at engine coolant temperature circuit Low signal voltage or open circuit detected at engine coolant temperature circuit Engine coolant temperature is above engine protection warning limit Engine coolant signal indicates engine coolant temperature is above engine protection critical limit High signal voltage or open circuit detected at intake manifold air temperature circuit Low signal voltage or open circuit at the intake manifold air temperature circuit

Effect (only when code is active)

Action

Engine may not start or may be difficult to start

Call Cummins Service

The engine will shut down or will not start

Call Cummins Service

Possible reduced engine performance

Call Cummins Service

Possible reduced engine performance

Call Cummins Service

Engine power derate

Call Cummins Service

None on performance

Call Cummins Service

None on performance

Call Cummins Service

Possible reduced engine performance

Call Cummins Service

Fan will stay on if controlled by the Engine Control Module (ECM)

Call Cummins Service

Fan will stay on if controlled by the Engine Call Cummins Control Module (ECM) Service Progressive power and/or Check coolant speed derate increasing level, clean cooling in severity from time of package alert Progressive power and/or Check coolant speed derate increasing level, clean cooling in severity from time of package alert

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Fan will stay on if controlled by the Engine Control Module (ECM)

Call Cummins Service

Fan will stay on if controlled by the Engine Control mModule (ECM)

Call Cummins Service

Electrical systems - Engine control system

155

105

red

187

3510

amber

195

111

amber

196

111

amber

197

111

amber

221

108

amber

222

108

amber

227

3510

amber

234

190

red

235

111

red

238

3511

amber

239

3511

amber

271

1347

amber

272

1347

285

286

639

Intake manifold air temperature signal indicates intake manifold air temperature above engine protection critical limit Low voltage detected at the sensor supply number 2 circuit High signal voltage or open circuit detected at coolant level circuit Low signal voltage or open circuit detected at coolant level circuit Low engine coolant level detected High voltage detected at barometric pressure circuit Low voltage detected at barometric pressure circuit High voltage detected at sensor supply number 2 circuit Engine speed signal indicates engine speed above engine protection limit The engine coolant is severely low Low voltage detected on the +5 volt sensor supply circuit to the engine speed sensor High voltage detected on the +5 volt sensor supply circuit to the engine speed sensor Low signal voltage is detected at the fuel pump actuator circuit

Progressive power and/or speed derate increasing in severity from time of alert

Clean cooling package

Possible reduced engine performance

Call Cummins Service

None on performance

Check wire harness, check level sensor

None on performance Possible reduced engine performance

Check coolant level

Possible reduced engine performance

Call Cummins Service

Possible reduced engine performance

Call Cummins Service

Possible reduced engine performance

Call Cummins Service

Possible reduced engine Reverse powering of the engine performance Engine will be shut down Check coolant level Engine may run rough, may stop running, may not start or may be difficult Call Cummins to start Service Engine may run rough, may stop running, may not start or may be difficult Call Cummins to start Service

Possible reduced engine performance Engine may run rough, may stop running, may High signal voltage is detected at the fuel pump not start or may be difficult to start actuator circuit amber The ECM expected information from a multiplexed device but At least one multiplexed did not receive it soon enough or did not receive device will not operate properly it at all amber The ECM expected information from a At least one multiplexed multiplexed device but only received a portion of device will not operate properly amber the necessary information

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Check wire harness, check level sensor

Call Cummins Service

Check chassis J1939 wiring connections, terminating resistors and nodes Check chassis J1939 wiring connections, terminating resistors and nodes

Electrical systems - Engine control system

The OEM vehicle electronic control unit (VECU) detected a fault with the remote accelerator Current detected at injector 1 when voltage is turned off Current detected at injector 5 when voltage is turned off Current detected at injector 3 when voltage is turned off Current detected at injector 6 when voltage is turned off Current detected at injector 2 when voltage is turned off Current detected at injector 4 when voltage is turned off The engine coolant temperature sensor is reading an erratic value at initial key on ECM power supply errors have been detected The ECM measured injector boost voltage is low Low voltage detected at sensor supply number 1 circuit High voltage detected at sensor supply number 1 circuit Oil pressure signal indicates oil pressure is below the engine protection critical limit

Remote accelerator will not operate

Check chassis J1939 wiring connections, terminating resistors and nodes

Possible reduced engine performance

Call Cummins Service

Possible reduced engine performance

Call Cummins Service

Possible reduced engine performance

Call Cummins Service

Possible reduced engine performance

Call Cummins Service

Possible reduced engine performance

Call Cummins Service

Possible reduced engine performance

Call Cummins Service

None on performance Possible reduced engine performance

Call Cummins Service Check ECM power supply

Possible reduced engine performance

Call Cummins Service

Possible reduced engine performance

Call Cummins Service

Possible reduced engine performance Progressive power and/or speed derate increasing in severity from time of alert

Call Cummins Service

288

974

red

322

651

amber

323

655

amber

324

653

amber

325

656

amber

331

652

amber

332

654

amber

334

110

amber

343

629

amber

351

3597

amber

352

3509

amber

386

3509

amber

415

100

418

426

639

427

639

428

429

Check oil level Drain water from the Water has been detected fuel filter, check filter None on performance amber in the fuel filter wire harness Check chassis J1939 Communication between None on performance. wiring connections, the ECM and another device on the SAE J1939 J1939 devices possibly terminating resistors do not operate. and nodes data link has been lost none Check chassis J1939 Communication between wiring connections, the ECM and another device on the SAE J1939 Engine speed will ramp terminating resistors and nodes data link has been lost down and remain at idle none High voltage detected at Check filter wire None on performance amber the water-in-fuel circuit harness Low voltage detected at Check filter wire None on performance amber the water-in-fuel circuit harness red

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Electrical systems - Engine control system

441

168

amber

442

168

amber

449

157

red

451

157

amber

452

157

amber

483

1349

amber

484

1349

amber

515

3514

amber

516

3514

amber

553

157

amber

555

101

amber

556

101

red

559

157

amber

584

677

amber

585

677

amber

595

103

amber

649

1378

amber

Engine may run rough, ECM supply voltage may stop running, may is below the minimum not start or may be difficult system voltage level to start ECM supply voltage is above the maximum system voltage level None on performance The ECM has detected that fuel pressure is higher than the Possible reduced engine commanded pressure performance Progressive power and/or High signal voltage speed derate increasing detected at the fuel rail in severity from time of pressure sensor circuit alert Progressive power and/or Low signal voltage speed derate increasing detected at the fuel rail in severity from time of pressure sensor circuit alert High signal voltage detected at the fuel rail Possible reduced engine pressure sensor circuit performance Low signal voltage detected at the fuel rail Possible reduced engine pressure sensor circuit performance High voltage detected on the +5 volt sensor supply circuit to the fuel Possible reduced engine rail pressure sensor performance Low voltage detected on the +5 volt sensor supply circuit to the fuel Possible reduced engine rail pressure sensor performance The ECM has detected that fuel pressure is higher than the Possible reduced engine commanded pressure performance The crankcase breather filter requires None on performance maintenance The crankcase breather filter requires Possible reduced engine performance maintenance The ECM has detected Engine may run rough, that fuel pressure is lower may stop running, may than the commanded not start or may be difficult pressure to start Either the engine will not start or the engine will Open circuit or high not have starter lockout voltage detected at protection starter lockout circuit Either the engine will not start or the engine will Low voltage detected at not have starter lockout protection the starter lockout circuit High turbocharger speed has been detected by the Possible reduced engine performance ECM Change engine oil and None on performance filter 47691240 24/02/2015

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Check for low battery voltage, check for low voltage during cranking Call Cummins Service

Check fuel return line for restrictions

Call Cummins Service

Call Cummins Service Call Cummins Service Call Cummins Service

Call Cummins Service

Call Cummins Service Change crankcase breather filter element Change crankcase breather filter element Check for air in fuel, high fuel inlet restriction

Check engine wiring harness

Check engine wiring harness Call Cummins Service Change engine oil and filter

Electrical systems - Engine control system

687

103

amber

689

190

amber

691

1172

amber

692

1172

amber

731

723

amber

741

1176

amber

742

1176

amber

743

1176

amber

778

723

amber

1117

3597

none

1515

red

1654

1323

amber

1655

1324

amber

1656

1325

amber

1657

1326

amber

1658

1327

amber

Low turbocharger speed detected by the ECM The ECM has detected an error in the engine speed signal High signal voltage detected at the turbocharger compressor intake air temperature circuit Low signal voltage detected at the turbocharger compressor intake air temperature circuit Engine position signal form the crankshaft position sensor and camshaft position sensor do not match High signal voltage detected at the turbocharger compressor intake pressure sensor circuit Low signal voltage detected at the turbocharger compressor intake pressure sensor circuit

The ECM has detected a loss of signal from the camshaft position sensor Supply voltage to the ECM fell below a calibrated limit momentarily, or the ECM was not allowed to power down correctly The J1939 multiplexing controller has indicated a malfunction of the multiplexed accelerator pedal Engine misfire has been detected in cylinder number 1 Engine misfire has been detected in cylinder number 2 Engine misfire has been detected in cylinder number 3 Engine misfire has been detected in cylinder number 4 Engine misfire has been detected in cylinder number 5

Call Cummins Service

Possible reduced engine performance

Call Cummins Service

Possible reduced engine performance

Call Cummins Service

Possible reduced engine performance

Call Cummins Service

Possible reduced engine performance

Call Cummins Service

Possible reduced engine performance

Call Cummins Service

Possible reduced engine performance Possible reduced engine performance

Call Cummins Service Call Cummins Service

Possible reduced engine performance

Call Cummins Service Allow 30 seconds after shutting key off before turning key back on or Possible reduced engine before turning battery performance disconnect switch off

Engine will only idle

Check chassis J1939 wiring connections, terminating resistors and nodes

Possible low power, rough idle, or misfire

Call Cummins Service

Possible low power, rough idle, or misfire

Call Cummins Service

Possible low power, rough idle, or misfire

Call Cummins Service

Possible low power, rough idle, or misfire

Call Cummins Service

Possible low power, rough idle, or misfire

Call Cummins Service

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Possible reduced engine performance

Electrical systems - Engine control system

1659

1328

amber

1664

4796

amber

1668

1761

amber

1669

1761

amber

1673

1761

amber

1677

3031

amber

1678

3031

amber

1679

3031

amber

1682

3362

amber

1683

3363

amber

1684

3363

amber

1685

3364

amber

1686

3364

amber

Engine misfire has been detected in cylinder Possible low power, rough number 6 idle, or misfire

Call Cummins Service Check that diesel oxidation catalyst The aftertreatment diesel hasn't been damage, oxidation catalyst is not removed from present in the exhaust Possible reduced engine vehicle or tampered system performance with Low signal voltage detected at the aftertreatment diesel exhaust fluid tank level Possible reduced engine Check engine wiring performance harness sensor circuit High signal voltage detected at the aftertreatment diesel exhaust fluid tank level Possible reduced engine Check engine wiring performance sensor circuit harness The aftertreatment diesel exhaust fluid tank level has fallen below the Possible reduced engine Fill the diesel exhaust critical warning level performance fluid tank Low signal voltage detected at the aftertreatment diesel exhaust fluid tank Possible reduced engine Check engine wiring temperature sensor performance harness circuit High signal voltage or open circuit detected at the diesel exhaust fluid tank temperature sensor Possible reduced engine Check engine wiring performance circuit harness The diesel exhaust fluid tank temperature sensor has indicated a tank temperature too high or too low for the ambient Possible reduced engine Check engine wiring performance conditions harness Check for low DEF fluid level, check for plugged DEF filters, The aftertreatment diesel check for damaged exhaust fluid dosing unit Possible reduced engine or plugged heated is unable to prime performance DEF lines High signal voltage Check DEF heater detected at the valve wiring, check aftertreatment diesel exhaust fluid tank heater Possible reduced engine for defective heater performance valve circuit Low signal voltage Check DEF heater detected at the valve wiring, check aftertreatment diesel exhaust fluid tank heater Possible reduced engine for defective heater performance valve circuit Possible reduced engine Check engine wiring performance harness Possible reduced engine Check engine wiring performance harness

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Electrical systems - Engine control system

1691

5298

amber

1694

3226

amber

1695

3513

amber

1696

3513

amber

1699

1761

amber

1712

3363

amber

1713

3363

amber

1715

3364

amber

1843

101

amber

1844

101

amber

1852

amber

1866

411

amber

1885

3216

amber

The temperature increase Possible frequent across the aftertreatment need for aftertreatment catalyst is lower than Call Cummins regeneration expected Service An incorrect NOx sensor reading has been detected by the Call Cummins aftertreatment outlet NOx Possible reduced engine performance Service sensor High voltage detected at sensor supply number The engine will operate in Check engine wiring 5 circuit in the OEM limp mode harness harness Low voltage detected at sensor supply number The engine will operate in Check engine wiring 5 circuit in the OEM limp mode harness harness Check engine wire harness, check for Catalyst solution level is Catalyst solution injection damaged or plugged not changing with engine into the aftertreatment DEF lines and DEF system is disabled operating conditions nozzle Check for low coolant level, check for restrictions in coolant The aftertreatment diesel plumbing, check for exhaust fluid tank heater malfunction in heater is unable to thaw the Possible reduced engine control valve or its frozen diesel exhaust wiring performance fluid Check if heater control valve is stuck open, if there is coolant leaking past the valve seat, if the valve is installed The diesel exhaust fluid correctly, check heater is continuously in wiring to valve the on position None on performance Check engine wiring Engine power derate harness High signal voltage detected at the crankcase Call Cummins pressure circuit None on performance Service Low signal voltage detected at the crankcase Call Cummins pressure circuit None on performance Service The Water-In-Fuel indicates that the water level is above the warning Drain water from the None on performance level fuel filter An error in the EGR delta pressure signal was detected at initial key on or the sensor failed the Possible reduced engine Call Cummins performance autozero test Service An internal circuit error has been detected by the aftertreatment intake Possible reduced engine Check engine wiring performance harness NOx sensor

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Electrical systems - Engine control system

1887

3226

amber

1896

2791

amber

1898

641

amber

1938

3597

amber

1942

101

amber

1962

641

amber

1974

101

amber

2198

641

amber

2265

1075

amber

2266

1075

amber

2272

amber

2273

411

amber

2274

411

amber

2288

103

none

2311

633

amber

2321

190

none

An internal circuit error has been detected by the aftertreatment outlet NOx sensor The EGR valve has failed the automatic calibration procedure at initial key on The VGT has failed the automatic calibration procedure at initial key on Low battery voltage detected by the VGT actuator The ECM has detected that the crankcase pressure signal is reading an erratic value at initial key on or during engine operation High internal VGT actuator temperature has been detected The crankcase breather filter requires maintenance Intermittent communication between the smart VGT controller and the ECM has been detected High voltage or open circuit detected at the fuel lift pump signal circuit Low signal voltage detected at the fuel lift pump signal circuit Low signal voltage detected at the EGR valve position sensor circuit High signal voltage detected at the EGR differential pressure sensor circuit Low signal voltage detected at the EGR differential pressure sensor circuit High turbocharger speed has been detected by the ECM The fuel pump actuator circuit resistance is too high or too low, or an intermittent connection has been detected Crankshaft engine speed sensor intermittent synchronization

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Possible reduced engine Check engine wiring performance harness Possible reduced engine performance

Call Cummins Service

Possible reduced engine performance

Call Cummins Service

Possible reduced engine performance

Check charging circuit

None on performance

Call Cummins Service

None on performance

Call Cummins Service Change crankcase breather filter element

Possible reduced engine performance

Call Cummins Service

Engine may not start or may be difficult to start

Call Cummins Service

Engine may not start or may be difficult to start

Call Cummins Service

Possible reduced engine performance

Call Cummins Service

Possible reduced engine performance

Call Cummins Service

Possible reduced engine performance

Call Cummins Service

Possible reduced engine performance

Call Cummins Service

Possible reduced engine performance

Call Cummins Service

Possible reduced engine performance

Call Cummins Service

None on performance

Electrical systems - Engine control system

2322

723

none

2346

2789

none

2347

2629

none

2349

2791

amber

2387

641

amber

2448

111

amber

2449

641

red

2554

1209

amber

2555

729

amber

2556

729

amber

2634

641

red

2635

641

red

2636

641

red

2637

5018

none

2646

110

amber

2659

110

none

Camshaft engine speed sensor intermittent synchronization Turbocharger turbine inlet temperature has exceeded the engine protection limit High turbocharger compressor outlet temperature has been calculated by the ECM Motor terminal or motor coil open circuit has been detected by the ECM The smart VGT controller has detected incorrect stop limits, or the VGT is unable to move to the closed position Low engine coolant level detected The VGT has been installed incorrectly The exhaust gas pressure sensor is reading an erratic value High voltage detected at the intake air heater signal circuit Low voltage detected at the intake air heater signal circuit An internal error has been detected by the smart VGT controller A calibration mismatch between the VGT actuator and the ECM has been detected No communications on the J1939 data link between the engine ECM and the smart VGT controller The front face of the aftertreatment oxidation catalyst has been detected to be plugged with soot The EGR valve was closed to reduce engine coolant temperature Engine coolant signal indicates coolant temperature is above the engine coolant temperature engine protection warning limit

Possible reduced engine performance

Call Cummins Service

Engine power derate

Check for leaks in CAC air circuit

Engine power derate

Check for air intake system leaks

Possible reduced engine performance

Call Cummins Service

Possible reduced engine performance

Call Cummins Service

None on performance Possible reduced engine performance

Check coolant level Call Cummins Service

Check for leaks in the exhaust system Check engine wiring The air heaters can be on harness, check grid heater relay or off all the time Check engine wiring The air heaters can be on harness, check grid heater relay or off all the time Possible reduced engine performance

Possible reduced engine performance

Call Cummins Service

Possible reduced engine performance

Call Cummins Service

Possible reduced engine performance

Call Cummins Service

Possible reduced engine performance

Call Cummins Service Check coolant level, clean cooling package

Possible reduced engine performance

Check coolant Progressive power derate increasing in severity from level, clean cooling package time of alert

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Electrical systems - Engine control system

2771

3226

2961

412

2962

412

2964

105

No communications or an invalid data transfer rate detected on the J1939 data link between the ECM and the aftertreatment outlet NOx sensor amber EGR temperature has exceeded the engine protection limit none EGR temperature has exceeded the engine protection limit amber Intake manifold air temperature signal indicates intake manifold air temperature above engine protection warning limit none

2973

102

amber

2976

3361

amber

3142

4360

amber

3143

4360

amber

3144

4360

amber

3146

4363

amber

3147

4363

amber

3148

4363

amber

3151

3165

4794

4363

amber

red

Possible reduced engine Check engine wiring performance harness Check coolant Possible reduced engine level, clean cooling package performance Check coolant Possible reduced engine level, clean cooling package performance

Clean charge air cooler, check for restrictions in CAC airflow Check for air leaks in the air intake system, Possible reduced engine check for restrictions performance in CAC airflow

Progressive power and/or speed derate increasing in severity from time of alert

The intake manifold pressure sensor is reading an erratic value The aftertreatment diesel exhaust fluid dosing temperature is irrational High signal voltage detected at the SCR intake temperature sensor circuit Low signal voltage detected at the SCR intake temperature sensor circuit The SCR intake temperature sensor is not changing with engine operating conditions High signal voltage detected at the SCR outlet temperature sensor circuit Low signal voltage detected at the SCR outlet temperature sensor circuit The SCR outlet temperature sensor is not changing with engine operating conditions

The aftertreatment SCR catalyst in the exhaust system is not present The SCR outlet temperature sensor reading has exceeded the maximum engine protection limit

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Possible reduced engine Check engine wiring performance harness

Possible reduced engine performance

Call Cummins Service

Possible reduced engine performance

Call Cummins Service

Possible reduced engine performance

Call Cummins Service

Possible reduced engine Check engine wiring performance harness

Possible reduced engine Check engine wiring performance harness Check that SCR hasn't been damage, removed from Possible reduced engine vehicle or tampered performance with

Possible reduced engine performance

Check for degraded, diluted or incorrect diesel exhaust fluid

Electrical systems - Engine control system

3228

3229

3216

4360

amber

red

3231

4360

red

3232

3216

amber

3235

4363

red

3237

3238

3239

3241

4340

4342

3242

3363

3251

4765

3258

4340

amber

An incorrect NOx sensor reading has been detected by the aftertreatment intake NOx sensor The SCR intake temperature sensor reading has exceeded the maximum engine protection limit The SCR intake temperature sensor reading has exceeded the maximum engine protection limit No communications or an invalid data transfer rate detected on the J1939 data link between the ECM and the aftertreatment intake NOx sensor The SCR outlet temperature sensor reading has exceeded the maximum engine protection limit High signal voltage detected at the diesel exhaust fluid line heater 1 circuit Low signal voltage detected at the diesel exhaust fluid line heater 1 circuit High signal voltage detected at the diesel exhaust fluid line heater 2 circuit Low signal voltage detected at the diesel exhaust fluid line heater 2 circuit

Possible reduced engine performance

Check for exhaust system leakage

Progressive power and/or Check for speed derate increasing in severity from time of contaminated diesel exhaust fluid alert Progressive power and/or Check for speed derate increasing in severity from time of contaminated diesel exhaust fluid alert

Possible reduced engine Check engine wiring performance harness Check for degraded, diluted or incorrect diesel exhaust fluid, Possible reduced engine check engine wire performance harness

Possible reduced engine performance

Check engine wiring harness, check heated DEF lines

Possible reduced engine performance

Check engine wiring harness, check heated DEF lines

Possible reduced engine performance

Check engine wiring harness, check heated DEF lines

Check engine wiring harness, check heated DEF lines Check for low coolant level, check for restrictions in coolant plumbing, check for malfunction in heater Possible reduced engine control valve or its wiring performance Possible reduced engine performance

The aftertreatment diesel exhaust fluid temperature did not increase when the aftertreatment diesel exhaust fluid heater was commanded on amber The diesel oxidation catalyst intake Progressive power and/or temperature sensor reading has exceeded the speed derate increasing in severity from time of Check engine wiring maximum temperature alert harness limit red Check engine wiring Open circuit detected in harness, check the diesel exhaust fluid Possible reduced engine performance heated DEF lines line heater 1 amber

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Electrical systems - Engine control system

3261

4342

amber

3313

4765

amber

3314

4765

amber

3315

4765

amber

3341

107

amber

3422

4344

amber

3423

4344

amber

3425

4344

amber

3497

1761

amber

3498

1761

Open circuit detected in the diesel exhaust fluid line heater 2 Low voltage detected at the catalyst intake sensor circuit High voltage detected at the catalyst intake sensor circuit The aftertreatment diesel oxidation catalyst intake temperature sensor is not changing with engine operating conditions

High signal voltage detected at the diesel exhaust fluid line heater 3 circuit Low signal voltage detected at the diesel exhaust fluid line heater 3 circuit Open circuit detected in the diesel exhaust fluid line heater 3

The aftertreatment diesel exhaust fluid level is low The aftertreatment diesel exhaust fluid level is very low amber

3543

4094

amber

3545

3226

amber

3547

4096

amber

3555

1081

amber

3558

3361

amber

3559

3361

amber

3562

5491

amber

Possible reduced engine performance

Check engine wiring harness, check heated DEF lines

Possible reduced engine Check engine wiring performance harness Possible reduced engine Check engine wiring performance harness

Possible reduced engine Check engine wiring performance harness Possible reduced engine Change air filter performance elements

Possible reduced engine performance

Check engine wiring harness, check heated DEF lines

Check engine wiring harness, check heated DEF lines Check engine wiring Possible reduced engine harness, check performance heated DEF lines Fill the diesel exhaust fluid tank, check engine wire harness None on performance Fill the diesel exhaust fluid tank, check engine wire harness None on performance Check for degraded, diluted or incorrect diesel exhaust fluid, Possible reduced engine check for exhaust system leaks performance Possible reduced engine performance

The diesel exhaust fluid quality is not sufficient enough to provide adequate NOx reduction The aftertreatment outlet Check engine wiring NOx sensor reading is None on performance harness not valid The diesel exhaust fluid Possible reduced engine Fill the diesel exhaust tank is empty performance fluid tank Check chassis J1939 wiring connections, terminating resistors A loss of communication None on performance and nodes has been detected High signal voltage detected at the aftertreatment diesel Possible reduced engine Check engine wiring exhaust fluid dosing unit performance harness Low signal voltage detected at the aftertreatment diesel Possible reduced engine Check engine wiring exhaust fluid dosing unit performance harness High signal voltage detected at the diesel exhaust fluid line heater Possible reduced engine Check engine wiring relay performance harness

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Electrical systems - Engine control system

3563

5491

amber

3567

5394

amber

3568

5394

amber

3571

4334

amber

3572

4334

amber

Low signal voltage detected at the diesel exhaust fluid line heater relay A circuit error has been detected in the aftertreatment diesel exhaust fluid dosing valve circuit A mechanical malfunction has been detected in the DEF dosing valve High signal voltage detected at the diesel exhaust fluid pressure sensor circuit Low signal voltage detected at the diesel exhaust fluid pressure sensor circuit

amber

Low diesel exhaust fluid pressure has been detected in the dosing unit

The diesel exhaust fluid dosing unit has blockage in the diesel exhaust fluid amber return flow

High signal voltage detected at the diesel amber exhaust fluid return valve

Low signal voltage detected at the diesel amber exhaust fluid return valve

3574

3575

3577

3578

4334

4376

3582

4364

amber

3583

5031

amber

NOx conversion across the SCR catalyst is too low The aftertreatment outlet NOx sensor heater is unable to maintain its normal operating temperature

amber

The diesel exhaust fluid pressure sensor has reported a reading too high or too low for the operating conditions

3596

4334

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Possible reduced engine Check engine wiring performance harness

Possible reduced engine Check engine wiring performance harness Check for degraded, Possible reduced engine diluted or incorrect performance diesel exhaust fluid

Possible reduced engine Check engine wiring performance harness

Possible reduced engine Check engine wiring performance harness Check for low DEF fluid level, check for plugged DEF filters, check for damaged or plugged heated DEF lines, check Possible reduced engine engine wire harness performance Check for plugged or frozen diesel exhaust fluid return line from the doser to the Possible reduced engine pump, check engine performance wire harness Check for damaged or plugged heated DEF lines, check Possible reduced engine engine wire harness performance Check for damaged or plugged heated DEF lines, check Possible reduced engine engine wire harness performance Check for degraded, diluted or incorrect diesel exhaust fluid, Possible reduced engine check for exhaust system leaks performance

Check engine wiring harness Check for plugged DEF filters, check for damaged or plugged heated DEF lines, Possible reduced engine check engine wire performance harness None on performance

Electrical systems - Engine control system

3649

5024

amber

3681

3228

amber

3682

3218

amber

3697

630

red

3712

5246

red

3714

1569

amber

3717

3226

amber

3718

3216

amber

3724

168

amber

3725

3216

amber

3727

5571

none

3737

1675

3741

5571

3748

3216

3749

3226

The aftertreatment outlet NOx sensor heater is unable to maintain its normal operating temperature The aftertreatment outlet NOx sensor indicates that the power supply to the sensor is incorrect The Aftertreatment outlet NOx sensor indicates that the power supply to the sensor is incorrect Error internal to the ECM related to engine software failures Critical SCR related fault codes have been active for an extended period of time and require immediate attention Critical fault codes related to engine operation are active A nominal system voltage mismatch has been detected by the aftertreatment outlet NOx sensor A nominal system voltage mismatch has been detected by the aftertreatment intake NOx sensor Low voltage to the EGR valve device driver has been detected The aftertreatment NOx sensor reading is not valid The fuel rail high pressure relief valve has opened at a lower than expected pressure

None on performance

Check engine wiring harness

None on performance

Check engine wiring harness

None on performance

Check engine wiring harness

Engine may not start or may be difficult to start

Call Cummins Service

Engine power derate

Call Cummins Service

Possible reduced engine performance

Call Cummins Service

None on performance

Check engine wiring harness

None on performance

Check engine wiring harness

Possible reduced engine performance

Call Cummins Service

None on performance

Check engine wiring harness

Possible reduced engine performance

Call Cummins Service Check for cause of excessive engine cranking, poor Starter operation is battery connections, prohibited until the starter check engine has adequately cooled harness Engine may run rough, Check for air in may stop running, may not start or may be difficult fuel, high fuel return restriction to start

The starter motor has been temporarily disabled in order to prevent starter damage none The fuel rail high pressure relief valve has opened due to high fuel rail pressure amber An offset in the intake NOx sensor reading has Call Cummins None on performance been detected Service amber An offset in the outlet NOx sensor reading has Possible reduced engine Check engine wiring performance been detected harness amber

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Electrical systems - Engine control system

3867

3364

3868

3364

3876

3364

3877

3364

3878

3364

4152

5743

4155

5746

4156

5746

4157

4376

4159

5743

4164

5743

4165

5743

The diesel exhaust fluid Check for degraded, (DEF) has been detected Possible reduced engine diluted or incorrect to be below a critical performance diesel exhaust fluid threshold amber No communications or an invalid data transfer rate detected on the J1939 data link between the ECM and the aftertreatment DEF Check engine wiring quality sensor Engine power derate harness amber Fill DEF tank, check for degraded, diluted or incorrect diesel Engine power derate exhaust fluid amber Check for degraded, diluted or incorrect Engine power derate amber diesel exhaust fluid The diesel exhaust fluid pressure sensor has reported a reading too Check for degraded, high or too low for the diluted or incorrect operating conditions Engine power derate diesel exhaust fluid amber Check for poor No communications battery connections, on the J1939 data link check engine between the engine ECM harness for incorrect and the aftertreatment SCR temperature sensor Possible reduced engine or damaged J1939 terminating resistor performance module amber High signal voltage detected at the aftertreatment diesel exhaust fluid dosing unit Possible reduced engine Check engine wiring heater relay circuit performance harness amber Low signal voltage detected at the aftertreatment diesel exhaust fluid dosing unit Possible reduced engine Check engine wiring heater relay circuit performance amber harness A stuck aftertreatment Call Cummins diesel exhaust fluid return None on performance Service amber valve has been detected An internal error has been detected in the aftertreatment SCR Possible reduced engine temperature sensor Call Cummins performance module Service amber High battery supply voltage detected at the Check charging aftertreatment SCR Possible reduced engine system and batteries temperature sensor for high voltage performance module amber Check for poor Low battery supply battery connections, voltage detected at the check charging aftertreatment SCR circuit for causes Possible reduced engine temperature sensor for low voltage performance module amber

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Electrical systems - Engine control system

4166

5743

amber

4168

5742

amber

4169

5745

amber

4171

5745

amber

4213

3695

amber

4249

4337

amber

4251

5798

amber

4261

5743

amber

4262

5571

amber

4263

5571

amber

4277

3364

amber

4517

237

amber

4533

4766

amber

High internal temperature detected in the aftertreatment SCR Check exhaust Possible reduced engine temperature sensor system for leaks performance module The aftertreatment diesel exhaust fluid unit heater Check engine wiring is detected to be stuck on None on performance harness The aftertreatment diesel exhaust fluid unit heater Possible reduced engine Check engine wiring performance harness is detected to be stuck off The aftertreatment diesel Call Cummins exhaust fluid dosing unit Possible reduced engine performance Service failed to thaw Check that inhibit switch is not in the on The aftertreatment position, check wiring Possible frequent regeneration permit switch is stuck in the off need for aftertreatment between switch and engine ECM regeneration or inhibit position The aftertreatment diesel exhaust fluid dosing unit Check engine wiring temperature is stuck None on performance harness The aftertreatment diesel exhaust fluid dosing unit heater temperature Check engine wiring reading is stuck None on performance harness Intermittent battery voltage supply detected at the aftertreatment SCR temperature sensor Possible reduced engine Check engine wiring performance harness module High signal voltage or open circuit is detected Engine may run rough, at the high pressure may stop running, may common rail fuel pressure not start or may be difficult Check engine wiring relief valve circuit to start harness Low signal voltage or Engine may run rough, open circuit is detected may stop running, may at the high pressure common rail fuel pressure not start or may be difficult Check engine wiring to start harness relief valve circuit No communications or an invalid data transfer rate detected on the J1939 data link between the ECM and the aftertreatment DEF Check engine wiring quality sensor Engine power derate harness The vehicle identification number has not been Call Cummins programmed into the None on performance Service ECM High signal voltage detected at the aftertreatment diesel oxidation catalyst Possible reduced engine Check engine wiring temperature sensor performance circuit harness

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Electrical systems - Engine control system

4534

4766

amber

4572

3031

amber

4585

4792

red

4731

3031

amber

4732

1761

amber

4734

701

red

4737

3031

amber

4739

1761

amber

4745

3515

amber

4768

3521

amber

4769

1761

amber

4863

5245

amber

4867

5571

amber

4956

6713

red

4957

6713

red

Low signal voltage detected at the aftertreatment diesel oxidation catalyst temperature sensor circuit The ECM lost communication with the aftertreatment diesel exhaust fluid tank temperature sensor The incorrect SCR system has been installed The received datalink message was not valid The received datalink message was not valid No communications on the J1939 data link between the engine ECM and the machine constrained engine operation module An unknown error has been detected with the aftertreatment diesel exhaust fluid tank temperature sensor An unknown error has been detected with the aftertreatment diesel exhaust fluid tank level sensor

Possible reduced engine Check engine wiring performance harness

Possible reduced engine Check engine wiring performance harness Call Cummins Engine will be shut down Service Possible reduced engine Check engine wiring performance harness Check engine wiring None on performance harness

Engine power derate

Check chassis J1939 wiring connections, terminating resistors and nodes

Engine power derate

Check engine wiring harness

Possible reduced engine Check engine wiring performance harness Possible reduced engine Check engine wiring performance harness Check for degraded, Unknown fluid inside the diluted or incorrect Engine power derate DEF tank diesel exhaust fluid A valid diesel exhaust fluid tank level reading Possible reduced engine Check engine wiring performance harness has not been received Critical SCR related fault codes have been active for an extended period of time and require Possible reduced engine Call Cummins performance immediate attention Service The high pressure common rail fuel relief valve circuit resistance is Engine may run rough, too high or too low, or an may stop running, may Call Cummins intermittent connection not start or may be difficult to start Service has been detected VGT software does not Possible reduced engine Call Cummins match application performance Service The VGT actuator and ECM software is not Possible reduced engine Call Cummins compatible performance Service

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Electrical systems - Engine control system

5177

6713

amber

5386

4766

amber

5387

4766

amber

5388

4766

red

5389

4766

amber

5391

6882

amber

5392

6882

amber

5393

6882

amber

5394

6882

amber

5395

6882

amber

The ECM lost communication or did not support message from the VGT actuator The aftertreatment diesel exhaust oxidation catalyst outlet temperature is not changing with engine operating conditions The aftertreatment diesel oxidation catalyst outlet temperature sensor reading has exceeded the maximum engine protection temperature limit The aftertreatment diesel oxidation catalyst outlet temperature sensor reading has exceeded the maximum engine protection temperature limit The aftertreatment diesel oxidation catalyst outlet temperature sensor reading has exceeded the maximum engine protection temperature limit No communications on the J1939 data link between the engine ECM and the aftertreatment diesel oxidation catalyst temperature sensor module An internal error has been detected in the aftertreatment diesel oxidation catalyst temperature sensor module High battery supply voltage detected at the aftertreatment diesel oxidation catalyst temperature sensor module Low battery supply voltage detected at the aftertreatment diesel oxidation catalyst temperature sensor module Intermittent battery voltage supply detected at the aftertreatment diesel oxidation catalyst temperature sensor module

Possible reduced engine performance

Call Cummins Service

Possible reduced engine Check engine wiring performance harness

Progressive power and/or speed derate increasing in severity from time of Check engine wiring alert harness

Progressive power and/or speed derate increasing in severity from time of alert

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Call Cummins Service

Possible reduced engine Check engine wiring performance harness Check for poor battery connections, check charging circuit for causes for low voltage, check Possible reduced engine engine harness performance J1939 circuit

Possible reduced engine performance

Call Cummins Service

Possible reduced engine Check engine wiring performance harness Check for poor battery connections, check charging circuit for causes for Possible reduced engine low voltage, check engine harness performance

Possible reduced engine Check engine wiring performance harness

Electrical systems - Engine control system

5396

6882

High internal temperature detected in the aftertreatment diesel oxidation catalyst Possible reduced engine temperature sensor performance module amber

5576

107

amber

5585

5571

amber

5617

5018

red

5631

6928

none

5632

6918

amber

5653

6881

amber

5654

6881

amber

Check exhaust system for leaks Change air filter None on performance elements Change fuel filters, check for high fuel Excessive fuel flow inlet restriction, restriction to the high pressure fuel pump has Possible reduced engine check for plugged performance fuel tank vent been detected The incorrect DOC Possible reduced engine Call Cummins system has been installed performance Service Check that inhibit switch is not in the on The system was unable position, check wiring to perform an active SCR between switch and system cleaning of the engine ECM None on performance aftertreatment SCR filter Check that inhibit Cleaning of the SCR switch is not in the on system has been position, check wiring prevented due to the between switch and permit switch being engine ECM None on performance disabled No communications or an invalid data transfer Check chassis J1939 rate detected on the J1939 data link between At least one multiplexed wiring connections, device will not operate terminating resistors the ECM and the SCR properly and nodes override switch Check chassis J1939 At least one multiplexed wiring connections, The received datalink device will not operate terminating resistors message was not valid properly and nodes

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Index Electrical systems - 55 Engine control system - 015 Engine Control Unit (ECU) - HB - Display stored fault codes - Code retrieval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine Control Unit (ECU) - View - Engine diagnostic fault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Electrical systems - 55 Engine starting system - 201

SP.295F SP.300F SP.345F SP.400F

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Contents Electrical systems - 55 Engine starting system - 201

FUNCTIONAL DATA Engine starting system Overview - Starter troubleshooting and circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - Engine starting system

Engine starting system - Overview - Starter troubleshooting and circuit Refer to the Cummins Engine Operation and Maintenance Manual for problems not covered in this manual. Engine will not crank

Coolant temperature too high

Check that the drive control lever is in Neutral. Check that Neutral start switch is working properly. Check that starter relays are working properly. Clean air inlet screens. Clean debris out of radiator, oil cooler, CAC, and AC condenser fins. Check coolant level.

STARTING CIRCUIT Refer to the following illustration for circuit path of the starting system.

RAIL15SP00319HA

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Index Electrical systems - 55 Engine starting system - 201 Engine starting system - Overview - Starter troubleshooting and circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - 55 Alternator - 301

SP.295F SP.300F SP.345F SP.400F

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Contents Electrical systems - 55 Alternator - 301

SERVICE Alternator Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Electrical systems - Alternator

Alternator - Remove Prior operation: Remove the serpentine belt. Refer to Accessory belt - Remove â&#x20AC;&#x201D; Serpentine belt (10.414) NOTE: The battery should be disconnected or the ring terminal wrapped to prevent unintentional grounding. 1. Move the vehicle to a hard level surface. 2. Turn the ignition key to the OFF position. Remove the key from the ignition. 3. Access the battery disconnect switch. Turn the switch to the OFF position. 4. Access the alternator (1) by opening the engine enclosure doors. The alternator is on the left hand side of the engine.

RAIL15SP00321AA

RAIL13SP03424AA

5. Tag the electrical wire, and disconnect the nut (1), lockwasher (2), and ring terminal (3) from backside of alternator (4). 6. Remove the link capscrew (5) at lower portion of alternator (4). 7. Remove the mounting capscrew (6) and nut (7) at upper portion of alternator (4). 8. Remove the alternator (4).

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Electrical systems - Alternator

Alternator - Install 1. Position alternator (4) and install mounting capscrew (6) and nut (7). Tighten the capscrews securely. 2. Install link capscrew (5). Tighten the capscrews securely. 3. Connect electrical wire with nut (1), lockwasher (2), and ring terminal (3) to backside of alternator (4), and remove tag from wire.

RAIL13SP03424AA

RAIL15SP00321AA

4. Install the serpentine belt. Refer to Accessory belt Install â&#x20AC;&#x201D; Serpentine belt (10.414)

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Index Electrical systems - 55 Alternator - 301 Alternator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Alternator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - 55 Battery - 302

SP.295F SP.300F SP.345F SP.400F

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Contents Electrical systems - 55 Battery - 302

FUNCTIONAL DATA Battery connect and disconnect system Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - Battery

Battery connect and disconnect system - Overview Battery disconnect switch On the side of the engine cowling, next to the ladder grab rail is a battery disconnect switch. Turning the switch off (straight up) will disconnect the batteries from the vehicles electrical system. Turn the switch on (horizontal) to enable the entire electrical system. The electrical system can be disconnected when the vehicle is left for extended periods of time or if there is a drain on the batteries. The switch can also be locked (with a pad lock) when the vehicle is left unattended.

RAIL14SP00818AA

NOTE: After turning the ignition switch off, wait at least one minute before turning the battery disconnect off. This will allow the diesel exhaust fluid system to purge all liquid from the lines.

Battery combiner The vehicle is equipped with a battery combiner for control of the battery power usage. The combiner functions to protect sensitive electronic equipment during engine cranking by separating the battery banks. The battery banks are separated into two groups, group 1 has two batteries used for starting, and group two has one battery used for the electronics of the machine. When engine cranking is completed, the combiner senses a charging level voltage of over 13.1 Vdc and combines the battery banks. This allows machine to have all three batteries at its disposal during operation. When the machine is shut off (engine turned off), the combiner will once again separate the battery banks when the voltage drops below 12.7 Vdc. With the batteries separated, the normal loads on the machine are isolated to only the electronics battery. If the operator was to drain this battery (leave lights on, leave viper on, etc) the starting battery bank would see no ill effect, meaning they would stay completely charged since they are separated from the electronics battery. The battery combiner (1) and a combiner switch (2) are located at the rear of machine, next to the left side vehicle battery (3) . Access to the combiner switch and the combiner is made by opening the rear door.

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Electrical systems - Battery

RAIL14SP01325AA

The combiner switch is intended for use only if the electronics battery has been drained. By turning the switch to the ON position, the combiner manually combines the battery banks, and back feeds the system, which allows the machine to start using the fully charged starting batteries. NOTE: When the switch is in the â&#x20AC;&#x153;Onâ&#x20AC;? position, the batteries are combined at all times. When the machine has started and the alternator begins to charge the drained battery, the switch must be placed back to the OFF position to ensure intended functionality of combiner system.

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Index Electrical systems - 55 Battery - 302 Battery connect and disconnect system - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - 55 Electronic modules - 640

SP.295F SP.300F SP.345F SP.400F

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Contents Electrical systems - 55 Electronic modules - 640

FUNCTIONAL DATA Electronic modules Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - Electronic modules

Electronic modules - Overview Electronic of the vehicle is through a Control Area Network (CAN) data bus. The system is comprised of an engine controller, the chassis monitor, a master controller (MC2), an expansion module (XS2), the joystick control (grip), an XIO2 module, two multiplexing vehicle electrical centers (MVEC), and a product control node module. The CAN bus system features two wire serial communication for CAN-high and CAN low signals, twisted pair wiring, parallel connection of all modules involve, and termination resistors at the ends of the bus. Depending on the configuration of the vehicle there may be three CAN buses: The vehicle CAN (J1939), product control CAN (Raven), and guidance/GPS (Trimble). These are identified on the electrical schematic as J1939, Raven, and Trimble

Chassis Monitor The chassis monitor is mounted to the armrest console in the cab. The monitor features a color display and is a sealed enclosure with sealed connector. The chassis monitor is used for overall vehicle monitoring of the engine and engine diagnostics, system diagnostics, and fault indications.

RAIL14SP00882AA

Master Controller The master controller (MC2) controls the communications of the various modules associated with the vehicle functioning. The MC2 stores the master program for the vehicle, The controller features status indicators in the form of blinking lights on the controller housing. The controller is a sealed enclosure with sealed connectors. The controller is mounted under the cab and is accessible from the bottom side of the vehicle. The MC2 controller is unique to each machine and cannot be switched out with another controller without reprogramming.

RAIL14SP00090AA

Expansion Module The expansion module (XS2) primarily controls communication to the boom, product delivery, and lighting systems of the vehicle. The controller is similar in size and shape to the MC2 controller. The controller features digital inputs and outputs, status indicators in the form of blinking lights on the controller housing. The controller is a sealed enclosure with sealed connectors. The controller is mounted under the cab next to the MC2 controller and is accessible from the bottom side of the vehicle. The XS2 controller is not unique to each machine and can be switched out with another controller. 47691240 24/02/2015

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Electrical systems - Electronic modules

RAIL14SP00090AA

Joystick control handle The joystick control handle (grip) is the main control component for operator input for the vehicle. The grip feature push buttons for the control of the boom and product delivery functions, and engine speed and shifting. The grip also acts as the throttle for the vehicle. The grip is mounted to the armrest console.

RAIL14SP00086AA

Input/Output Module The input/output module (XIO2) handles the inputs and outputs for the cab controls such as the grip, the warning light panel, and the brake pedal. The XIO2 module features analog inputs, digital inputs and outputs, RS-485 interface (grip), status indicators in the form of blinking lights on the module housing. The controller is a sealed enclosure with sealed connectors. The module is mounted in the engine compartment.

RAIL14SP00092AA

There is an optional XIO2 module used on the vehicle which is used to replace the Raven super node when third party control of the spraying system is required. The module, know as XIO2 hourglass style, is mounted in the armrest console under the switch panel. The hourglass style node allows grip outputs to 3rd party control systems and features analog inputs, digital inputs and outputs, and has status indicators in the form of blinking light mounted to the node circuit board.

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Electrical systems - Electronic modules

RAIL14SP00088AA

Multiplexing Vehicle Electrical Center The Multiplexing Vehicle Electrical Center (MVEC) is fuse and relay panel. There are two MVECs on the vehicle. Each MVEC features 16 fuses, 8 relays, are CAN bus controlled and can be diagnosed via the chassis monitor. The two MVECs on the vehicle have unique fuses and software and cannot be interchanged.

RAIL14SP00089AA

Product control node The Product control node, or Super Node, controls boom functions and speed, product delivery, and Accuboom functions associated with Raven control. The node is totally enclosed and is mounted under the cab. Vehicles utilizing Autoboom height control will have an additional node mounted in an enclosure on the boom.

RAIL14SP00091AA

Terminators Terminators are terminating resistors that are part of the CAN bus. The resistors have a rating of 120 ÎŠ. There are three main terminators, one each for the CAN bus structure of the vehicle. Terminators include, and engine terminator, J1939 vehicle CAN master module (MC2) terminators, and two Raven CAN bus terminators. An additional Trimble CAN bus terminator is required for third party CAN control. 47691240 24/02/2015

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Electrical systems - Electronic modules

The engine terminator is located by the engine ECU. The J1939 terminators are connected to the MC2 and XS2 modules and are switched through the software. The two Raven terminators are located on the right boom lift arm and on the right hand frame rail just forward of the auxiliary valve.

RAIL14SP00082AA

The Trimble terminators are located at the front of the armrest and on the GPS harness.

RAIL14SP00083AA

RAIL14SP00084AA

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Index Electrical systems - 55 Electronic modules - 640 Electronic modules - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - 55 Heating, Ventilation, and Air-Conditioning (HVAC) control system 050

SP.295F SP.300F SP.345F SP.400F

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Contents Electrical systems - 55 Heating, Ventilation, and Air-Conditioning (HVAC) control system - 050

SERVICE Blower Remove - Pressurize blower motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install - Pressurize blower motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Remove - Recirculation blower motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Install - Recirculation blower motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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Electrical systems - Heating, Ventilation, and Air-Conditioning (HVAC) control system

Blower - Remove - Pressurize blower motor 1. Move the machine to a hard and level surface. 2. Turn the ignition key to the “OFF” position. 3. Turn off the power to the batteries by turning the switch attached to the engine panel to the “OFF” position. 4. Fold the instructors seat down.

RAIL13SP04730AA

RAIL13SP04724AA

RAIL13SP04736AA

5. Fold the operator seat down.

6. Remove the upper rear panel mounting bolts (1) securing the upper rear panel to the back panel. 7. Place the upper rear panel to the side. NOTE: Be sure not to disconnect the electrical connections on the bottom side of the rear panel.

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Electrical systems - Heating, Ventilation, and Air-Conditioning (HVAC) control system

8. Loosen the hose clamp (1) securing the bottom hose to the pressurize blower motor housing.

RAIL13SP04747AA

RAIL13SP04729AA

RAIL13SP04727AA

9. Remove the hose (1) from the pressurize blower motor housing (2).

10. Remove the four mounting strap bolts (1) holding the pressurize blower motor in position. 11. Remove the mounting strap.

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Electrical systems - Heating, Ventilation, and Air-Conditioning (HVAC) control system

12. Disconnect the pressurize blower motor electrical connector (1). 13. Lift the pressurize blower motor from the mounting bracket and out of the machine.

RAIL13SP04729AA

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Electrical systems - Heating, Ventilation, and Air-Conditioning (HVAC) control system

Blower - Install - Pressurize blower motor 1. Install the pressurize blower motor (3) in the proper position inside of the blower/evaporator housing. 2. Install the blower motor bracket (2) and the mounting bolts (1) securing the pressurize blower motor in the blower/evaporator housing. 3. Connect the electrical connector on the pressurize blower motor.

RAIL13SP04969AA

RAIL13SP04968AA

RAIL13SP04731AA

4. Install the blower/evaporator housing front panel (2) into the proper position on the blower/evaporator housing (1). 5. Install the front panel mounting bolts and tighten.

6. Install the back panel into the proper position in the cab of the sprayer.

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Electrical systems - Heating, Ventilation, and Air-Conditioning (HVAC) control system

7. Install the back panel mounting bolts (1) securing the back panel into the interior of the sprayer cab.

RAIL13SP04732AA

RAIL13SP04734AA

RAIL13SP04732AA

8. Install the floor mat properly into the interior of the cab. 9. Install the seat belt mounting bracket (2), the seat belt (1), and the seat belt mounting bolt (3) and tighten.

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Electrical systems - Heating, Ventilation, and Air-Conditioning (HVAC) control system

10. Install the electrical connections (1) on the back of the right rear panel (2).

RAIL13SP04971AA

RAIL13SP04736AA

11. Install the two upper rear panels (1) into the proper positions.

12. Install all of the upper rear panel mounting bolts (1) and tighten.

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Electrical systems - Heating, Ventilation, and Air-Conditioning (HVAC) control system

13. Install the operator seat (1) into the sprayer cab.

RAIL13SP04724AA

RAIL13SP04730AA

14. Install the instructor seat (1) into the sprayer cab. 15. Turn the power to the batteries on by turning the switch attached to the engine panel to the â&#x20AC;&#x153;ONâ&#x20AC;? position. 16. Cycle the blower motor multiple times to ensure proper functionality of the system.

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Electrical systems - Heating, Ventilation, and Air-Conditioning (HVAC) control system

Blower - Remove - Recirculation blower motor 1. Move the machine to a hard and level surface. 2. Turn the machine key to the “OFF” position. 3. Turn the power to the batteries off by turning the switch attached to the engine panel to the “OFF” position. 4. Remove the instructor seat (1) from the interior of the machine cab.

RAIL13SP04730AA

RAIL13SP04724AA

RAIL13SP04736AA

5. Remove the operator seat (1) from the interior of the machine cab.

6. Remove the mounting screws (1) securing the upper rear panel to the back panel.

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Electrical systems - Heating, Ventilation, and Air-Conditioning (HVAC) control system

7. Mark and disconnect the two electrical connections attached to the cigar lighter. Access the connections on the underside of the upper panel.

RAIL13SP04971AA

RAIL13SP04739AA

RAIL13SP04970AA

8. Remove the two upper rear panels (1) from the interior of the machine cab.

9. Remove the floor mat from the interior of the machine cab. 10. Remove the seat belt mounting bolt (3). 11. Remove the seat belt (1) and the seat belt mounting bracket (2).

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Electrical systems - Heating, Ventilation, and Air-Conditioning (HVAC) control system

12. Remove the back panel mounting bolts (1) securing the back panel in position.

RAIL13SP04970AA

RAIL13SP04734AA

RAIL13SP04731AA

13. Remove the back panel (1) from the cab.

14. Remove the screws attaching the front panel (1) to the blower/evaporator housing (2). 15. Remove the front plate from the blower motor housing. 16. Unhook the electrical connector connected to the blower motor.

RAIL13SP04968AA

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Electrical systems - Heating, Ventilation, and Air-Conditioning (HVAC) control system

17. Remove the mounting bolts from the blower motor mounting bracket (1) and remove the blower motor from the evaporator housing.

RAIL13SP04969AA

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Electrical systems - Heating, Ventilation, and Air-Conditioning (HVAC) control system

Blower - Install - Recirculation blower motor 1. Install the blower motor (3) in the proper position inside of the blower/evaporator housing. 2. Install the blower motor bracket (2) and the mounting bolts (1) securing the blower motor in the blower/evaporator housing. 3. Connect the electrical connector on the blower motor.

RAIL13SP04969AA

RAIL13SP04968AA

RAIL13SP04731AA

4. Install the blower/evaporator housing front panel (2) into the proper position on the blower/evaporator housing (1). 5. Install the front panel mounting bolts and tighten.

6. Install the back panel into the proper position in the cab of the machine.

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Electrical systems - Heating, Ventilation, and Air-Conditioning (HVAC) control system

7. Install the back panel mounting bolts (1) securing the back panel into the interior of the machine cab.

RAIL13SP04732AA

RAIL13SP04734AA

RAIL13SP04732AA

8. Install the floor mat properly into the interior of the cab. 9. Install the seat belt mounting bracket (2), the seat belt (1), and the seat belt mounting bolt (3) and tighten.

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Electrical systems - Heating, Ventilation, and Air-Conditioning (HVAC) control system

10. Install the electrical connections (1) on the back of the right rear panel (2).

RAIL13SP04971AA

RAIL13SP04736AA

11. Install the two upper rear panels (1) into the proper positions.

12. Install all of the upper rear panel mounting bolts (1) and tighten.

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Electrical systems - Heating, Ventilation, and Air-Conditioning (HVAC) control system

13. Install the operator seat (1) into the machine cab.

RAIL13SP04724AA

RAIL13SP04730AA

14. Install the instructor seat (1) into the machine cab. 15. Turn the power to the batteries on by turning the switch attached to the engine panel to the â&#x20AC;&#x153;ONâ&#x20AC;? position. 16. Cycle the blower motor multiple times to ensure proper functionality of the system.

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Index Electrical systems - 55 Heating, Ventilation, and Air-Conditioning (HVAC) control system - 050 Blower - Install - Pressurize blower motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Blower - Install - Recirculation blower motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Blower - Remove - Pressurize blower motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Blower - Remove - Recirculation blower motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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Electrical systems - 55 Steering control system - 047

SP.295F SP.300F SP.345F SP.400F

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Contents Electrical systems - 55 Steering control system - 047

SERVICE Steering control system Remove - Four wheel steer components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install - Four wheel steer components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Electrical systems - Steering control system

Steering control system - Remove - Four wheel steer components Lineal position sensors 1. Three lineal position sensors (1) are mounted inline with the wheel steer cylinders. The positions sensors are mounted inline with left and right rear cylinders and the left front cylinder.

RAIL13SP05041AA

RAIL13SP05047AA

2. Disconnect the electrical connector attached to the sensor wire.

3. Remove the sensor from its mounting position by removing the nut (1) from the ball end joint at the front of the sensor.

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Electrical systems - Steering control system

4. Remove the nut from the rear ball end joint attaching the sensor to the steering cylinder. 5. Remove the sensor from the machine.

RAIL13SP05050AA

RAIL13SP05048AA

Proximity sensor 1. Two proximity sensors (1) are mounted adjacent to the left and right rear stop cylinders (2).

2. Remove the proximity sensor by disconnecting the electrical connector attached to the sensor wire.

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Electrical systems - Steering control system

3. Remove the screw, nut and washer (1) attaching the sensor to the mounting bracket. 4. Remove the sensor from the bracket.

RAIL13SP05048AA

RAIL13SP05044AA

RAIL13SP05045AA

XI 02 control 1. The XI 02 control box (1) controls all digital input and output signals. The control is located under the raised deck above the rear fender. 2. Remove the control by disconnecting the electrical connection attached to the control. Remove the nuts, washers and screws attaching the control to the underside of the deck. Remove the control from the machine.

MC2 master controller 1. The MC2 master controller (1) generates the pulse width modulation (PWM) signal sent to the steering control valve. The controller is mounted under the cab. 2. Remove the controller from the machine by disconnecting the electrical connector and remove the bolts attaching the controller to the machine.

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Electrical systems - Steering control system

Steering control system - Install - Four wheel steer components Lineal position sensors 1. Position the lineal position sensor (1) inline with the designated steering cylinder.

RAIL13SP05041AA

RAIL13SP05050AA

RAIL13SP05047AA

2. Attach the rear end of the sensor to the steering cylinder using the nut. Tighten securely.

3. Attach the front end of the sensor to the steering cylinder pin weldment (1) using the nut (2). Tighten securely.

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Electrical systems - Steering control system

4. Connect the electrical connector to the senor connector.

RAIL13SP05041AA

RAIL13SP05048AA

Proximity sensor 1. Attach the proximity sensor (1) to the mounting bracket (2) using the screw, nut, and washer (3). Tighten securely.

2. Connect the electrical connector to the proximity sensor.

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Electrical systems - Steering control system

XI 02 controller 1. Attach the XI 02 control to the underside of the raised deck using screws, washers, and nuts. Tighten securely. 2. Connect the electrical connector to the control.

RAIL13SP05044AA

RAIL13SP05045AA

MC2 master controller 1. Attach the MC2 master controller to the underside of the cab using the mounting bolts. Tighten securely. 2. Connect the electrical connector to the MC2 master controller.

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Index Electrical systems - 55 Steering control system - 047 Steering control system - Install - Four wheel steer components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Steering control system - Remove - Four wheel steer components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404 SERVICE - Technical Publications & Tools

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SERVICE MANUAL Spraying SP.295F SP.300F SP.345F SP.400F

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Contents Spraying - 78

[78.110] Chemical spraying. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.1 [78.111] Spraying pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.2 [78.120] Foam marking system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.3

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Contents Spraying - 78 Chemical spraying - 110

FUNCTIONAL DATA Chemical spraying Overview - Sprayer overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Chemical spraying Adjust - Flow meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Calibrate - Flow meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Product tank Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Rinse tank Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Remove - Hand rinse tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Install - Hand rinse tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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Spraying - Chemical spraying

Chemical spraying - Overview - Sprayer overview 1. Confirm main product strainer (1) and boom strainers (2) are clean and free of undissolved powder, etc.

2. Check the following components and lines as indicated: • Flow control valve (Switch to manual control and increase/decrease pressure to confirm operation) • Intake of pump • Impeller • Monitor, for flow control operation • Ball valves NOTE: If the ball valves have been thermally tripped, the power to the ball valves must be disconnected for 20 seconds and then reconnected. • Gauge, for correct operation

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RAIL13SP03387AA

RAIL13SP03390AA

Spraying - Chemical spraying

3. Confirm speed input from GPS (1) , radar, or ground speed sender (2). Is the speed reading steady and accurate?

RAIL13SP03389AA

RAIL13SP03398AA

RAIL13SP03877AA

4. Switch product controller to manual to momentarily eliminate speed and flow meter input. Turn product pump switch in cab on to energize the product pump coil to allow the oil to flow to the 114 l (30 US gal) flow control valve, which regulates the speed of product pump. Use a voltmeter to test/confirm 12 V and ground at product pump coil. Next test for magnetism with a steel object on top of coil. If voltage is present with little or no magnetism, the coil may be faulty. If 12 V is not present, test the pump on/off switch in cab console, or (if so equipped) the optional remote pump switch located by the fill station. One of these components may be at fault.

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Spraying - Chemical spraying

5. The 114 l (30 US gal) flow control valve increases and decreases the flow of oil to the product pump motor driving the product pump impeller. • The valve motors can be opened and closed by using the manual increase and decrease on the control console. • If the motor will not open or close, use a voltmeter to test the wire connected to the flow valve. When in manual and increasing, a reading of 12 - 13–1/2 V between the increase and decrease connector should be identified. When decreasing, the polarity will reverse. If voltage is not detected, test at the connector in the lower rear corner of the cab where it enters.

RAIL13SP03394AA

RAIL13SP03395AA

6. The sprayers also have a separate harness for the flow control valve and flow meter. The second test point position for testing the flow control valve would be at the lower cab corner, but with a marking PD 22.

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Spraying - Chemical spraying

7. With a voltmeter, test the plug as shown above from 2 a clock (1) to the 6 a ’clock (2) positions, and from the 2 a clock (1) to the 10 a clock (3) positions for 5 V. Positions are relative from the keyway of the connector (4). Next, use the following instructions to manually determine if the cable is transmitting a signal from the flow meter to the console. The opposite end of the cable attaches to the lower right hand corner of the cab and a voltage and continuity test can be conducted to confirm a break in the cable to the meter. • Enter a METER CAL number of "1" in the console key labeled “Meter Cal 5”. • Depress the key on the console labeled “Tank Volume 9”. Clear and enter "0". • Place BOOM switch ON, master and power ON. • With a small jumper wire (or paper clip), short between 2 a clock (1) and 6 a clock (2) sockets with a “short / no short” motion. • Each time a contact is made, the TOTAL VOLUME should increment up 1 or more counts. • If TOTAL VOLUME does not count up, remove the section of cable and repeat the test at the connector next closest to the console. Replace defective cable as required. • Perform all voltage checks. • If all cables test good, replace the flow meter. • After testing is complete, re-enter correct METER CAL numbers before application. 8. Before removing the flow meter for inspection, if available, plug in a replacement meter and blowthrough with the cable attached. Using the previously outlined procedure, attempt to count up and confirm operation.

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RAIL13SP03392AA

Spraying - Chemical spraying

9. Inspect the installed flow meter for any physical damage wires, plug, etc. which would affect the operation. Remove the flow meter from the line and check to be sure that the fin area turns freely. The unit can be split by removing the clamp and cleaning the internal components with tank cleaner solution. If the flow meter still will not send a signal, remove and replace it. Be sure to confirm the new meter Cal number and enter it into the control console.

RAIL13SP03393AA

RAIL13SP03402AA

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Spraying - Chemical spraying

Chemical spraying - Adjust - Flow meter 1. Remove the flow meter from the sprayer and flush with clean water to remove any chemicals. 2. Remove the flange bolts or clamp from the flow meter. 3. Remove the turbine hub and turbine from inside the flow meter. 4. Clean the turbine hub of metal filings and any other foreign material, such as wettable powders. Confirm that the turbine blades are not worn. Hold turbine and turbine hub in your hand and spin turbine. It should spin freely with very little drag. 5. If transducer (XDCR) assembly is replaced or if turbine stud is adjusted or replaced, verify the turbine fit before reassembling. Hold turbine hub with turbine on transducer. Spin turbine by blowing on it. Tighten turbine stub until turbine stalls. Loosen turbine stud 1/3 turn. The turbine should spin freely. 6. Reassemble the flow meter. 7. Using a low-pressure 34.5 kPa (5.0 psi) jet of air, verify that the turbine spins freely. If there is drag, loosen the hex stud on the bottom of the turbine hub 1/16 turn until the turbine spins freely. 8. If the turbine spins freely and if the cables have checked out per the Chemical spraying - Overview Sprayer overview (78.110) cable test procedure, but flow meter still is not totalizing properly, replace the flow meter transducer. 9. If flow meter transducer is replaced, flow meter will require to be recalibrated as outlined in Chemical spraying - Calibrate - Flow meter (78.110) recalibration procedure.

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Spraying - Chemical spraying

Chemical spraying - Calibrate - Flow meter 1. Enter a METER CAL number of 10 (38) in the key labeled METER CAL 5. 2. Enter a TOTAL VOLUME of 0 in the key labeled TOTAL VOLUME. 3. Switch OFF all booms. 4. Remove a boom hose and place it into a calibrated 19 l (5 US gal) container. 5. Switch ON appropriate boom switch, for the hose that was just placed into the 19 l (5 US gal) container, and the MASTER switch. Pump exactly 38 l (10 US gal). 6. Readout in TOTAL VOLUME is the new METER CAL number. This number should be within +/- 3 percent of the calibration number stamped on the tag of the Flow Meter. 7. Repeat this procedure several times to confirm accuracy. (Always "zero out" the TOTAL VOLUME display before retesting.) NOTE: For greater precision, set METER CAL to 100 and pump 379 l (100 US gal) of water. 8. To verify Flow Meter calibration, fill applicator tank with a predetermined amount of measured liquid. DO NOT RELY ON GRADUATION NUMBERS MOLDED INTO APPLICATOR TANK. Empty the applicator tank under normal operating conditions. If the number displayed under TOTAL VOLUME is different from the predetermined amount of measured liquid by more than +/- 3 percent, complete the following calculation: Example METER CAL TOTAL VOLUME Predetermined amount of measured liquid Corrected METER CAL =

= 720 (190) = 260 (984) = 250 (946) METER CAL x TOTAL VOLUME / Predetermined amount of measured liquid

ENGLISH UNITS: Gallons = 720 x 260 / 250 = 749 Corrected METER CAL = 749 (198)

METRIC UNITS: Liters = 190 x 984 / 946 = 198

9. Enter corrected METER CAL before resuming application.

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Spraying - Chemical spraying

Product tank - Remove 1. Position right sprayer arm out. 2. Drain product tank. NOTE: On vehicles with a 1600-gallon product tank, partially drain fuel tank and rinse tank, loosen the attaching hardware of the fuel tank and the rinse tank. Move the tanks out of the way in order to enable the removal of product tank. 3. Tag and mark fluid lines on product tank. Cut wire tires as required for line disconnect. 4. Loosen band clamp/hardware (1) and disconnect large product line (2) located at product tank (3) that protrudes underneath vehicle.

RAIL13SP03437AA

RAIL13SP03441AA

RAIL13SP03439AA

5. Loosen band clamp/hardware (4) and disconnect vent line (5) from fitting (6) on top of product tank (3). 6. Loosen band clamp/hardware (7) and disconnect upper and lower product lines (8) from product tank fittings (9).

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Spraying - Chemical spraying

7. Remove four hex bolts (10), eight flat washers (11), and four locknuts (12) securing product tank brackets (13) to frame. 8. Attach suitable lifting device to product tank (3), following all safety precautions for device.

RAIL13SP01126AA

CAUTION Heavy object! The component is heavy. Use care not to drop the component when installing, removing, or handling. Failure to comply could result in minor or moderate injury. C0095A

Remove product tank (3) from vehicle. 10. Remove lifting device.

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Spraying - Chemical spraying

Product tank - Install 1. Using lifting device, position product tank onto vehicle, following all safety precautions for lifting device. 2. Secure product tank (3) to frame by installing four hex bolts (10), eight flat washers (11), and four locknuts (12) into product tank brackets (13).

RAIL13SP01126AA

RAIL13SP03441AA

RAIL13SP03439AA

RAIL13SP03437AA

3. Install band clamp/hardware (7) securing upper and lower product lines (8) onto product tank fittings (9). 4. Install band clamp/hardware (4) securing vent line (5) onto fitting (6) on top of product tank (3).

5. Install band clamp/hardware (1) securing large product line (2) at connection point underneath product tank (3). 6. Remove lifting device from product tank.

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Spraying - Chemical spraying

Rinse tank - Remove 1. Drain the fluid from the tank. Remove the hex plug from the bottom of the tank after the fluid has been drained. 2. Loose the nut on the band clamp (1) securing the water line (2) to the rinse tank (3) and pull water line off of the fitting. 3. Remove four hex bolts (4), eight flat washers (5), and four locknuts (6) securing rinse tank weldment brackets (7) to frame. NOTE: If equipped with a foamer, remove foamer line from bottom of rinse tank.

RAIL13SP01143FA

4. Attach suitable lifting device to rinse tank, following all safety precautions for device. 5. Remove rinse tank/weldments assembly from frame with lifting device. 6. Remove lifting device.

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Spraying - Chemical spraying

Rinse tank - Install 1. With lifting device, position rinse tank/weldments assembly onto frame. 2. Secure rinse tank weldment brackets (7) to frame by installing four hex bolts (4), eight flat washers (5), and four locknuts (6). 3. Install water line (2) onto tank (3) by securing with band clamp/nut (1).

RAIL13SP01143FA

4. Install water line for foamer, if equipped. 5. Remove lifting device. 6. Install hex plug into rinse tank.

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Spraying - Chemical spraying

Rinse tank - Remove - Hand rinse tank 1. Drain the fluid form the hand rinse tank. The hand wash tank is located at the upper left hand rear side of the cab. 2. Remove the hose and clamp from the tank outlet. 3. Remove the bolts securing the tank to the mounting bracket. Remove the tank from the vehicle.

RAIL12SP01102AA

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Spraying - Chemical spraying

Rinse tank - Install - Hand rinse tank 1. Position the hand rinse tank (1) on the mounting bracket located at the upper left hand rear of the cab. 2. Secure the tank to the mounting bracket using the bolts previously removed. Tighten the bolts securely. 3. Attach the hose to the hand rinse tank using the hose clamp (2) . Tighten the clamp securely. 4. Fill the hand rinse tank with fresh rinse water. Open the upper and lower valves (3) to ensure flow from the tank.

RAIL12SP01102AA

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Index Spraying - 78 Chemical spraying - 110 Chemical spraying - Adjust - Flow meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Chemical spraying - Calibrate - Flow meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Chemical spraying - Overview - Sprayer overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Product tank - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Product tank - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Rinse tank - Install - Hand rinse tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Rinse tank - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Rinse tank - Remove - Hand rinse tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Rinse tank - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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Spraying - 78 Spraying pump - 111

SP.295F SP.300F SP.345F SP.400F

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Contents Spraying - 78 Spraying pump - 111

FUNCTIONAL DATA Product pump Overview - Product pump troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Product pump Service instruction - Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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Spraying - Spraying pump

Product pump - Overview - Product pump troubleshooting If spraying performance is unsatisfactory or hydraulic system heat is excessive, check the following troubleshooting guide for possible problems and solutions. Problem Low discharge

Possible cause Pump not primed.

Possible solution Remove topmost vent plug from face of pump and run pump to expel trapped air. Air leaks in suction line. Check and reseal inlet fittings. Blocked or clogged line strainer. Inspect strainer and clear any debris from screen. Impeller plugged. Inspect and clear obstruction. Undersize suction line or collapsed Suction line should be the same hose. diameter as inlet port of pump or larger. (If equipped with bypass adjustment Adjust bypass screw on side of screw) Bypass adjustment screw not hydraulic motor in until fully screwed in. set properly Eye of impeller rubbing on volute. Remove volute (front cover) and inspect the impeller. If wear detected, sand the impeller eye O.D. with emery cloth.

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Spraying - Spraying pump

Product pump - Service instruction - Maintenance 1. Clean the spraying system by flushing the pump and the entire spraying system with a solution that will chemically neutralize the liquid that has been used for spraying. Mix according to the manufacturerâ&#x20AC;&#x2122;s directions. 2. Flush the pump with RV antifreeze. after cleaning the pump in order to prevent corrosion. NOTE: Plug the pump ports to keep out air during storage. For short periods of idleness, noncorrosive liquids may be left in the pump, but air must be kept out. Plug the ports or seal the port connections

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Spraying - Spraying pump

Product pump - Remove 1. Close the product tank valve. Drain all product lines. Flush cleaner solution through the pump before disassembling. 2. Locate product pump toward left side of vehicle, inside frame, under product tank. 3. Remove three hydraulic hoses (feed, return, case drain) from hydraulic motor. 4. Cap and plug all hose ends and motor ports. 5. Disconnect all product hoses from pump and remove pump from frame.

RAIL13SP03450AA

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Spraying - Spraying pump

Product pump - Disassemble Product pump disassembly 1. Using a 9/16 in box end wrench, remove four hex head bolts holding pump casing to mounting flange. If necessary, tap pump casing outlet port with rubber mallet or hammer to separate. 2. To remove impeller nut, insert a large screwdriver or file (at least 254 mm (10 in) long) into impeller vanes to prevent impeller from turning when loosening nut. Use a 5/8 in socket wrench to remove impeller nut by turning it counterclockwise.

RAIL13SP01127AA

RAIL13SP01128AA

3. Once nut is removed, place screwdriver on each side behind impeller and pry away from mounting flange. Remove woodruff key from shaft. Remove O-ring from mounting flange.

4. Remove the pump seal by lightly lubricating the shaft for easier removal of seal. Using two screwdrivers positioned opposite each other, pry the rotary portion of the seal from the shaft. NOTE: In the case of a severe pump seal leak, the shaft/bearing assembly in the hydraulic motor should be inspected for possible contamination. 5. Using a 1/2 in box end wrench, remove four bolts holding motor to mounting flange. Remove motor. 6. Using a screwdriver and hammer, tap out stationary portion of mechanical seal from motor-side of mounting flange. 47691240 24/02/2015

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Spraying - Spraying pump

NOTE: If motor is not removed, seal can be pried out with a small screwdriver. However, seal will be damaged by removal in this manner. A new seal must be used when pump is reassembled. 7. Clean the outlet port, inlet port, and sealing areas of O-ring on pump casing and mounting flange using a circular bottle-type wire brush with air or hand drill. Clean the seal cavity in the mounting flange using a port brush. 8. After wire brush cleaning, it is recommended that pump casing and mounting flange be further cleaned in a solvent tank to remove rust and corrosion particles.

Standard hydraulic motor disassembly 9. Remove mounting flange from motor body and place hydraulic motor in a vise.

RAIL13SP01131AA

10. Remove tank port adapter and pressure port adapter with a large crescent wrench or 1â&#x20AC;&#x201C;1/16 in box end wrench. 11. Using a 9/16 in box end wrench, loosen nut on bypass adjusting screw. 12. Use a small screwdriver to remove the bypass adjusting screw from motor. (This will remove the screw, nut, washer, and thread seal gasket.) (Earlier models only.) 13. Use a 1/4 in Allen (hex) wrench to remove the socket head cap screws from the motor end plate.

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Spraying - Spraying pump

14. Use a small screwdriver to carefully pry apart the end plate and gerotor housing, at the boss area of the housing, if motor end plate will not lift off easily. If gerotor housing will not lift off easily, carefully pry apart boss area between the gerotor housing and the motor body. It may be necessary to alternate sides when prying apart motor sections.

RAIL13SP01132AA

15. Remove both parts of gerotor. 16. Remove key from shaft. 17. Remove O-ring from motor end plate and body with a flat instrument such as a knife blade. 18. Inspect motor end plate, body, and gerotor housing for wear and/or gouging. NOTE: If gouging has occurred in both motor end plate and body, motor is not repairable. If gouging has occurred in the motor end plate, body, or gerotor housing, the part that is worn must be replaced. If gerotor housing is damaged, gerotor parts must also be replaced.

Motor shaft removal and disassembly 19. Remove the slinger ring from the motor shaft. 20.

CAUTION Eye injury hazard! Always wear eye or full face protection when performing this procedure. Failure to comply could result in minor or moderate injury. C0081A

Using large retaining ring pliers, remove retaining ring next to ball bearing in motor body.

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Spraying - Spraying pump

21. Remove a retaining ring that is binding against the bearings by placing the motor body, with the threaded portion of the shaft facing downward, on an arbor press. Use a piece of unthreaded metal pipe ( 25.4 mm (1.0 in) diameter x 101.6 mm (4.0 in) high slid over the shaft, gently press down with the arbor press with enough force to relieve the pressure on the retaining ring.

RAIL13SP01133AA

RAIL13SP01134AA

22. Place motor body in position on arbor press. Threaded portion of shaft should be inside fixture. Press out shaft assembly with arbor press. 23. Remove large retaining ring from shaft with a screwdriver. Remove thrust bearing assembly from shaft (includes thrust bearing and two thrust bearing races) and seal spacer. 24. Remove the small retaining ring next to the shaft ball bearing. 25. Remove the bearings from shaft by placing the shaft (threaded end up) in arbor press fixture. Place two support bars opposite each other and between seal on the shaft and the arbor press fixture. Using an arbor press, press the shaft through the bearing, seal spacer and the seal.

26. Inspect sealing area of the shaft for wear. Inspect other shaft assembly components for wear and replace if necessary. 27. Clean all motor parts in a solvent bath.

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Spraying - Spraying pump

Product pump - Assemble Motor shaft assembly 1. The sealing lips on a new seal must be expanded to fit on shaft. Press seal onto large end of shaft with seal lip facing out. Do not push seal past keyway on shaft. 2. Once seal lip has expanded, remove seal from shaft. 3. With the seal lip facing the large end of the shaft, slide the seal over threaded end of shaft and gently push onto raised area of the shaft, stopping approximately 6.35 mm (0.25 in) from large retaining ring groove. 4. Over large end of the shaft, install seal spacer, thrust bearing race, thrust bearing, second thrust bearing race, and large retaining ring. 5. Over the threaded end of the shaft, install the spacer ring and the ball bearing. 6. Insert shaft (threaded end down) into arbor press fixture. Place two support bars opposite each other and between the bearing and fixture. Place on an arbor press and carefully press shaft down, allowing just enough room for retaining ring next to the bearing to be installed. NOTE: Make sure the spacer ring between the seal and bearing is free floating (not binding). Should the main needle bearings in the hydraulic motor need replacement, a new body and/or end plate with the main bearing already installed must be used. If this occurs, check other internal parts of the motor for damage and wear. 7. Place the shaft assembly into the motor body bearing bore with the threaded end up. 8. On arbor press, place body on arbor press fixture. NOTE: Make sure the surface edge of the fixture is smooth and clean

RAIL13SP01135AA

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Spraying - Spraying pump

9. An unthreaded piece of pipe 25.4 mm (1.0 in) diameter x 101.6 mm (4.0 in) high is needed to support the outer bearing race on the shaft ball bearing. Place this pipe over the shaft and press shaft assembly down until retaining ring can be installed in its groove in the bearing core of the motor body

RAIL13SP01136AA

Hydraulic motor parts assembly 10. Place motor body in a vise with large end of shaft facing up. 11. Install O-ring in body. 12. Install key on shaft. Place inner gear of gerotor onto shaft making sure gerotor slot lines up with key in shaft. NOTE: The key can slide up behind the inner gear of the gerotor when the gear is installed. Make sure the key is visible in the slot after the gear is in place. 13. Install outer portion of gerotor, making sure gerotor is centered within O-ring groove on body. 14. Install gerotor housing, making sure pins in gerotor housing line up with their respective holes in body. 15. Lightly lubricate area between inner and outer gerotor, and outer gerotor and gerotor housing, with hydraulic oil or mineral oil. 16. Install O-ring on motor end plate. 17. Place end plate on gerotor housing, making sure holes in end plate line up with pins in gerotor housing. 18. Install four socket head cap screws in motor end plate, and using a 1/4 in Allen wrench, tighten cap screws alternately and evenly in a crisscross pattern to approximately 20 NÂˇm (15 lb ft) of torque. 19. Install thread seal gasket on bypass adjusting screw (if equipped). Put gasket on from slotted end and turn until four threads on screw are showing. Install washer and nut. Install bypass adjusting screw in motor end plate. NOTE: For closed-center hydraulic systems, turn bypass adjusting screw in until it bottoms out in end plate. Tighten nut down with a 9/16 in box end wrench. 20. Replace O-ring on both port adapters.

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Spraying - Spraying pump

21. Install pressure port adapter and tank port adapter back onto motor. (For ease of installation, tighten pressure port adapter first, then tank port adapter.) 22. Remove hydraulic motor from vise. Turn shaft by hand to check for binding. 23. Install slinger ring over motor shaft. 24. Install motor into pump mounting flange. 25. Insert four hex head bolts; then, alternately and evenly, tighten them.

Pump Assembly 26. Lubricate seal cavity in mounting flange with NLGI NO. 2 MULTI -PURPOSE LITHIUM EP GREASE or equivalent. Do not lubricate shaft. 27. Install stationary portion of mechanical seal by sliding over shaft with ceramic side out. 28. To seat the seal in seal cavity, use a piece of 3/4 in PVC pipe, 101.6 - 152.4 mm (4.0 - 6.0 in). Lubricate sealing surface on seal after it is seated. Do not lubricate shaft. 29. To install rotary portion of mechanical seal, place it over shaft with carbon-side facing in, and press against stationary portion. 30. Install rubber gasket over shaft against rotary portion of seal. NOTICE: The threads of the plastic seal nut are fine and can be easily cross-threaded. To prevent cross-threading, turn the plastic seal nut counterclockwise until area of thread engagement is detected; then turn the plastic seal nut clockwise until it is secure. Do not over tighten the plastic seal nut.

RAIL13SP01130AA

31. Insert woodruff key into shaft key slot; then place impeller on shaft and align it with key and press against the mechanical seal assembly. Apply LOCTITEÂŽ 243â&#x201E;˘ to impeller nut, and using a 5/8 in socket wrench and a screwdriver to hold impeller, install impeller nut. 32. Install O-ring on mounting flange. Replace O-ring if worn or damaged. 33. Place pump casing on mounting flange, insert and tighten bolts.

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Spraying - Spraying pump

Product pump - Install 1. Install the pump assembly into the frame. 2. Connect all the product hoses to the pump. 3. Uncap all hose ends and motor ports. 4. Attach the three hydraulic hoses (feed, return, case drain) to the hydraulic motor.

RAIL13SP03450AA

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Index Spraying - 78 Spraying pump - 111 Product pump - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Product pump - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Product pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Product pump - Overview - Product pump troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Product pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Product pump - Service instruction - Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Spraying - 78 Foam marking system - 120

SP.295F SP.300F SP.345F SP.400F

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Contents Spraying - 78 Foam marking system - 120

FUNCTIONAL DATA Foam marking system Overview - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Foam marking system Service instruction - Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Test - Control box test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Spraying - Foam marking system

Foam marking system - Overview - Troubleshooting Problem You do not get foam.

Possible cause Air supply not properly connected.

Not enough foam concentrate.

Not enough foam.

In-line filter dirty or clogged. Shut off valve closed. Not enough foam concentrate.

Wet foam.

Hole in air line. Pinched air or liquid lines. Clogged in-line filter/foam heads. Not enough foam concentrate.

Foam does not last on the ground.

Dirty in-line filter/foam heads. Too little concentrate being used.

Blowing foam in windy weather.

Foam too light or dry. Decrease concentrate with in-cab switch

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Possible solution Be sure the air line and liquid lines do not have a hole in them or are not pinched. Remove air and liquid tubing at each foam mixing chamber and check for flow. Very hard water may require a greater amount of concentrate to produce good foam. Not having enough foam concentrate may make good foam, but not make enough of it. Use a high-quality foam concentrate. Adjust foam concentrate with in-cab switch. Check and clean the in-line filter. Open shut off valve near filter. Adjust foam concentrate with in-cab switch. Check air and liquid lines. Check and clean filter/foam heads. Adjust foam concentrate with in-cab switch. Check and clean filter/foam heads. Use higher quality foam concentrate or increase concentrate with in cab switch. Decrease concentrate with in-cab switch.

Spraying - Foam marking system

Foam marking system - Service instruction - Maintenance Foam heads and In-Line Filter 1. The screens inside the foam heads should be washed periodically with hot water. 2. The in-line filter element should be cleaned occasionally to ensure sufficient liquid flow to the foam head assemblies.

RAIL13SP01144FA

Foamhead Assembly Item 1 2 3 4 5 6 7 8 9 10 11

Description Hose Barb Nipple Top Housing Gasket Screen Base Housing Reducer (Brass) Tee (Brass) Straight Quick Connect with Venturi Black Poly Tubing Reducer (Brass) Black Poly Tubing

Control module 1. The unit should have hot water run through each side periodically to ensure proper flow.

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Spraying - Foam marking system

Pressure relief valve 1. VERSATRAC model foam markers are equipped with a relief valve that has been factory set at 138 kPa (20 psi). This valve prevents over-pressurization of the system. Check its operation periodically. Do not attempt to operate the system or adjust the relief valve above 138 kPa (20 psi).

Winterization of foamer system NOTE: The liquid lines and tank must be drained completely prior to storage. If liquid in this system is allowed to freeze, several components of the system may be damaged. 1. Remove the in-line filter bowl at the bottom of the tank and flush the tank with warm water. 2. Replace the in-line filter. Fill the tank with at least two gallons of hot water. Turn on machine and system and allow water to run out each side until no foam is generated. Repeat if necessary. 3. Add antifreeze to the tank. Do not use windshield washer fluid because it can clog the foamer. 4. Turn on machine and system until antifreeze reaches each foam head. 5. Check the air lines and liquid lines for holes and replace as required. Be sure to flush, then drain all liquid from the system prior to storage in freezing temperatures.

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Spraying - Foam marking system

Foam marking system - Test - Control box test 1. Disconnect the control box cable from the power unit/ tank assembly and test at the control box cable plug with a tester to verify voltage, as follows. 2. With power connected to the control box power leads [Red (+) Black (-)], set power source to 12 VDC. 3. Check Pin 4 (black) to (-) on tester and Pin 2 (red) to (+) on tester. Result: Should have 12 VDC signal when switch is turned to Right side only. Supplies power to the liquid and air side switching solenoids when on Right side. 4. Check Pin 4 (black) to (-) on tester and Pin 1 (brown) to (+) on tester. Result: Should have 12 VDC signal when switch is turned to Right side only. Supplies power to the liquid and air side switching solenoids when on Right side. 5. Check Pin 5 (green) to (-) on tester and Pin 2 (red) to (+) on tester. Result: Should have 12 VDC signal when the switch is turned to Left or Right side and also when the Foam Frequency Knob is increased and decreased. Supplies PWM signal to water pump. 6. Pin 6 (white) to (-) on tester and Pin 2 (red) to (+) on tester. Result: Should have 12 VDC signal when the switch is turned to Left or Right side and also when the Foam Frequency and the Foam Mixture Knobs are increased and decreased. Supplies PWM signal to concentrate pump. 7. If the control box does not function as described in Step 3 through Step 6, it should be returned for repairs to the internal circuit board.

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Index Spraying - 78 Foam marking system - 120 Foam marking system - Overview - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Foam marking system - Service instruction - Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Foam marking system - Test - Control box test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404 SERVICE - Technical Publications & Tools

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SERVICE MANUAL Platform, cab, bodywork, and decals SP.295F SP.300F SP.345F SP.400F

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Contents Platform, cab, bodywork, and decals - 90

[90.151] Cab interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1 [90.120] Mechanically-adjusted operator seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2 [90.100] Engine hood and panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.3 [90.116] Fenders and guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.4

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Platform, cab, bodywork, and decals - 90 Cab interior - 151

SP.295F SP.300F SP.345F SP.400F

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Contents Platform, cab, bodywork, and decals - 90 Cab interior - 151

SERVICE Instructional seat Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Platform, cab, bodywork, and decals - Cab interior

Instructional seat - Remove 1. Move the machine to a hard and level surface. 2. Turn the ignition key to the â&#x20AC;&#x153;OFFâ&#x20AC;? position. 3. Fold the base of the instructional seat up in order to access the seat mounting bolts. 4. Fold the floor mat (1) back in order to remove the instructional seat from the interior of the cab.

RAIL13SP05154AA

RAIL13SP05152AA

5. Remove the two instructional seat mounting bolts (1) and remove the instructional seat from the interior of the cab.

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Platform, cab, bodywork, and decals - Cab interior

Instructional seat - Install 1. Install the instructional seat into the proper position in the interior of the cab. 2. Install the two instructional seat mounting bolts and tighten to the proper specifications.

RAIL13SP05152AA

RAIL13SP05154AA

3. Place the floor mat into the proper position around the instructional seat.

4. Place the base of the instructional seat into the proper position. 5. Cycle the seat up and down multiple times to ensure the proper component functionality.

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Index Platform, cab, bodywork, and decals - 90 Cab interior - 151 Instructional seat - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Instructional seat - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Platform, cab, bodywork, and decals - 90 Mechanically-adjusted operator seat - 120

SP.295F SP.300F SP.345F SP.400F

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Contents Platform, cab, bodywork, and decals - 90 Mechanically-adjusted operator seat - 120

SERVICE Operator seat Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Seat suspension unit Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Platform, cab, bodywork, and decals - Mechanically-adjusted operator seat

Operator seat - Remove 1. Move the machine to a hard and level surface. 2. Turn the ignition key to the “OFF” position. 3. Turn the power to the batteries off by turning the switch attached to the engine panel to the “OFF” position.

RAIL14SP00818AA

RAIL13SP05155AA

RAIL13SP05149AA

4. Support the armrest assembly and remove the four nuts (1) securing the seat mounting plate to the armrest.

5. Remove the four bolts (1) (one on each corner of the seat) securing the seat and the seat mounting plate to the base.

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Platform, cab, bodywork, and decals - Mechanically-adjusted operator seat

6. Unhook the electrical connection (1) on the rear of the seat.

RAIL13SP05149AA

RAIL13SP04724AA

7. Remove the seat from the interior of the cab.

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Platform, cab, bodywork, and decals - Mechanically-adjusted operator seat

Operator seat - Install 1.

CAUTION Avoid injury! The seat is heavy and will require two people or a lifting device to remove from the cab. Failure to comply could result in minor or moderate injury. C0089A

Install the seat (1) and the seat mounting plate into the proper position in the interior of the cab.

RAIL13SP04724AA

RAIL13SP05155AA

RAIL13SP05149AA

2. Using the four nuts (1), secure the seat and the seat mounting plate to the armrest. 3. Tighten the nuts to the proper specifications.

4. Using the four nuts (1) and bolts, secure the seat and the seat mounting plate to the base (2). 5. Tighten the bolts and nuts to the proper specifications.

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Platform, cab, bodywork, and decals - Mechanically-adjusted operator seat

WARNING Improper operation or service of this machine can result in an accident. Before working on any component(s) of the electrical circuit, put the ignition key in the off (shut down) position. When disconnecting batteries, always disconnect the negative (-) cable first. When reconnecting batteries, always connect the negative (-) cable last. Failure to comply could result in death or serious injury. W0943A

Hook the electrical connection located at the rear of the seat. RAIL13SP05149AA

RAIL14SP00818AA

7. Turn the power to the batteries on by turning the switch attached to the engine panel to the â&#x20AC;&#x153;ONâ&#x20AC;? position.

8. Cycle and move the seat to ensure the proper installation of the seat has been achieved.

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Platform, cab, bodywork, and decals - Mechanically-adjusted operator seat

Seat suspension unit - Remove 1. Move the machine to a hard and level surface. 2. Turn the ignition key to the â&#x20AC;&#x153;OFFâ&#x20AC;? position. 3. Remove the operator seat. Refer to Operator seat Remove (90.120). 4. Remove the floor mat from the interior of the cab. 5. Access the seat suspension unit mounting bolts by moving the cowling (1) around the suspension unit up and away from the bolts.

RAIL13SP05149AA

RAIL13SP05153AA

6. Remove the four suspension unit mounting bolts (one on each corner of the unit) securing the suspension unit to the interior of the cab.

WARNING Heavy object! The following instruction requires two people. Failure to comply could result in death or serious injury. W1270A

Remove the seat suspension unit from the interior of the cab.

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Platform, cab, bodywork, and decals - Mechanically-adjusted operator seat

Seat suspension unit - Install 1. Place the seat suspension unit into position in the interior of the cab. 2. Secure the seat suspension to the floor of the cab using the four mounting bolts. 3. Place the seat cowling around the mounting bolt area.

RAIL13SP05153AA

Next operation: Install the operators seat onto the seat suspension Operator seat - Install (90.120).

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Index Platform, cab, bodywork, and decals - 90 Mechanically-adjusted operator seat - 120 Operator seat - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Operator seat - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Seat suspension unit - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Seat suspension unit - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Platform, cab, bodywork, and decals - 90 Engine hood and panels - 100

SP.295F SP.300F SP.345F SP.400F

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Contents Platform, cab, bodywork, and decals - 90 Engine hood and panels - 100

SERVICE Engine hood and panels Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Bottom engine hood Remove - Engine belly pan doors (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Install - Engine belly pan doors (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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Platform, cab, bodywork, and decals - Engine hood and panels

Engine hood and panels - Remove NA NA NA NA

SP.295F SP.300F SP.345F SP.400F

1. Move the machine on to a hard level surface. 2. Turn the ignition key to the “OFF” position and remove the key from the ignition. 3. Allow the engine and components to cool prior to working on the vehicle. 4. Turn off power from the batteries by turning the power switch (1) to the “OFF” position.

RAIL14SP01001AA

RAIL14SP00793AA

RAIL14SP01501AA

Engine enclosure roof removal 5. Unlatch the engine enclosure roof by pulling down on the rubber cover hook (1) and releasing it from the cover latch. 6. Open the engine enclosure roof and disconnect the gas springs (2) from the roof panel. Allow the gas springs to lay flat in the engine compartment framework.

7. Close the roof panel and remove the bolts and washers (1) from the engine enclosure roof.

8. Remove the roof from the vehicle with the help from an assistant.

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Engine enclosure rear door removal 9. Unlatch the rear door by sliding the latch knob (1) to the side. The latch is located under the cooling package next to the remote battery terminals.

RAIL14SP00792AA

RAIL14SP00791AA

10. Lift the rear door (1) upward to gain access to the interior of the door.

11. Disconnect the electrical connections for the rear tail lights and the backup alarm. Disconnect the electrical connection for the backup camera, if equipped.

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12. Detach the lanyard (1) from the rear door by removing the bolt, washers and nut (2). 13. Attach an appropriate lifting device to the rear door. Ensure that the rear door is fully secured to the lifting device before proceeding with further mounting hardware removal.

RAIL14SP01506BA

RAIL14SP00791AA

14. Remove the gas spring from the rear door.

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15. Remove the bolts and washer (1) attaching the rear door to the mounting weldment (2). Remove the rear door from the vehicle.

RAIL14SP01502AA

Engine enclosure lower right hand door removal 16. Open the engine enclosure lower right hand door (1) by pushing the latch knob upward. The latch knob is located at the lower front area of the door. The suspension must raised to the highest position in order for the door to swing open freely. 17. Attach an appropriate lifting device to the door. Ensure that the door is fully supported before removal of the mounting hardware.

RAIL14SP00794AA

RAIL15SP00260AA

18. Pull the engine door stop rod (1) from the mounting hole located in the vehicle frame. Leave the rod attached to the door (2) . 19. Remove the carriage bolts, washers, door hinge bushings, and nuts securing the door to the hinge brackets. Remove the door from the vehicle.

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Engine enclosure upper right hand panel removal 20. Unlatch the engine enclosure sliding doors. Lift up on the doors and remove the doors from the vehicle.

RAIL14SP01014AA

RAIL15SP00259AA

RAIL14SP01503AA

21. Disconnect the air intake hose (1) from the inside of the upper right hand panel (2) by removing the hose clamp (3) attaching the hose to the panel.

22. Attach an appropriate lifting device to the upper right hand panel. Ensure the panel is fully supported before removal of the panel mounting hardware. 23. Remove the bolts, washers, and nuts (1) securing the rear end of the upper panel to the vehicle frame post.

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24. Remove the nuts and washers (1) from the upper right hand panel mounting studs, located at the front end of the panel. The studs are part of the panel. 25. Slide the upper right hand panel forward in order for the mounting studs of the panel to be removed from the mounting holes located in the vehicle frame posts. Remove the panel from the vehicle.

RAIL14SP01503AA

RAIL14SP01504AA

Engine enclosure left hand panel removal 26. Attach an appropriate lifting device to the left hand panel. Ensure the panel is fully secured before removal of the panel hardware. 27. Remove the bolts, washers, and nuts (1) securing the rear end of the left hand panel to the vehicle frame post. 28. Remove the nuts and washers (2) from the left hand panel mounting studs, located at the front end of the panel. The studs are part of the panel. 29. Slide the left hand panel forward in order for the mounting studs (3) of the panel to be removed from the mounting holes located in the vehicle frame posts. Remove the panel from the vehicle.

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Platform, cab, bodywork, and decals - Engine hood and panels

Engine hood and panels - Install NA NA NA NA

SP.295F SP.300F SP.345F SP.400F

Engine enclosure left hand panel installation 1. Attach the left hand panel to the vehicle by positioning the panel on the left hand side of the vehicle. Slide the panel mounting studs (1) into the slots of the vehicle frame post. 2. Secure the front edge of the panel to the vehicle using the nuts and washers (2). 3. Secure the rear edge of the panel to the vehicle using the nuts, washers, and bolts (3).

RAIL14SP01504AA

RAIL14SP01503AA

Engine enclosure upper right hand panel installation 4. Attach the upper right hand panel to the right hand side of the vehicle. Slide the panel mounting studs (1) into the slots of the vehicle frame post. 5. Secure the front edge of the panel to the vehicle using the nuts and washers (2).

6. Secure the rear edge of the panel to the vehicle using the nuts, washers, and bolts (3).

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Engine enclosure lower right hand door installation 7. Attach the lower right hand door (1) to the lower right hand side of the vehicle. Position the hinge brackets of the door to the vehicle frame hinge mounts. 8. Secure the door to the vehicle using the carriage bolts, washers, door hinge bushings, and nuts (2) 9. Close the door and ensure proper door movement and locking.

RAIL15SP00261AA

RAIL14SP01502AA

Engine enclosure rear door installation 10. Attach the rear door (1) to the vehicle. Secure the door to the mounting weldment (2) using the bolts and washer (3)

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11. Extend to door to the full open position. Install the gas spring (1) to the door and to the vehicle frame.

RAIL14SP00791AA

RAIL14SP01506BA

RAIL14SP00791AA

12. Attach the lanyard (1) to the rear door using the bolt, nut, and washers (2)

13. Connect the electrical connections for the rear tail lights and the backup alarm. Connect the electrical connection for the backup camera, if equipped. 14. Close the door and ensure proper door movement and locking.

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Engine enclosure roof installation 15. Position the engine enclosure roof (1) onto the top on the engine enclosure frame. 16. Align the mounting holes in the roof with the clip nuts attached to the mounting holes in the roof hinges (2). The hinges are attached to the engine enclosure frame. 17. Attach the roof to the hinges using the bolts and washers (3). Tighten securely.

RAIL14SP01507BA

18. Open the roof and attach the gas springs to the roof. 19. Close the roof and ensure that the roof is aligned with the existing panels, and that the roof locks properly. Adjust as required.

RAIL14SP00793AA

RAIL14SP01014AA

20. Attach the engine enclosure doors onto the engine enclosure. Lock the doors in place.

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Bottom engine hood - Remove - Engine belly pan doors SP.295F [YFYM00858 - ] Model year 2015 after OAT coolant specification SP.300F [YFYM00858 - ] Model Year 2015 after OAT coolant specification SP.345F [YFYM00858 - ] Model year 2015 after OAT coolant specification SP.400F [YFYM00858 - ] Model year 2015 after OAT coolant specification

1. Open the engine belly doors and allow the doors to hang freely. 2. Remove the engine belly door by removing the cotter pins and flat washers from the clevis pins (1) which attach the doors to the belly door mounting bracket (2). 3. Disassemble the engine belly door by removing the hardware that attaches the door panel (3) and the latching mechanism (4) to the door frame (5). 4. Repeat the removal and disassemble for the second engine belly pan door.

RAIL15SP00265CA

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5. Remove the left hand latching bracket (1) from the engine enclosure frame by removing the bolts, flat washers, and nuts (2).

RAIL15SP00266BA

RAIL15SP00262AA

6. Remove the right hand latching bracket (1) from the engine enclosure frame by removing the bolts, flat washers, and nuts (2).

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Bottom engine hood - Install - Engine belly pan doors SP.295F [YFYM00858 - ] Model year 2015 after OAT coolant specification SP.300F [YFYM00858 - ] Model Year 2015 after OAT coolant specification SP.345F [YFYM00858 - ] Model year 2015 after OAT coolant specification SP.400F [YFYM00858 - ] Model year 2015 after OAT coolant specification

1. Attach the left hand latching bracket (1) to the engine enclosure frame using the bolts, flat washers, and nuts (2). Tighten the bolts securely.

RAIL15SP00266BA

RAIL15SP00262AA

2. Attach the right hand latching bracket (1) to the engine enclosure frame using the bolts, flat washers, and nuts (2). Tighten the bolts securely.

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3. Assemble the engine belly door by attaching the door panel (1) to the door frame (2). Assemble the latching mechanism (3) to the frame using the hardware. Install the door gasket (4) if necessary. 4. Position the hinges of the assembled door onto vehicle frame at the hinge mounting points (4). 5. Attach the door to the hinge points using the clevis pins and flat washers (5) . Secure the clevis pins in place using the cotter pins. 6. Repeat the assemble and installation for the second engine belly pan door.

RAIL15SP00265CA

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Index Platform, cab, bodywork, and decals - 90 Engine hood and panels - 100 Bottom engine hood - Install - Engine belly pan doors (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Bottom engine hood - Remove - Engine belly pan doors (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Engine hood and panels - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Engine hood and panels - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

(*) See content for specific models 47691240 24/02/2015

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Platform, cab, bodywork, and decals - 90 Fenders and guards - 116

SP.295F SP.300F SP.345F SP.400F

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Contents Platform, cab, bodywork, and decals - 90 Fenders and guards - 116

SERVICE Fender Remove - Front steering cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install - Front steering cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Remove - Front and rear fenders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install - Front and rear fenders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Platform guard Remove - Short frame belly pan (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Install - Short frame belly pan (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Remove - Long frame belly pan (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Install - Long frame belly pan (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

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Platform, cab, bodywork, and decals - Fenders and guards

Fender - Remove - Front steering cover 1. Cut and remove cable ties securing electrical wiring of two front lights. NOTE: The side light is mounted to a bracket that remains on the vehicle frame and requires no disconnection or wire tagging. 2. Tag and mark wiring for two front lights and disconnect electrical connectors (1).

RAIL13SP03404AA

RAIL13SP01117AA

RAIL13SP03400AA

WARNING Avoid injury! The component is heavy. Removal/installation requires two persons or a lifting device. Failure to comply could result in death or serious injury. W1141A

Remove five bolts (2), 10 washers (3), two spacers (4), and five nuts (5), to disengage steering cover (6) from frame and steering weldment.

4. Lift off and remove steering cover.

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Fender - Install - Front steering cover 1.

WARNING Avoid injury! The component is heavy. Removal/installation requires two persons or a lifting device. Failure to comply could result in death or serious injury. W1141A

Lift up and position steering cover onto frame and weldments. Reposition side light through light opening in steering cover.

RAIL13SP03400AA

RAIL13SP01117AA

RAIL13SP03404AA

2. Secure steering cover (6) to steering weldment and frame by installing five bolts (2), 10 washers ( (3), two spacers (4), and five nuts (5).

3. Connect two front light electrical connectors (1).

4. Secure lights electrical wiring with cable ties. Remove tagging.

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Fender - Remove - Front and rear fenders Front fender 1. Remove six locknuts (1), washers (2), and carriage bolts (3) that connect fender (4) to fender bracket weldments (5), and remove fender (4).

RAIL13SP03396AA

RAIL13SP03399AA

RAIL13SP03397AA

2. Remove two nuts (6), four washers (7), two bolts (8), and rear bracket weldment (5) from leg assembly (9).

3. Remove two nuts (6), four washers (7), two bolts (8), and front bracket weldment (5) from leg assembly (9).

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Rear fender 1. Remove six locknuts (1), washers (2), and carriage bolts (3) that connect fender (4) to fender bracket weldments (5), and remove fender (4)

RAIL13SP03396AA

RAIL13SP03410AA

RAIL13SP03399AA

2. Remove the rear nozzle, nozzle bracket, and hose prior to removing fender and bracket.

3. Remove two nuts (6), four washers (7), two bolts (8), and rear bracket weldment (5) from leg assembly (9).

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4. Remove two nuts (6), four washers (7), two bolts (8), and front bracket weldment (5) from leg assembly (9).

RAIL13SP03397AA

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Fender - Install - Front and rear fenders Front fenders 1. Install two nuts (6), four washers (7), and two bolts (8), securing front bracket weldment (5) to leg assembly (9).

RAIL13SP03397AA

RAIL13SP03399AA

RAIL13SP03396AA

2. Install two nuts (6), four washers (7), and two bolts (8) securing rear bracket weldment (5) to leg assembly (9).

3. Install six locknuts (1), washers (2), and carriage bolts (3) securing fender (4) to fender bracket weldments (5).

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Rear fender 4. Install two nuts (6), four washers (7), and two bolts (8), securing front bracket weldment (5) to leg assembly (9).

RAIL13SP03397AA

RAIL13SP03410AA

RAIL13SP03399AA

5. Attach the rear nozzles, and the nozzle brackets to the fender bracket weldment arms using wires ties.

6. Install two nuts (6), four washers (7), and two bolts (8) securing rear bracket weldment (5) to leg assembly (9).

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7. Install six locknuts (1), washers (2), and carriage bolts (3) securing fender (4) to fender bracket weldments (5).

RAIL13SP03396AA

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Platform guard - Remove - Short frame belly pan SP.295F

1. Leg widen the vehicle all the way out. 2. Park vehicle on a level surface. 3. Apply the parking brake. 4. Shut off the engine and remove the ignition key. 5. Unlatch the front right hand and left hand belly pan doors and allow the doors to hang freely. 6. Unlatch the mid frame right and left hand belly pan doors and allow the doors to hang freely. 7. Support the left mid frame belly pan door assembly (1) and remove the hitch pin (2) securing the door to the pivot bracket. Remove the door from the vehicle. Repeat for the right mid frame belly pan door assembly.

RAIL14SP01127AA

RAIL15SP00268AA

8. Support the front left hand belly pan door assembly (1) and remove the hitch pin (2) securing the door to the pivot bracket. Remove the door from the vehicle. Repeat for the front right hand belly pan door assembly.

9. Remove the belly pan door mounting brackets (1) from the vehicle by removing the hardware attaching the brackets to the vehicle frame. 10. Remove the belly pan door hitch brackets (2) from the vehicle by removing the hardware attaching the brackets to the vehicle frame.

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Platform guard - Install - Short frame belly pan SP.295F [YFYM00001 - YFYM00857] Model year 2015 before OAT coolant. specification SP.295F [YFYM00858 - ] Model year 2015 after OAT coolant specification

1. Leg widen the vehicle all the way out. 2. Park vehicle on a level surface. 3. Apply the parking brake. 4. Shut off the engine and remove the ignition key.

Assemble Front Left & Right Belly Pan Panels: 5. Position the Front Left Hand Belly Pan Panel (1) on a work bench with the large indentation away from you and the panel lip up. Position the Belly Pan Option Weldment (2) on to the panel. Align the right hand corner mounting hole of the weldment with the right hand corner second mounting hole in the right hand corner of the panel. The latch mounting tabs should be pointing upward. Insert a ¼-20 x ¾ Stainless Steel Button Head Bolt with a ¼ x 1 x .05 Stainless Steel Flat Washer (3) up through the panel and the weldment from the panel side. Assemble a ¼ Stainless Steel Flat Washer and a ¼-20 Stainless Steel Nylock Nut (4) onto the bolt. Do not fully tighten until all the bolts are assembled.

RAIL14SP01149FA

RAIL14SP01142AA

6. Line up the remaining holes in the weldment with the corresponding holes in the panel. Insert a ¼-20 x ¾ Stainless Steel Button Head Bolt with a ¼ x 1 x .05 Stainless Steel Flat Washer up through the remaining holes. Assemble a ¼ Stainless Steel Flat Washer and a ¼-20 Stainless Steel Nylock Nut onto each bolt. 7. Tighten all bolts securely after assembly. 8. Assemble the stop bolt to the rear hook. Position the Belly Pan Option Hook (1) with the handle to your left and with the hook portion facing upward. Insert a ¼-20 x 1-1/4 Stainless Steel Bolt with a ¼ Stainless Steel Flat Washer (2) through the stop tab of the hook. Secure in place with a ¼ Stainless Steel Flat Washer and a ¼-20 Stainless Steel Nylock Nut (3). Tighten securely.

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9. Assemble the rear hook with stop bolt (1) to the front left hand belly pan panel (2). Position the rear hook with the handle to your left and the hook up.

RAIL14SP01150FA

RAIL14SP01170AA

RAIL14SP01151FA

10. Place a 3/8 Wide Stainless Steel Flat Washer (1) on to a 3/8-16 x 1-1/4 Stainless Steel Bolt (2), followed by a Ladder Pivot Bushing (3). Insert the bolt with bushing into the larger hole next to the stop bolt.

11. On the other side of the hook, assemble two 5/8 Stainless Steel Flat Washers (1). Be sure the bushing goes through both 5/8 flat washers and insert the bolt through the rear hook mounting tab on the panel. Secure the bolt in place with a 3/8 Wide Stainless Steel Flat Washer (2) and a 3/8-16 Stainless Steel Nylock Nut (3). Tighten securely

12. Assemble the front hook (1) to the front left hand belly pan panel (2). Position the Front Belly Pan Option Hook (1) with the handle to your left and the hook up.

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13. Place a 3/8 Wide Stainless Steel Flat Washer (1) on to a 3/8-16 x 1-1/4 Stainless Steel Bolt (2), followed by a Ladder Pivot Bushing (3). Insert the bolt with washer and bushing into the larger hole of the hook.

RAIL14SP01171AA

RAIL14SP01153FA

14. On the other side of the hook assemble two 5/8 Stainless Steel Flat Washers (1) . Be sure the bushing goes through both 5/8 flat washers. Insert the bolt through the front hook mounting tab on the panel. Secure the bolt in place with a 3/8 Wide Stainless Steel Flat Washer (2) and a 3/8-16 Stainless Steel Nylock Nut (3). Tighten securely.

15. Assemble the Spring (1) to the rear mounting hole in the panel frame.

16. Insert a Âź-20 x 1-1/4 Stainless Steel Bolt (1) with a Âź Stainless Steel Flat Washer (2) through the tab from the back side.

RAIL14SP01172AA

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17. On the front side of the tab, assemble a ¼ Stainless Steel Flat Washer (1) followed by a ¼-20 Stainless Steel Nylock Nut (2). Tighten securely. Place the end of the spring (4) on to the bolt, followed by a ¼ Stainless Steel Flat Washer (4) followed by a ¼-20 Stainless Steel Nylock Nut (5). Tighten securely.

RAIL14SP01172AA

RAIL14SP01153FA

RAIL14SP01173AA

18. Assemble the Latch Rod (1) to the rear hook (2). Position the latch rod against the hook with the mount end up and the reinforcement lip away from the hook.

19. Insert a ¼-20 x 1-1/4 Stainless Steel Bolt (1) with a ¼ Stainless Steel Flat Washer (2) through the latch rod (3) . Place a ¼ Stainless Steel Flat Washer (4) on to the bolt. Insert the bolt through the unused hole in the hook. assemble a ¼ Stainless Steel Flat Washer (5) followed by a ¼-20 Stainless Steel Nylock Nut (6) on to the bolt. Tighten securely.

20. Place the open end of the spring (1) on to the bolt followed by a ¼ Stainless Steel Flat Washer (2) and a ¼-20 Stainless Steel Nylock Nut (2). Tighten securely.

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21. Assemble the front edge of the latch rod (1) to the front hook (2). Insert a ¼-20 x 1-1/4 Stainless Steel Bolt (3) through the latch rod. Place a ¼ Stainless Steel Flat Washer (4) on to the bolt. Insert the bolt through the unused hole in the hook. On to the bolt assemble two ¼ Stainless Steel Flat Washers (5) followed by a ¼-20 Stainless Steel Nylock Nut (6) . Tighten securely.

RAIL14SP01174AA

RAIL14SP01154FA

RAIL14SP01143AA

22. Place the left hand front panel near the front left side of the vehicle with the latch rod toward the center. 23. Position the Front Right Hand Belly Pan Panel (1) on a work bench with the large indentation facing away from you, and with the panel lip up. On top of the panel, position the Belly Pan Option Weldment (2) . Align the left hand corner mounting hole with the second mounting hole in the panel on the left hand corner. The latch mounting tabs should be pointing upward. From the panel side, insert a ¼-20 x ¾ Stainless Steel Button Head Bolt (3) with a ¼ x 1 x .05 Stainless Steel Flat Washer (4) up through the panel and the weldment. Assemble a ¼ Stainless Steel Flat Washer (5) and a ¼-20 Stainless Steel Nylock Nut (6). Do not fully tighten until all the bolts are assembled. Align the remaining holes in the weldment with the corresponding holes in the panel. Insert a ¼-20 x ¾ Stainless Steel Button Head Bolt with a ¼ x 1 x .05 Stainless Steel Flat Washer up through the remaining holes. Assemble a ¼ Stainless Steel Flat Washer and a ¼-20 Stainless Steel Nylock Nut onto each bolt. Tighten all bolts securely after assembly. 24. Assemble the stop bolt to the rear hook. Position the Belly Pan Option Hook (1) with the handle to your right and the hook up. Insert a ¼-20 x 1-1/4 Stainless Steel Bolt (2) with a ¼ Stainless Steel Flat Washer (3) through the stop tab of the hook. Secure in place with a ¼ Stainless Steel Flat Washer (4) and a ¼-20 Stainless Steel Nylock Nut (5). Tighten securely.

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25. Assemble the rear hook with stop bolt (1) to the front right hand belly pan panel (2). Position the rear hook with the handle to your right and the hook up.

RAIL14SP01155FA

RAIL14SP01175AA

RAIL14SP01156FA

26. On to a 3/8-16 x 1-1/4 Stainless Steel Bolt (1) place a 3/8 Wide Stainless Steel Flat Washer (2) followed by a Ladder Pivot Bushing (3). Insert the bolt with bushing into the larger hole next to the stop bolt.

27. Assemble two 5/8 Stainless Steel Flat Washers (1) on to the other side of the hook. Be sure the bushing goes through both 5/8 flat washers and insert the bolt through the rear hook mounting tab on the panel. Secure the bolt in place with a 3/8 Wide Stainless Steel Flat Washer (2) and a 3/8-16 Stainless Steel Nylock Nut (3) . Tighten securely.

28. Assemble the front hook (1) to the front right hand belly pan panel (2). Position the Front Belly Pan Option Hook (1) with the handle to your right and the hook up.

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29. Place a 3/8 Wide Stainless Steel Flat Washer (1), followed by a Ladder Pivot Bushing (2) on to a 3/8-16 x 1-1/4 Stainless Steel Bolt (3). Insert the bolt with bushing into the larger hole of the hook.

RAIL14SP01176AA

RAIL14SP01157FA

RAIL14SP01177AA

30. Assemble two 5/8 Stainless Steel Flat Washers (1) on the opposite side of the hook. Be sure the bushing goes through both 5/8 flat washers and insert the bolt through the front hook mounting tab on the panel. Secure the bolt in place with a 3/8 Wide Stainless Steel Flat Washer (2) and a 3/8-16 Stainless Steel Nylock Nut (3). Tighten securely.

31. Assemble the Spring (1) to the rear mounting hole in the panel frame.

32. Insert a ¼-20 x 1-1/4 Stainless Steel Bolt (1) with a ¼ Stainless Steel Flat Washer (2), through the tab from the back side. Assemble a ¼ Stainless Steel Flat Washer (3) followed by a ¼-20 Stainless Steel Nylock Nut (4) on the front side of the tab. Tighten securely.

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33. Place the end of the spring on to the bolt, followed by a ¼ Stainless Steel Flat Washer (1) followed by a ¼-20 Stainless Steel Nylock Nut (2). Tighten securely.

RAIL14SP01177AA

RAIL14SP01158FA

RAIL14SP01179AA

34. Assemble the Latch Rod (1) to the rear hook (2) . Position the latch rod against the hook with the mount end up and the reinforcement lip away from the hook.

35. Insert a ¼-20 x 1-1/4 Stainless Steel Bolt (1) with a ¼ Stainless Steel Flat Washer (2) through the latch rod. Place a ¼ Stainless Steel Flat Washer (3) on to the bolt. Insert the bolt through the unused hole in the hook.

36. On to the bolt assemble a ¼ Stainless Steel Flat Washer (1) followed by a ¼-20 Stainless Steel Nylock Nut (2). Tighten securely.

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37. Place the open end of the spring (1) on to the bolt followed by a ¼ Stainless Steel Flat Washer (2) and a ¼-20 Stainless Steel Nylock Nut (3). Tighten securely.

RAIL14SP01179AA

RAIL14SP01180AA

RAIL14SP01159FA

38. Assemble the front edge of the latch rod to the front hook. Insert a ¼-20 x 1-1/4 Stainless Steel Bolt (1) through the latch rod, place a ¼ Stainless Steel Flat Washer (2) on to the bolt. Insert the bolt through the unused hole in the hook. On to the bolt assemble two ¼ Stainless Steel Flat Washers (3) followed by a ¼-20 Stainless Steel Nylock Nut (4). Tighten securely.

39. Place the right hand front panel near the front right side of the vehicle with the latch rod toward the center. 40. Position a Short Frame Mid Belly Pan Panel (1) on a work bench with the large indentation away from you and the panel lip up. On top of the panel, position the Belly Pan Option Weldment (2). Align the right hand corner mounting hole with the second mounting hole in the panel on the right hand corner. The latch mounting tabs should be pointing upward.

41. From the panel side, insert a ¼-20 x ¾ Stainless Steel Button Head Bolt (1) with a ¼ x 1 x .05 Stainless Steel Flat Washer (2) up through the panel and the weldment. Assemble a ¼ Stainless Steel Flat Washer (3) and a ¼-20 Stainless Steel Nylock Nut (4). Do not fully tighten until all the bolts are assembled. Line up the remaining holes in the weldment with the corresponding holes in the panel. Insert a ¼-20 x ¾ Stainless Steel Button Head Bolt with a ¼ x 1 x .05 Stainless Steel Flat Washer up through the remaining holes. Assemble a ¼ Stainless Steel Flat Washer and a ¼-20 Stainless Steel Nylock Nut onto each bolt. After all the bolts are assembled, tighten all bolts securely.

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42. Assemble the stop bolt to the belly pan hook. Position the Belly Pan Option Hook (1) with the handle to your left and with the hook portion facing upward. Insert a ¼-20 x 1-1/4 Stainless Steel Bolt with a ¼ Stainless Steel Flat Washer (2) through the stop tab of the hook. Secure in place with a ¼ Stainless Steel Flat Washer and a ¼-20 Stainless Steel Nylock Nut (3). Tighten securely.

RAIL14SP01142AA

RAIL14SP01160FA

RAIL14SP01170AA

43. Assemble the hook with stop bolt (1) to the short frame mid belly pan panel (2). Position the hook with the handle to your left and the hook up.

44. On to a 3/8-16 x 1-1/4 Stainless Steel Bolt (1) place a 3/8 Wide Stainless Steel Flat Washer (2) followed by a Ladder Pivot Bushing (3). Insert the bolt with bushing into the larger hole next to the stop bolt.

45. On the other side of the hook, assemble two 5/8 Stainless Steel Flat Washers (1). Be sure the bushing goes through both 5/8 flat washers and insert the bolt through the hook mounting tab on the panel. Secure the bolt in place with a 3/8 Wide Stainless Steel Flat Washer (2) and a 3/8-16 Stainless Steel Nylock Nut (3). Tighten securely

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46. Assemble the hook (1) to the short frame mid belly pan panel (2). Position the Belly Pan Option Hook (1) with the handle to your left and the hook up.

RAIL14SP01161FA

RAIL14SP01171AA

RAIL14SP01162FA

47. On to a 3/8-16 x 1-1/4 Stainless Steel Bolt (1) place a 3/8 Wide Stainless Steel Flat Washer (2) followed by a Ladder Pivot Bushing (3). Insert the bolt with bushing into the larger hole of the hook.

48. On the other side of the hook, assemble two 5/8 Stainless Steel Flat Washers (1). Be sure the bushing goes through both 5/8 flat washers and insert the bolt through the hook mounting tab on the panel. Secure the bolt in place with a 3/8 Wide Stainless Steel Flat Washer (2) and a 3/8-16 Stainless Steel Nylock Nut (3). Tighten securely.

49. Assemble the Spring (1) to the mounting hole in the panel frame (2).

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50. From the back side of the tab, insert a ¼-20 x 1-1/4 Stainless Steel Bolt (1) with a ¼ Stainless Steel Flat Washer (2) through the tab.

RAIL14SP01172AA

RAIL14SP01163FA

RAIL14SP01173AA

51. On the front side of the tab, assemble a ¼ Stainless Steel Flat Washer (1) followed by a ¼-20 Stainless Steel Nylock Nut (2). Tighten securely. Place the end of the spring on to the bolt, followed by a ¼ Stainless Steel Flat Washer (3) followed by a ¼-20 Stainless Steel Nylock Nut (4). Tighten securely.

52. Assemble the Latch Rod (1) to the hook (with stop bolt) (2). Position the latch rod against the hook with the mount end up and the reinforcement lip away from the hook.

53. Insert a ¼-20 x 1-1/4 Stainless Steel Bolt (1) with a ¼ Stainless Steel Flat Washer (2) through the latch rod, place a ¼ Stainless Steel Flat Washer (3) on to the bolt. Insert the bolt through the unused hole in the hook.

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54. On to the bolt assemble a ¼ Stainless Steel Flat Washer (1) followed by a ¼-20 Stainless Steel Nylock Nut (2). Tighten securely. Place the open end of the spring on to the bolt followed by a ¼ Stainless Steel Flat Washer (3) and a ¼-20 Stainless Steel Nylock Nut (4). Tighten securely.

RAIL14SP01173AA

RAIL14SP01174AA

RAIL14SP01122AA

55. Assemble the opposite end of the latch rod to the other hook. Insert a ¼-20 x 1-1/4 Stainless Steel Bolt (1) through the latch rod, place a ¼ Stainless Steel Flat Washer (2) on to the bolt. Insert the bolt through the unused hole in the hook. On to the bolt assemble two ¼ Stainless Steel Flat Washers (3) followed by a ¼-20 Stainless Steel Nylock Nut (4). Tighten securely.

56. Repeat step 40 through step 55 to assemble the remaining short frame mid belly pan panels.

Install rear and mid belly pan brackets NOTE: Apply LOCTITE® 8150™ or equivalent to all stainless steel hardware before assembling. 57. Remove the two bolts (1) securing the rear rinse tank saddle (2) to the frame on the right side of the vehicle. Save the flat washers, locknuts and bolts. Remove the two bolts from the left side of the rinse tank saddle. Save the flat washers, locknuts and bolts.

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58. Remove the two bolts (1) securing the fuel tank saddle (2) to the frame on the left side of the vehicle. Save the flat washers, locknuts and bolts. Remove the two bolts from the right side of the fuel tank saddle. Save the flat washers, locknuts and bolts.

RAIL14SP01123AA

RAIL14SP01164FA

RAIL14SP01165FA

59. Position the Short Left Hand Rear Belly Pan Bracket (1) , Short Right Hand Rear Belly Pan Bracket (2) , Left Hand Short Mid Belly Pan Bracket (3) and the Right Hand Short Mid Belly Pan Bracket (4) under the frame. The mounting pivot tabs should be to the outside and the mounting plates pointing up. Be sure that the mounting brackets are positioned as shown, with the narrow section mounting plates at the rear (6).

60. Position the mounting plate of the left hand rear belly pan bracket (1) in place on the outside of the frame (2). Position the mounting plate between the hydraulic hoses and/or tubes and the vehicle frame. Using saved hardware from the rinse tank mount, secure the mounting plate (3) to the rinse tank and the vehicle frame. Do not fully tighten until the belly pan brackets are installed between the rear and mid brackets.

NOTE: It may be necessary to loosen the bracket holding the hydraulic hoses to the rear left side of the frame in order to correctly position the rear plate with the rinse tank saddle mounting holes. Be sure to retighten this bracket when complete. 61. Position the mounting plate of the right hand rear belly pan bracket (1) in place on the outside of the frame (2) . Position the mounting plate between the hydraulic hoses and/or tubes and the vehicle frame. Using saved hardware from the rinse tank mount, secure the mounting plate (3) to the rinse tank and the vehicle frame. Do not fully tighten until the belly pan brackets are installed between the rear and mid brackets.

RAIL14SP01166FA

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62. Position the mounting plate of the left hand short mid belly pan bracket (1) in place on the outside of the frame (2) . Position the mounting plate between the hydraulic hoses and/or tubes and the vehicle frame. Using saved hardware from the fuel tank mount, secure the mounting plate (3) to the fuel tank and the vehicle frame. Do not fully tighten until the belly pan brackets are installed between the rear and mid brackets.

RAIL14SP01165FA

RAIL14SP01166FA

RAIL14SP01167FA

RAIL14SP01168FA

63. Position the mounting plate of the right hand short mid belly pan bracket (1) in place on the outside of the frame (2) . Position the mounting plate between the hydraulic hoses and/or tubes and the vehicle frame. Using saved hardware from the fuel tank mount, secure the mounting plate (3) to the fuel tank and the vehicle frame. Do not fully tighten until the belly pan brackets are installed between the rear and mid brackets.

64. Position a Belly Pan Bracket (1) with the mounting tab facing toward the center of the vehicle at the point where the rear and mid belly pan brackets meet. Locate the hole in the frame by placing the belly pan bracket temporarily in place below the rear and mid belly pan brackets. Secure the belly pan bracket to the frame with a ½-13 x 2” Stainless Steel Button Head Bolt (2) along with a ½ Wide Stainless Steel Flat Washer (3) on each bolt. Insert the bolt through the bracket and the frame. Secure in place with a ½ Wide Stainless Steel Flat Washer (4) and ½-13 Stainless Steel Nylock Nut (5) . Do not fully tighten. Repeat to assemble the belly pan bracket on the other side of the vehicle. 65. Assemble the rear and mid belly pan brackets (1) to the belly pan bracket (2). Line up the outer holes in the belly pan bracket with the end hole in each of the rear and mid belly pan brackets. Insert a 5/16-18 x 1 Stainless Steel Carriage Bolt (3) through the holes from the bottom up. Secure in place with a 5/16 Stainless Steel Flat Washer (4) and a 5/16-18 Stainless Steel Nylock Nut (5) . Tighten securely. Fully tighten all the hardware on the rear, mid and belly pan brackets. Repeat to assemble the rear and mid belly pan brackets to the belly pan bracket on the other side of the vehicle.

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66. Assemble the Cross Belly Pan Bracket (1) between the belly pan brackets. Place the cross bracket on top of the belly pan bracket mounting flanges with the angled lip up. Position the bracket with the longer section to the rear. Insert the 5/16-18 x 1 Stainless Steel Carriage Bolts (2) through the holes from the bottom up. Secure in place with a 5/16 Stainless Steel Flat Washer (3) and a 5/16-18 Stainless Steel Nylock Nut (4) on each bolt. Tighten securely. Repeat to assemble the opposite end of the cross bracket to the belly pan bracket on the other side of the vehicle.

RAIL14SP01144AA

RAIL14SP01437FA

RAIL14SP01145AA

RAIL14SP01436FA

67. For units built between July 2012 and June 2014, the rear pan (1) below the engine will need to have two notches cut into the front lip. Use the following illustration and values given below to measure and mark the positions of the two notches. Notch cutting may be preformed without removing the belly pan from the vehicle. A = 47.63 cm (18.75 in) B = 9.22 cm (3.63 in) C = 22.9 cm (9.0 in) D = 6.99 cm (2.75 in)

68. Assemble a Belly Pan Pivot Bracket (1) to each of the pivot mounting tabs (2) on the rear and mid belly pan brackets. Position the pivot bracket on the top side of the tab with the angled edges down and the pivot pin holes to the outside. Insert a 5/16-18 x 1 Stainless Steel Carriage Bolt (3) through the tab and the pivot bracket from the bottom up. Secure in place with a 5/16 Stainless Steel Flat Washer (4) and a 5/16-18 Stainless Steel Nylock Nut (5). Only snug up at this time.

69. When assembling the kit components on to vehicles built between July 2012 and June 2014, assemble the rear cross brace (1) to the tabs on the rear right and left brackets (2) . Reuse the hardware used to mount the belly pan pivot bracket. Position the cross brace with the center plate pointing rearward. Align the holes and insert the hardware

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70. Assemble the Door Hitch Bracket (1) to the plate welded to the front cross frame (2) . Position the bracket under the mounting plate. Line up the slots with the holes and insert 5/16-18 x 1 Stainless Steel Carriage Bolts (3) through the door hitch bracket from the bottom up. Secure in place with 5/16 Stainless Steel Flat Washers and 5/16-18 Stainless Steel Nylock Nuts . Only snug up at this time.

RAIL14SP01124AA

RAIL14SP01125AA

71. Insert a 3/8-16 x 8 Stainless Steel Bolt with a 3/8 Wide Stainless Steel Flat Washer (1) through the forward set of holes in the door hitch bracket (2). Secure in place with another 3/8 Wide Stainless Steel Flat Washer and a 3/8-16 Stainless Steel Nylock Nut (3). Tighten securely.

72. Assemble the Door Hitch Offset Bracket (1) to the Door Hitch Mount Plate (2). With the angled lips down, place the door hitch offset bracket on top of the mount plate with the mounting holes facing away from the edge. Insert a 5/16-18 x 1 Stainless Steel Carriage Bolt (3) through the door hitch offset bracket from the top down. Secure in place with 5/16 Stainless Steel Flat Washers and 5/16-18 Stainless Steel Nylock Nuts. Do not fully tighten.

73. Under the cab, locate two accumulators (1). Locate the radar mount bracket under the accumulators. Place the mount plate with bracket attached (2) on the underside of the radar mount bracket with the angled lips pointing down. Line up the holes and insert 5/16-18 x 1 Stainless Steel Carriage Bolts (3) through the plate from the bottom up. Secure in place with 5/16 Stainless Steel Flat Washers and 5/16-18 Stainless Steel Nylock Nuts . Do not fully tighten.

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74. Insert a 3/8-16 x 8 Stainless Steel Bolt with a 3/8 Wide Stainless Steel Flat Washer (1) through the holes in the door hitch offset bracket and the door hitch mount plate. Secure in place with another 3/8 Wide Stainless Steel Flat Washer and a 3/8-16 Stainless Steel Nylock Nut . Tighten securely.

RAIL14SP01125AA

RAIL14SP01126AA

RAIL14SP01169FA

75. Assemble two Door Hitch Brackets (1) to the plate welded to the cross belly pan bracket (2) under the product tank. Position each bracket under the mounting plate. Line up the slots with the holes and insert 5/16-18 x 1 Stainless Steel Carriage Bolts (3) through the door hitch bracket from the bottom up (rear bracket) or top down (front bracket). Secure in place with 5/16 Stainless Steel Flat Washers and 5/16-18 Stainless Steel Nylock Nuts. Only snug up at this time.

76. Insert a 3/8-16 x 8 Stainless Steel Bolt with a 3/8 Wide Stainless Steel Flat Washer (1) through the rear hole on the rear side and the front hole on the front side of the cross belly pan bracket. Secure in place with another 3/8 Wide Stainless Steel Flat Washer and a 3/8-16 Stainless Steel Nylock Nut . Tighten both securely.

77. At the front side of the cross frame between the engine and the rinse tank, locate the mounting plate welded to the cross frame. Place a Door Hitch Bracket (1) below the plate. Line up the slotted holes and insert 5/16-18 x 1 Stainless Steel Carriage Bolts (2) through the door hitch bracket from the bottom up. Secure in place with 5/16 Stainless Steel Flat Washers (3) and 5/16-18 Stainless Steel Nylock Nuts (4). Do not fully tighten.

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78. Insert a 3/8-16 x 8 Stainless Steel Bolt (1) with a 3/8 Wide Stainless Steel Flat Washer (2) through the rear hole of the door hitch bracket (3) . Secure in place with another 3/8 Wide Stainless Steel Flat Washer (4) and a 3/8-16 Stainless Steel Nylock Nut (5) . Tighten securely.

RAIL14SP01146AA

RAIL14SP01127AA

RAIL14SP01128AA

RAIL14SP01147AA

79. Using the Hitch Pins (1) hang the mid belly pan panels (2) on to the pivot bracket (3). Insert the hitch pin through the pivot brackets and through the pivots on each panel on the rear and mid belly pan brackets. Secure the hitch pins in place with the clip pins. 80. After the panels are assembled at the pivot points, adjust all brackets and door hitch assemblies to allow smooth latching of the panels. Tighten all hardware when proper adjustment is complete.

Install front belly pan panel brackets 81. Remove the two bolts (1) securing the hose scuff guard (2) at the left front outside of the vehicle frame. Discard the hardware.

82. Place the Left Hand Front Belly Pan Bracket (1) in position on the frame. The mounting plate with the two holes is to the front with the pivot mount tabs (2) toward the outside.

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83. Insert the front left hand belly pan bracket rear mounting plate (1) up between the hydraulic hoses and the frame.

RAIL14SP01129AA

RAIL14SP01128AA

RAIL14SP01130AA

RAIL14SP01145AA

84. Secure the front mounting plate and hose scuff guard to the frame. Use the ½-13 x 2” Stainless Steel Button Head Bolts (1) along with a ½ Wide Stainless Steel Flat Washer (2) on each bolt. Insert both bolts and secure in place with ½ Wide Stainless Steel Flat Washers (3) and ½-13 Stainless Steel Nylock Nuts (4). Tighten securely

85. Secure the front left hand belly pan bracket rear mounting plate to the frame (1) using the ½-13 x 2” Stainless Steel Button Head Bolts with ½ Wide Stainless Steel Flat Washers (2). Insert the bolts and secure in place with ½ Wide Stainless Steel Flat Washers and ½-13 Stainless Steel Nylock Nuts . Tighten securely.

86. Repeat step 81 through step 85 to assemble the Right Hand Front Belly Pan Bracket . 87. Assemble a Belly Pan Pivot Bracket (1) to each of the pivot mounting tabs (2) on the front right and left hand belly pan brackets. Position the pivot bracket on the top side of the tab with the angled edges down and the pivot pin holes to the outside. Insert a 5/16-18 x 1 Stainless Steel Carriage Bolt (3) through the tab and the pivot bracket from the bottom up. Secure in place with a 5/16 Stainless Steel Flat Washer and a 5/16-18 Stainless Steel Nylock Nut .Do not fully tighten.

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88. Using the Hitch Pins (1), hang the front left hand and right hand belly pan panels (2) on to the pivot brackets (3). Insert the hitch pin through the pivot brackets and through the pivots on each panel on the rear and mid belly pan brackets. Secure the hitch pins in place with the clip pins. 89. After the panels are assembled at the pivot points, adjust all brackets and door hitch assemblies to allow smooth latching of the panels. Tighten all hardware when proper adjustment is complete.

RAIL14SP01127AA

RAIL14SP01131AA

RAIL14SP01136AA

Install Lift Arm Shield Plate 90. Assemble the Front Lift Arm Shield (1) to the lower lift arms Using the two Lift Arm Shield Mount Plates (2), two Front Shield Braces shown in 92 , six 3/8-16 x 5 Stainless Steel Carriage Bolts , eight 3/8 Wide Stainless Steel Flat Washers , eight 3/8-16 Stainless Steel Nylock Nuts, and two 3/8-16 x 1 Stainless Steel Carriage Bolt (3) .Loosely assemble the front shield to the lower lift arms, do not fully tighten. The lower carriage bolt should be 2 to 3 inches in front of the gusset plates (4) on the lift arm. 91. Slowly lower the lift arms, checking for any interference with the belly pan doors. Tighten the carriage bolts after proper adjustment. Do not tighten the lower inside carriage bolt on each lift arm at this time. 92. Assemble the front shield braces (1) to the inside of the front shield (2). Place the sharp angle end of the brace on to the lower carriage bolt (3). Loosely assemble the flat washer and lock nut (4) . Line up the hole in the shield with the slot in the brace. From the front of the shield insert the 3/8-16 x 1 stainless steel carriage bolt through the shield and the brace. Secure in place with a 3/8 stainless steel flat washer and a stainless steel 3/8-16 Nylock nut. Tighten both ends securely. Repeat for the brace on the other side of the front shield.

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Install Right Rear Propel Hose Spring 93. Locate the slider retainer plate (1) where the right rear slider extends from the box tube of the frame. Remove the three carriage bolts, flat washers & lock nuts (3) securing the slider retainer plate to the frame. Discard this hardware. 94. Install new 3/8-16 x 1-3/4 Bolts , 3/8 Flat Washers & 3/8-16 Nylock Nuts (2) from the kit. Install the bolts from the outboard direction. Tighten the lock nuts only finger tight.

RAIL14SP01140AA

RAIL14SP01137AA

RAIL14SP01132AA

RAIL14SP01141AA

95. Place the Hose Support (1) from the kit behind the flange plate of the frame box tube and over the bolts (2). Completely tighten the locknuts.

96. Use a pliers to expand one end of a Spring (1) . Install the spring onto the eyelet hole in a nylon Hanging Strap (2) .

97. Use a pliers to expand the opposite end of the spring (1) . Install the spring into the hole of the hose support (2) .

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98. Open the Velcro of the hanging strap and wrap the strap around the bundle of propel hoses (1) , and through the buckle of the strap. Wrap the strap tightly around the hoses and secure the strap with the Velcro.

RAIL14SP01133AA

RAIL14SP01134AA

RAIL14SP01138AA

RAIL14SP01132AA

Install Left Rear Propel Hose Spring: 99. Locate the platform support plate (1) immediately behind the left rear slider box tube of the frame. Locate the mounting hole (2) on the outer side.

100. Install the Propel Hose Spring Anchor (1) to the platform support plate using the 3/8-16 x 1 Stainless Steel Bolt , both 3/8 Stainless Steel Flat Washers and the 3/8-16 Stainless Steel Nylock Lock Nut (2). Be sure to mount the spring anchor on the correct side of the platform support plate (depending on your particular model of machine) so that when extended, the spring will not interfere with the decorative fender supports tubes.

101. Use a pliers to expand one end of the second Spring (1) . Install the spring onto the eyelet hole in the second nylon Hanging Strap (2).

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102. Use a pliers to expand the opposite end of the spring (1) . Install the spring onto the spring anchor (2) .

RAIL14SP01139AA

RAIL14SP01135AA

103. Open the Velcro of the hanging strap and wrap the strap around the bundle of propel hoses and through the buckle of the strap (1) . Wrap the strap tightly around the hoses and secure the strap with the Velcro.

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Platform guard - Remove - Long frame belly pan SP.300F SP.345F SP.400F

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RAIL15SP00267AA

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Platform, cab, bodywork, and decals - Fenders and guards

Platform guard - Install - Long frame belly pan SP.300F SP.345F SP.400F

1. Leg widen the vehicle all the way out. 2. Park vehicle on a level surface. 3. Apply the parking brake. 4. Shut off the engine and remove the ignition key.

RAIL14SP01149FA

RAIL14SP01142AA

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9. Assemble the rear hook with stop bolt (1) to the front left hand belly pan panel (2). Position the rear hook with the handle to your left and the hook up.

RAIL14SP01150FA

RAIL14SP01170AA

RAIL14SP01151FA

12. Assemble the front hook (1) to the front left hand belly pan panel (2). Position the Front Belly Pan Option Hook (1) with the handle to your left and the hook up.

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RAIL14SP01171AA

RAIL14SP01153FA

15. Assemble the Spring (1) to the rear mounting hole in the panel frame.

16. Insert a Âź-20 x 1-1/4 Stainless Steel Bolt (1) with a Âź Stainless Steel Flat Washer (2) through the tab from the back side.

RAIL14SP01172AA

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RAIL14SP01172AA

RAIL14SP01153FA

RAIL14SP01173AA

18. Assemble the Latch Rod (1) to the rear hook (2). Position the latch rod against the hook with the mount end up and the reinforcement lip away from the hook.

20. Place the open end of the spring (1) on to the bolt followed by a ¼ Stainless Steel Flat Washer (2) and a ¼-20 Stainless Steel Nylock Nut (2). Tighten securely.

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RAIL14SP01174AA

RAIL14SP01154FA

RAIL14SP01143AA

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Platform, cab, bodywork, and decals - Fenders and guards

25. Assemble the rear hook with stop bolt (1) to the front right hand belly pan panel (2). Position the rear hook with the handle to your right and the hook up.

RAIL14SP01155FA

RAIL14SP01175AA

RAIL14SP01156FA

28. Assemble the front hook (1) to the front right hand belly pan panel (2). Position the Front Belly Pan Option Hook (1) with the handle to your right and the hook up.

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RAIL14SP01176AA

RAIL14SP01157FA

RAIL14SP01177AA

31. Assemble the Spring (1) to the rear mounting hole in the panel frame.

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33. Place the end of the spring on to the bolt, followed by a ¼ Stainless Steel Flat Washer (1) followed by a ¼-20 Stainless Steel Nylock Nut (2). Tighten securely.

RAIL14SP01177AA

RAIL14SP01158FA

RAIL14SP01179AA

34. Assemble the Latch Rod (1) to the rear hook (2) . Position the latch rod against the hook with the mount end up and the reinforcement lip away from the hook.

36. On to the bolt assemble a ¼ Stainless Steel Flat Washer (1) followed by a ¼-20 Stainless Steel Nylock Nut (2). Tighten securely.

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Platform, cab, bodywork, and decals - Fenders and guards

37. Place the open end of the spring (1) on to the bolt followed by a ¼ Stainless Steel Flat Washer (2) and a ¼-20 Stainless Steel Nylock Nut (3). Tighten securely.

RAIL14SP01179AA

RAIL14SP01180AA

RAIL14SP01181AA

39. Place the right hand front panel near the front right side of the vehicle with the latch rod toward the center. 40. Position a Long Frame Mid Belly Pan Panel (1) on a work bench with the large indentation away from you and the panel lip up. On top of the panel, position the Belly Pan Option Weldment (2). Align the right hand corner mounting hole with the second mounting hole in the panel on the right hand corner. The latch mounting tabs should be pointing upward.

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Platform, cab, bodywork, and decals - Fenders and guards

RAIL14SP01142AA

RAIL14SP01150FA

RAIL14SP01170AA

43. Assemble the hook with stop bolt (1) to the long frame mid belly pan panel (2). Position the hook with the handle to your left and the hook up.

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Platform, cab, bodywork, and decals - Fenders and guards

46. Assemble the hook (1) to the long frame mid belly pan panel (2). Position the Belly Pan Option Hook (1) with the handle to your left and the hook up.

RAIL14SP01151FA

RAIL14SP01171AA

RAIL14SP01152FA

49. Assemble the Spring (1) to the mounting hole in the panel frame (2).

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50. From the back side of the tab, insert a ¼-20 x 1-1/4 Stainless Steel Bolt (1) with a ¼ Stainless Steel Flat Washer (2) through the tab.

RAIL14SP01172AA

RAIL14SP01153FA

RAIL14SP01173AA

52. Assemble the Latch Rod (1) to the hook (with stop bolt) (2). Position the latch rod against the hook with the mount end up and the reinforcement lip away from the hook.

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RAIL14SP01173AA

RAIL14SP01174AA

RAIL14SP01122AA

56. Repeat step 40 through step 55 to assemble the remaining long frame belly pan panels.

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RAIL14SP01123AA

RAIL14SP01182AA

RAIL14SP01183AA

59. Position the Long Left Hand Rear Belly Pan Bracket (1) , Long Right Hand Rear Belly Pan Bracket (2) , Left Hand Mid Belly Pan Bracket (3) and the Right Hand Mid Belly Pan Bracket (4) under the frame. The mounting pivot tabs should be to the outside and the mounting plates pointing upward. Be sure that the mounting brackets are positioned as shown, with the narrow section mounting plates at the rear (6).

RAIL14SP01184AA

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62. Position the mounting plate of the left hand mid belly pan bracket (1) in place on the outside of the frame (2) . Position the mounting plate between the hydraulic hoses and/or tubes and the vehicle frame. Using saved hardware from the fuel tank mount, secure the mounting plate (3) to the fuel tank and the vehicle frame. Do not fully tighten until the belly pan brackets are installed between the rear and mid brackets.

RAIL14SP01183AA

RAIL14SP01184AA

RAIL14SP01222AA

RAIL14SP01223AA

63. Position the mounting plate of the right hand long belly pan bracket (1) in place on the outside of the frame (2) . Position the mounting plate between the hydraulic hoses and/or tubes and the vehicle frame. Using saved hardware from the fuel tank mount, secure the mounting plate (3) to the fuel tank and the vehicle frame. Do not fully tighten until the belly pan brackets are installed between the rear and mid brackets.

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RAIL14SP01144AA

RAIL14SP01437FA

RAIL14SP01145AA

RAIL14SP01436FA

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70. Assemble the Door Hitch Bracket (1) to the plate welded to the front cross frame (2). Position the bracket under the mounting plate. Line up the slots with the holes and insert 5/16-18 x 1 Stainless Steel Carriage Bolts through the door hitch bracket from the bottom up. Secure in place with 5/16 Stainless Steel Flat Washers MLR907379 and 5/16-18 Stainless Steel Nylock Nuts (3). Do not fully tighten.

RAIL14SP01124AA

RAIL14SP01125AA

71. Insert a 3/8-16 x 8 Stainless Steel Bolt with a 3/8 Wide Stainless Steel Flat Washer (1) through the forward set of holes in the door hitch bracket (2). Secure in place with another 3/8 Wide Stainless Steel Flat Washer (907465) and a 3/8-16 Stainless Steel Nylock Nut (907391). Tighten securely.

72. Assemble the Door Hitch Offset Bracket (1) to the Door Hitch Mount Plate (2). With the angled lips down, place the door hitch offset bracket on top of the mount plate with the mounting holes facing away from the edge. Insert a 5/16-18 x 1 Stainless Steel Carriage Bolt (3) through the door hitch offset bracket from the top down. Secure in place with 5/16 Stainless Steel Flat Washers (907379) and 5/16-18 Stainless Steel Nylock Nuts (907390). Do not fully tighten.

73. Under the cab, locate two accumulators (1) . Locate the radar mount bracket under the accumulators. Place the mount plate with bracket attached (2) on the underside of the radar mount bracket with the angled lips pointing down. Line up the holes and insert 5/16-18 x 1 Stainless Steel Carriage Bolts (3) through the plate from the bottom up. Secure in place with 5/16 Stainless Steel Flat Washers and 5/16-18 Stainless Steel Nylock Nuts . Do not fully tighten.

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RAIL14SP01125AA

RAIL14SP01126AA

RAIL14SP01224AA

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RAIL14SP01146AA

RAIL14SP01127AA

RAIL14SP01128AA

80. After the panels are assembled at the pivot points, adjust all brackets and door hitch assemblies to allow smooth latching of the panels. Tighten all hardware when proper adjustment is complete.

Install front belly pan panel brackets 81. Remove the two bolts (1) securing the hose scuff guard (2) at the left front outside of the vehicle frame. Discard the hardware.

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Platform, cab, bodywork, and decals - Fenders and guards

82. Place the Left Hand Front Belly Pan Bracket (1) in position on the frame. The mounting plate with the two holes is to the front with the pivot mount tabs (2) toward the outside.

RAIL14SP01147AA

RAIL14SP01129AA

RAIL14SP01128AA

RAIL14SP01130AA

83. Insert the front left hand belly pan bracket rear mounting plate (1) up between the hydraulic hoses and the frame.

84. Secure the front mounting plate (1) and hose scuff guard (2) to the frame. Use the ½-13 x 2” Stainless Steel Button Head Bolts with a ½ Wide Stainless Steel Flat Washer (3) on each bolt. Insert both bolts and secure in place with ½ Wide Stainless Steel Flat Washers and ½-13 Stainless Steel Nylock Nuts . Tighten securely

85. Secure the front left hand belly pan bracket rear mounting plate (1) to the frame. Use the ½-13 x 2” Stainless Steel Button Head Bolts with a ½ Wide Stainless Steel Flat Washer (2) on the bolt. Insert the bolt and secure in place with a ½ Wide Stainless Steel Flat Washer and ½-13 Stainless Steel Nylock Nut . Tighten securely.

86. Repeat step 81 through step 85 to assemble the Right Hand Front Belly Pan Bracket .

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Platform, cab, bodywork, and decals - Fenders and guards

87. Assemble a Belly Pan Pivot Bracket (1) to each of the pivot mounting tabs (2) on the front right and left hand belly pan brackets. Position the pivot bracket on the top side of the tab with the angled edges down and the pivot pin holes to the outside. Insert a 5/16-18 x 1 Stainless Steel Carriage Bolt (3) through the tab and the pivot bracket from the bottom up. Secure in place with a 5/16 Stainless Steel Flat Washer and a 5/16-18 Stainless Steel Nylock Nut . Do not fully tighten.

RAIL14SP01145AA

RAIL14SP01127AA

RAIL14SP01131AA

RAIL14SP01136AA

88. Using the Hitch Pins (1) hang the front left hand and right hand belly pan panels (2) on to the pivot brackets (3). Insert the hitch pin through the pivot brackets and through the pivots on each panel on the rear and mid belly pan brackets. Secure the hitch pins in place with the clip pins. 89. After the panels are assembled at the pivot points, adjust all brackets and door hitch assemblies to allow smooth latching of the panels. Tighten all hardware when proper adjustment is complete.

Install Lift Arm Shield Plate 90. Assemble the Front Lift Arm Shield (1) to the lower lift arms Using the two Lift Arm Shield Mount Plates , two Front Shield Braces shown in 92 , six 3/8-16 x 5 Stainless Steel Carriage Bolts , eight 3/8 Wide Stainless Steel Flat Washers , eight 3/8-16 Stainless Steel Nylock Nuts, and two 3/8-16 x 1 Stainless Steel Carriage Bolt (2) .Loosely assemble the front shield to the lower lift arms, do not fully tighten. The lower carriage bolt should be 2 to 3 inches in front of the gusset plates on the lift arm. 91. Slowly lower the lift arms, checking for any interference with the belly pan doors. Tighten the carriage bolts after proper adjustment. Do not tighten the lower inside carriage bolt on each lift arm at this time. 92. Assemble the front shield braces (1) to the inside of the front shield (2). Place the sharp angle end of the brace on to the lower carriage bolt. Loosely assemble the flat washer and lock nut. Line up the hole in the shield with the slot in the brace. From the front of the shield insert the 3/8-16 x 1 stainless steel carriage bolt (3) through the shield and the brace. Secure in place with a 3/8 stainless steel flat washer and a stainless steel 3/8-16 Nylock nut (4) . Tighten both ends securely. Repeat for the brace on the other side of the front shield.

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Install Right Rear Propel Hose Spring 93. Locate the slider retainer plate (1) where the right rear slider extends from the box tube of the frame. Remove the three carriage bolts, flat washers & lock nuts (2) securing the slider retainer plate to the frame. Discard this hardware. 94. Install new 3/8-16 x 1-3/4 Bolts , 3/8 Flat Washers & 3/8-16 Nylock Nuts (2) from the kit. Install the bolts from the outboard direction. Do not fully tighten the lock nuts.

RAIL14SP01140AA

RAIL14SP01137AA

RAIL14SP01132AA

RAIL14SP01141AA

95. Place the Hose Support (1) from the kit behind the flange plate of the frame box tube and over the bolts (2) . Fully tighten the locknuts.

96. Use a pliers to expand one end of a Spring (1) . Install the spring onto the eyelet hole in a nylon Hanging Strap (2) .

97. Use a pliers to expand the opposite end of the spring. Install the spring into the hole of the hose support (1) .

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98. Open the Velcro of the hanging strap and wrap the strap around the bundle of propel hoses, and through the buckle of the strap (1) . Wrap the strap tightly around the hoses and secure the strap with the Velcro.

RAIL14SP01133AA

RAIL14SP01134AA

RAIL14SP01138AA

RAIL14SP01132AA

Install Left Rear Propel Hose Spring: 99. Locate the platform support plate (1) immediately behind the left rear slider box tube of the frame. Locate the mounting hole (2) on the outer side.

100. Install the Propel Hose Spring Anchor (1) to the platform support plate using the 3/8-16 x 1 Stainless Steel Bolt , both 3/8 Stainless Steel Flat Washers and the 3/8-16 Stainless Steel Nylock Lock Nut (2) . Be sure to mount the spring anchor on the correct side of the platform support plate (depending on your particular model of machine) so that when extended, the spring will not interfere with the decorative fender supports tubes.

101. Use a pliers to expand one end of the second Spring (1) . Install the spring onto the eyelet hole in the second nylon Hanging Strap. (2).

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102. Use a pliers to expand the opposite end of the spring (1) . Install the spring onto the spring anchor (2) .

RAIL14SP01139AA

RAIL14SP01135AA

103. Open the Velcro of the hanging strap, and wrap the strap (1) around the bundle of propel hoses and through the buckle of the strap. Wrap the strap tightly around the hoses and secure the strap with the Velcro.

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Index Platform, cab, bodywork, and decals - 90 Fenders and guards - 116 Fender - Install - Front and rear fenders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Fender - Install - Front steering cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Fender - Remove - Front and rear fenders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Fender - Remove - Front steering cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Platform guard - Install - Long frame belly pan (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Platform guard - Install - Short frame belly pan (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Platform guard - Remove - Long frame belly pan (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Platform guard - Remove - Short frame belly pan (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

(*) See content for specific models 47691240 24/02/2015

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CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404 SERVICE - Technical Publications & Tools

47691240 24/02/2015 EN

CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404 SERVICE - Technical Publications & Tools

47691240 24/02/2015 EN

Ω

G B A

A B C

B A C

3 1

3 2 1

4 5

1 2

Ω

3 2 1

6 5 4

3 2 1

6 5 4

SHURFLO PUMP #07.05114 C

C AB

1 2 3

18 1

12 9

11 10

A B G

33 33 Ω

33 33 H

Ω

J K

B L

V F

M E

T S

N P

PIN 2

AIR

Right

liquid

AIR

Left

Fluid

liquid

Water

GUARDIAN SP.295F, SP.300F, SP.345F, SP.400F PIN YEYM00812 AND AFTER ELECTRICAL SCHEMATIC RAC 47756531 SHEET 1 SIDE 1

3 2 1

A B C

B A C

1 2

X W V

G F

J K

B A

T S

C D P

M N

A B

A B G

A B â&#x201E;¦

C A B

1 2 3

GUARDIAN SP.295F, SP.300F, SP.345F, SP.400F PIN YEYM00812 AND AFTER ELECTRICAL SCHEMATIC RAC 47756531 SHEET 1 SIDE 2

* * M AIR SEAT

31 1 3

4 27

26 29

25 23 21 2 34

8 10 14 12 16 18

20 22 24 19

19 17 15

13 11

3 7

+ -

GUARDIAN SP.295F, SP.300F, SP.345F, SP.400F PIN YEYM00812 AND AFTER ELECTRICAL SCHEMATIC RAC 47756531 SHEET 2 SIDE 1

GUARDIAN SP.295F, SP.300F, SP.345F, SP.400F PIN YEYM00812 AND AFTER ELECTRICAL SCHEMATIC RAC 47756531 SHEET 2 SIDE 2

LIFT CYLINDERS STEERING CYLINDER

REVERSING FAN OPTION REVERSING FAN MOTOR R

BRAKE PEDAL

SUSPENSION CYLINDER

STEERING VALVE

T P

P T

HYDRAULIC RESERVOIR AUXILIARY PUMP 75CC

R L

ACCUMULATOR 85CC

LEG WIDENING VALVES

SUSPENSION VALVES LEG WIDENING CYLINDERS

LEG WIDENING CYLINDERS

SUSPENSION ACCUMULATOR

COOLING PACKAGE Hydraulic Reservoir

SHUTTLE VALVE RETURN

CASE DRAIN

VALVE INTERGRATED C

PROD

1-35GPM

25 GPM

PB2 1

5GPM

1 PC2

CF1

FD1

EC1

1 SC1

SV3

S1 2

1 3

2000PSI

1 PC3

RV1 1

2 3

LIFT

2-6GPM

FC1

PC4

1 PC1

OR3 1/16 NPTF (0.055" Ã&#x2DC;)

SV1 VC12-2

NV2

FAN MOTOR

S2 SV2

RV2

1 NV1

PB STR

FAN PUMP

PB1

24-35GPM

OR?

At Hyd Filter

Case Filter

AUXILIARY PUMP 45CC SEE PRODUCT PUMP NOTE

FLOW CONTROL VALVE

Hyd Filter

FAN RELIEF

GUARDIAN SPRAYER SP.295F HYDRAULIC SCHEMATIC P.I.N. YEYM00812 AND AFTER RAC 47756533

47756533S1S1

BRAKE VALVE

.934 1C 1.401

X XD

BRAKE PRESSURE SWITCH 60 PSI

T 1

.467

XD X

1 Y1

467 934

.934 1.401

.467

R Y3

467 934

MW-14

DRIVE MOTOR

SWITCH X DX

R 1A

1B G1B

NVB

2C 1C

.873 1.747

NVA G2A

ACCUMULATOR 10 CU. IN.

-00

1.049 2.099

MS-18 DYNA-PLUS

Cooler Inlet See Aux

G2B

-02

2C 1C

2A 2B

RV2

MS-18 DYNA-PLUS -00

G1A

.873 1.747

-02

2C 1C

1.049 2.099

Hyd Filter

SWITCH 22PSI

Case Filter

SWITCH 35PSI

SHUTTLE VALVE

T P1 P

.032

LR X1

GPR

BRAKE VALVE 5 SP.

SENDER

TEMPERATURE PROBE

PRESSURE TRANSDUCER

LADDER CYLINDER

TANDEM PUMP

HYDRO1

DRIVE MOTOR

RV1

873(1049) 873(1049)

M2 M3

ACCUMULATOR 10 CU. IN.

M1 L2 M6

HYDRO2

873(1049) 873(1049)

DX X

M2 M1 L2 M3

PRESSURE TRANSDUCER

GUARDIAN SPRAYER SP.295F HYDRAULIC SCHEMATIC - PROPEL P.I.N. YEYM00812 AND AFTER RAC 47756533

47756533S1S2

STEERING CYLINDER

LIFT CYLINDER

STEERING CYLINDER

BRAKE PEDAL STEERING VALVE SUSPENSION CYLINDER

T P

P T

R L

HYDRAULIC RESERVOIR

AUXILIARY PUMP 75CC ACCUMULATOR 85CC

FAN RELIEF SP.300F

Model SP.300F

ACCUMULATOR 85CC

FAN PUMP

LEG WIDENING VALVES SUSPENSION VALVE LEG WIDENING CYLINDERS

LEG WIDENING CYLINDERS

SUSPENSION ACCUMULATOR

COOLING PACKAGE HYDRAULIC RESERVOIR Case Filter Hyd Filter

TO CASE DRAIN SEE PROPEL

AUXILIARY PUMP 45CC

PROD

1-35GPM

FLOW CONTROL VALVE

3 CF1

FD1

OR3 1/16 NPTF (0.055" Ã&#x2DC;)

EC1 2 1 SC1

1 PC3

S1 1 3

2000PSI

LIFT

2-6GPM

FC1

PC4

VALVE INTERGRATED

SV3

PC1

RV1 3

PC2

SV1 VC12-2

5GPM

2 1

FAN MOTOR

25 GPM

PB2

NV2

PB1

S2 SV2

RV2

1 NV1

PB STR

24-35GPM

OR?

FAN RELIEF SP.345F & SP.400F FAN PUMP 2

GUARDIAN SPRAYER SP.300F, SP.345F AND SP.400F HYDRAULIC SCHEMATIC P.I.N. YEYM00812 AND AFTER RAC 47756533 To Hyd Filter

47756533S2S1

BRAKE VALVE

X XD

BRAKE PRESSURE SWITCH 60 PSI

873(1049) 873(1049)

MS-18 DYNA-PLUS -00 -02

1.049 1C 2.099

SWITCH

1B G1B

A MS-18 DYNA-PLUS -00 -02

DRIVE MOTOR

.873 1C 1.747 2C

1B 1A

NVB

R 2

RV2

NVA

PRESSURE TRANSDUCER

G1A

SENDER

MS-18 DYNA-PLUS

Cooler Inlet See Aux

G2B

1.049 1C 2.099

873(1049) 873(1049)

G1A

RV1

DRIVE MOTOR

XD X

R 873(1049) 873(1049)

1.049 1C 2.099

-00

.873 1C 1.747 2C

-02

1.049 1C 2.099 2C

SWITCH 22PSI SWITCH 35PSI

Hyd Filter

Case Filter

SHUTTLE VALVE

X2 GX

T P1

.032

GPR

P X1

BRAKE VALVE 5 SP.

TEMPERATURE PROBE

LADDER CYLINDER

A TANDEM PUMP

M2 M3

M1 L2 M6

HYDRO2

X XD

MS-18 DYNA-PLUS -00 -02

.873 1C 1.747

HYDRO1

.873 1C1.747 2C

873(1049) 873(1049)

DRIVE MOTOR

XD X

M2 M1 L2 M3

PRESSURE TRANSDUCER

GUARDIAN SPRAYER SP.300F HYDRAULIC SCHEMATIC - PROPEL P.I.N. YEYM00812 AND AFTER RAC 47756533

47756533S2S2

BRAKE VALVE

DRIVE MOTOR

BRAKE PRESSURE SWITCH 60 PSI

X XD

XD X

1049 1049

A -02 MS-18 DYNA-PLUS 2C 1.049 1C

1049 1049

-02

MS-18 DYNA-PLUS 2C 1.049

2.099

SWITCH X XD

G DRIVE MOTOR

DRIVE MOTOR

1B G1B

NVB

G1A

1.049 1C 2.099 2C

1049 1049

RV1

MS-18 DYNA-PLUS -02

1B 1A

-02 MS-18 DYNA-PLUS 2C 1.049

XD X

R 1049 1049

RV2

NVA

G2B

2.099 PRESSURE TRANSDUCER

SENDER

G1A

SWITCH 22PSI

Cooler Inlet See Aux Diagram

Hyd Filter

SWITCH 35PSI

Case Filter

SHUTTLE VALVE

X2 GX

GPR

T P1

.032

P X1

BRAKE VALVE 3 SP. TEMPERATURE PROBE

LADDER CYLINDER FILTER ASSEMBLY

PRESSURE TRANSDUCER RELIEF VALVE

2A Propel

1A Propel

TANDEM PUMP

2B Propel

1B Propel

TANDEM PUMP

GUARDIAN SPRAYER SP.345F HYDRAULIC SCHEMATIC - PROPEL P.I.N. YEYM00812 AND AFTER RAC 47756533

47756533S3S1

BRAKE VALVE

1.516 1C 2.857 2C

X XD

.467 3C .934

1.516 2.857

4C 3C

DRIVE MOTOR

.467 .934

XD X

874 1049

467 467

BRAKE PRESSURE SWITCH 60 PSI

Y1 Y2

874 1049

467 467

1.516 1C 2.857 2C

X XD

4C 3C

.467 .934

SWITCH

1.516 1C 2.857

R 874 1049

1A 1B G1B

1A 1B NVB

Y1 Y2

G1A

RV2

G2A

PRESSURE TRANSDUCER

SENDER

X2 GX

467 467

DRIVE MOTOR

SWITCH 22PSI

SWITCH 35PSI

Hyd Filter

Case Filter

SHUTTLE VALVE

T P

.032

GPR

874 1049

MW-24-L2

Cooler Inlet See Aux Diagram

XD X

NVA

G2B

2A T

.467 .934

RV1

MW-24-L2

A DRIVE MOTOR

467 467

MW-24-L2

DRIVE MOTOR

P X1

BRAKE VALVE 5 SP.

LADDER CYLINDER

TEMPERATURE PROBE

PRESSURE TRANSDUCER

ACCUMULATOR 10 CU. IN.

FILTER ASSEMBLY

2A Propel

1A Propel

RELIEF VALVE

2B Propel

1B Propel

TANDEM PUMP

GUARDIAN SPRAYER SP.400F HYDRAULIC SCHEMATIC - PROPEL P.I.N. YEYM00812 AND AFTER RAC 47756533

47756533S3S2