New Holland SP3500 Defensor Service Repair Manual (48149953) – New Holland SP3500 – PDF Download by www.heydownloads.com

SERVICE MANUAL

SERVICE MANUAL SP3500 Defensor

SP3500 Defensor

1/1 Part number 48149953

Part number 48149953 English June 2018

SERVICE MANUAL SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

48149953 12/06/2018 EN

Link Product / Engine Product SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834- - ]

Market Product Latin America

48149953 12/06/2018

Engine F4HE9687T*J106

Contents INTRODUCTION Engine....................................................................................... 10 [10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 [10.216] Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 [10.206] Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 [10.202] Air cleaners and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 [10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6 [10.310] Aftercooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7 [10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8

Power coupling........................................................................... 19 [19.121] Pump-drive assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.1

Front axle system ....................................................................... 25 [25.100] Powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1 [25.108] Final drive hub, steering knuckles, and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.2 [25.122] Axle suspension control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.3

Rear axle system........................................................................ 27 [27.100] Powered rear axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.1 [27.124] Final drive hub, steering knuckles, and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.2

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

Brakes and controls .................................................................... 33 [33.202] Hydraulic service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1 [33.110] Parking brake or parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.2

Hydraulic systems....................................................................... 35 [35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 48149953 12/06/2018

[35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2 [35.104] Fixed displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3 [35.106] Variable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4 [35.105] Charge pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5 [35.703] Stabilizer hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.6 [35.735] Track frame widening system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.7 [35.911] Sprayer hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.8

Frames and ballasting ................................................................. 39 [39.130] Sprayer boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.1

Steering..................................................................................... 41 [41.101] Steering control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1 [41.206] Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2 [41.216] Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.3

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

Cab climate control ..................................................................... 50 [50.100] Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.1 [50.200] Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.2 [50.300] Cab pressurizing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.3

Electrical systems ....................................................................... 55 [55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.019] Hydrostatic drive control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 [55.DTC] FAULT CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3

Chemical applicators................................................................... 63 [63.100] Liquid fertilizer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63.1

Spraying .................................................................................... 78 48149953 12/06/2018

[78.110] Chemical spraying. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.1

Platform, cab, bodywork, and decals ............................................. 90 [90.150] Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1 [90.151] Cab interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2 [90.105] Machine shields and guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.3

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INTRODUCTION

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Contents INTRODUCTION Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Personal safety - Do not operate tag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Basic instructions - Ecology and the environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Basic instructions - Important notice regarding equipment servicing . . . . . . . . . . . . . . . . . . . . . . . . . 14 Basic instructions - Shop and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Torque - Minimum tightening torques for normal assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Torque - Standard torque data for hydraulic connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Capacities Fluid and lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

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INTRODUCTION

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 - Do not operate tag WARNING Maintenance hazard! Before you start servicing the machine, attach a DO NOT OPERATE warning tag to the machine in a visible area. Failure to comply could result in death or serious injury. W0004A

Attach a DO NOT OPERATE tag to the machine in an area that is clearly visible whenever the machine is not operating properly and/or requires service. Complete the tag information with the “reason” that the tag is attached by describing the malfunction or service required. Sign your name in the designated area on the tag to validate your reason for attaching the tag. The tag should only be removed by the person who signed and attached the tag, after validating that the repairs or services have been completed. Below is an example of a tag:

PIIL18SP00005AA

Tag components A. DO NOT REMOVE THIS TAG (Warning) The tag should only be removed by the person who signed and attached the tag, after validating that the repairs or services have been completed. B. DO NOT OPERATE – (Warning!) C. REASON - (Area for describing malfunction or service required before operation.) D. Signed by – (Signature area – to be signed by the person validating the reason for installation of the tag.)

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INTRODUCTION

Safety rules 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. When digging or using ground engaging attachments be aware of buried cables. Contact local utilities to determine the locations of services. 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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INTRODUCTION

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 you disengage 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. Jack or lift the machine only at jack or lift points indicated in this manual. Incorrect towing procedures can cause accidents. When towing a disabled machine follow the procedure in this manual. Use only rigid tow bars. 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, follow the instructions in the manual. 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. Follow instructions in the manual for proper tire inflation. Tires are heavy. Handling tires without proper equipment could cause death or serious injury. Never weld on a wheel with a tire installed. Always remove tire completely from wheel prior to welding. 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 until the tire is completely removed. 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. The tire MUST be completely removed from the wheel or rim prior to welding the wheel or rim.

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. Make sure brake pedal latch is engaged. Brake pedals must be locked together for road travel. Use safety chains for trailed equipment when provided with machine or equipment. 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.

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INTRODUCTION

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. 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 operator’s manual. Do not short across terminals. Follow manufacturer’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.

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.

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INTRODUCTION

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. Refer to Chapter 5 — Transport Operations for complete identification and operating instructions.

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. • Refer to Chapter 4 — Operating Instructions for proper use and adjustment of seat belts.

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INTRODUCTION

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 When digging or using ground-engaging equipment, be aware of buried cables and other services. Contact your local utilities or authorities, as appropriate to determine the locations of services. 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. 48149953 12/06/2018

INTRODUCTION

• Do not permit anyone to touch the machine until power has been shut off to the power lines.

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.

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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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Basic instructions - Ecology and the environment Soil, air, and water are vital factors of agriculture and life in general. When legislation does not yet rule the treatment of some of the substances required by advanced technology, sound judgment should govern the use and disposal of products of a chemical and petrochemical nature. NOTE: The following are recommendations that may be of assistance: • Become acquainted with and ensure that you understand the relative legislation applicable to your country. • Where no legislation exists, obtain information from suppliers of oils, filters, batteries, fuels, antifreeze, cleaning agents, etc., with regard to their effect on man and nature and how to safely store, use, and dispose of these substances. • Agricultural consultants will, in many cases, be able to help you as well.

Helpful hints • Avoid filling tanks using cans or inappropriate pressurized fuel delivery systems that may cause considerable spillage. • In general, avoid skin contact with all fuels, oils, acids, solvents, etc. Most of them 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 draining off used engine coolant mixtures, engine, gearbox and hydraulic oils, brake fluids, etc. Do not mix drained brake fluids or fuels with lubricants. Store them safely until they can be disposed of in a proper way to comply with local legislation and available resources. • Modern coolant mixtures, i.e. antifreeze and other additives, should be replaced every two years. They should not be allowed to get into the soil, but should be collected and disposed of properly. • Do not open the air-conditioning system yourself. It contains gases that should not be released into the atmosphere. Your NEW HOLLAND dealer or air conditioning specialist has a special extractor for this purpose and will have to recharge the system properly. • Repair any leaks or defects in the engine cooling 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 as penetrating weld splatter may burn a hole or weaken them, allowing the loss of oils, coolant, etc.

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INTRODUCTION

Basic instructions - 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 information in this manual is up-to-date at the date of the publication. It is the policy of the manufacturer for continuous improvement. Some information could not be updated due to modifications of a technical or commercial type, or changes to the laws and regulations of different countries. In case of questions, refer to your NEW HOLLAND Sales and Service Networks.

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INTRODUCTION

Basic instructions - Shop and assembly Shims installation For each adjustment operation, select adjusting shims and measure 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 indicated on each shim.

Rotating shaft seals For correct rotating shaft seal installation, proceed as follows: • Before assembly, allow the seal to soak in the oil it will be sealing for at least thirty minutes. • Thoroughly clean the shaft and check that the working surface on the shaft is not damaged. • Position the seal lip facing the fluid. With the hydrodynamic lip, take into consideration the shaft rotation direction and position the grooves so that they direct the fluid towards the inner side of the seal. • Coat the seal lip with a thin layer of lubricant (use oil rather than grease) and fill the gap between the seal lip and the dust guard with the double seal lip with grease, unless instructed otherwise. • 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. • While inserting the seal, check that it is perpendicular to the seat; once settled, make sure that it makes contact with the thrust element, if required. • To prevent damage to the shaft seal lip, position a protective guard during installation operations.

O-ring seals Lubricate the O-ring seals before inserting them into the seats. This prevents the seals from overturning and twisting, which jeopardizes sealing efficiency.

Sealing compounds Apply one of the following sealing compounds on the mating surfaces when specified: SILMATE® RTV1473, or LOCTITE® RTV 598™ or LOCTITE® INSTANT GASKET 587™ BLUE. Before applying the sealing compound, prepare the surfaces as directed on product container or as follows: • Remove any incrustations using a metal brush. • Thoroughly de-grease the surfaces using a locally approved cleaning agent such as safety solvent or brake parts cleaner.

Spare parts Only use "CNH Original Parts" or " NEW HOLLAND 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 Parts" can offer this guarantee. When ordering spare parts, always provide the following information: • Machine model (commercial name) and serial number • Part number of the ordered part, which can be found in the "Service Parts Catalogue", used for order processing

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INTRODUCTION

Protecting the Electrical/Electronic Systems During Charging or 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

To avoid damage to the electronic/electrical systems, always observe the following: 1. Never make or break any of the charging circuit connections, including the battery connections, when the engine is running. 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 welding near a computer module, remove the module from the machine. • Never allow welding cables to lay on, near or across any electrical wiring or electronic component while welding is in progress 4. Always disconnect the negative cable from the battery when charging the battery in the machine with a battery charger. NOTICE: If welding must be performed on the unit, the battery ground cable must be disconnected from the machine battery. The electronic monitoring system and charging system will be damaged if this is not done. Remove the battery ground cable. Reconnect the cable when welding is completed.

Tools The tools that NEW HOLLAND suggests and illustrated in this manual have been: • Specifically researched and designed for use with NEW HOLLAND machines • Essential for reliable repair operations • Accurately built and rigorously tested so as 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 NOTE: The terms "front", "rear", "right-hand" and "left-hand" (when referred to different parts) are determined from the rear, facing in the direction of travel of the machine during operation.

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

Nm 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

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

Nm 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

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

Grade 8 bolts, nuts and studs Size 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

Nm 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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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

INTRODUCTION

Grade 10.9 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

Nm 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 37° 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 48149953 12/06/2018

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 1-3/ 110 Nm ft 16-12 in 90 – 65 – 80 lb 1-3/ 110 Nm ft 16-12 in 125 – 92 – 105 lb 1-7/ 140 Nm ft 16-12 in 170 – 125 – 1-11/ 190 Nm 140 lb ft 16-12 in 2-12 in 200 – 150 – 254 Nm 180 lb ft 9/16-18 in

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

23 – 27 Nm 204 – 240 lb in 9/16-18 in 34 – 41 Nm 300 – 360 lb in 61 – 68 Nm 540 – 3/4-16 in 600 lb in 81 – 88 Nm 60 – 65 lb 7/8-14 in ft 115 – 85 – 90 lb 1-1/ 122 Nm ft 16-12 in 129 – 95 – 100 lb 1-13/ 136 Nm ft 16-12 in 156 – 115 – 1-5/ 169 Nm 125 lb ft 16-12 in 201 – 150 – 1`-5/ 217 Nm 160 lb ft 6-12 in 190 – 1-7/8-12 in 258 – 271 Nm 200 lb ft 7/16-20 in

INTRODUCTION

Torque - Standard torque data for hydraulic connections General information • Hydraulic connections require a minimum assembly torque in order to provide zero leakage at rated pressure with adequate fatigue resistance. Over-torquing of a hydraulic connection can also lead to leakage or failure. For some connections, NEW HOLLAND requires a different torque value than is listed in the ISO and SAE standards. • The torque values in this document should be used whenever possible or applicable. NOTICE: Always follow the instructions in this manual for specific torque values when you service components. The information in this section is for general guidance only when a procedure contains no specific torque value.

Tolerance • The tolerance for all torque values is ± 10%. This tolerance must include all assembly variation, not only the torque wrench repeatability.

Lubrication Application of grease or other lubricants to hydraulic connectors should be avoided. If clean hydraulic oil is already on the connection, it is not required to remove the oil. Generally, application of grease: • May cause a significant change in the torque required to properly tighten the connection. • May reduce the connection’s resistance to vibration. • Excessive grease may displace an elastomer seal during tightening. • Grease extrusion when connection is tightened may be mistaken for leakage. NEW HOLLAND products generally use O-Ring Boss (ORB) connectors that have Teflon™-coated O-rings, eliminating the need for O-ring lubrication during installation. For connections which are made into aluminum manifolds or with stainless steel connectors, it may be required to apply a lubricant to prevent galling. Use of LOCTITE® and other thread-locking compounds is prohibited. These compounds: • May cause a significant change in the torque required to properly tighten the connections. • Reduce the serviceability of the joint. • May prevent the O-ring from properly sealing if the compound gets on the O-ring.

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INTRODUCTION

Torque values for metric O-Ring Boss (ORB) port connections

Metric thread M8 x 1 M10 x 1 M12 x 1.5 M14 x 1.5 M16 x 1.5 M18 x 1.5 M22 x 1.5 M27 x 2 M30 x 2 M33 x 2 M42 x 2 M48 x 2 M60 x 2

S-Series * Ferrous Non-Ferrous N·m (lb ft) ± 10% N·m (lb ft) ± 10% 10.5 (7.7) 21 (15.5) 37 (27.3) 47 (34.7) 58 (42.8) 74 (54.6) 105 (77.4) 178 (131.3) 225 (166) 325 (239.7) 345 (254.5) 440 (324.5) 525 (387.2)

L-Series ** Ferrous Non-Ferrous N·m (lb ft) ± 10% N·m (lb ft) ± 10%

6.3 (4.6) 12.5 (9.2) 22 (16.2) 28 (20.7) 35 (25.8) 44 (32.5) 63 (46.5) 107 (78.9) 135 (99.6) 195 (143.8) 207 (152.7) 264 (194.7) 315 (232.3)

8.5 (6.3) 15.5 (11.4) 27 (19.9) 37 (27.3) 42 (31) 47 (34.7) 63 (46.5) 105 (77.4) 136 (100.3) 168 (123.9) 220 (162.3) 273 (201.4) 330 (243.4)

5 (3.7) 9.3 (6.9) 16 (11.8) 22 (16.2) 25 (18.4) 28 (20.7) 38 (28) 63 (46.5) 82 (60.5) 101 (74.5) 132 (97.4) 164 (121) 198 (146)

* S-Series connectors are used with O-Ring Face Seals (ORFS). ** L-Series connectors are used with 37° flare. Torque values for metric O-Ring Boss (ORB) port plugs

Ferrous

Non-ferrous

Metric thread

Internal hex N·m (lb ft) ± 10%

External hex N·m (lb ft) ± 10%

N·m (lb ft) ± 10%

M8 x 1 M10 x 1 M12 x 1.5 M14 x 1.5 M16 x 1.5 M18 x 1.5 M22 x 1.5 M27 x 2 M30 x 2 M33 x 2 M42 x 2 M48 x 2 M60 x 2

8.5 (6.3) 16 (11.8) 23 (17) 47 (34.7) 58 (42.8) 74 (54.6) 105 (77.4) 178 (131.3) 225 (166) 325 (239.7) 345 (254.5) 440 (324.5) 525 (387.2)

10.5 (7.7) 21 (15.5) 37 (27.3) 47 (34.7) 58 (42.8) 74 (54.6) 105 (77.4) 178 (131.3) 225 (166) 325 (239.7) 345 (254.5) 440 (324.5) 525 (387.2)

6.3 (4.6) 12.5 (9.2) 22 (16.2) 28 (20.7) 35 (25.8) 44 (32.5) 63 (46.5) 107 (78.9) 135 (99.6) 195 (143.8) 207 (152.7) 264 (194.7) 315 (232.3)

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INTRODUCTION

Torque values for port connections (British Standard Pipe Parallel (BSPP) thread ports and stud ends)

Metric tube Outside Diameter (OD) mm (in) BSPP thread G- Gas; A- medium coarse threads G 1/8 A G 1/4 A

G 3/8 A

S-Series *

L-Series **

– 6 (0.236) or 8 (0.315) 10 (0.394) or 12 (0.472)

6 (0.236) 8 (0.315) or 10 (0.394)

G 1/2 A

16 (0.630)

G 3/4 A G1A G 1 1/4 A G 1 1/2 A

20 (0.787) 25 (0.984) 30 (1.181) 38 (1.496)

12 (0.472) 15 (0.591) or 18 (0.709) 22 (0.866) 28 (1.102) 35 (1.378) 42 (1.654)

Ferrous

Non-Ferrous

S-Series N·m (lb ft) ± 10%

L-Series N·m (lb ft) ± 10%

S-Series N·m (lb ft) ± 10%

L-Series N·m (lb ft) ± 10%

–

21 (15.5)

–

12.5 (9.2)

63 (46.5)

53 (39.1)

38 (28)

32 (23.6)

95 (70.1)

84 (62)

57 (42)

50 (36.9)

136 (100.3)

105 (77.4)

82 (60.5)

63 (46.5)

210 (154.9) 400 (295) 525 (387.2) 660 (486.8)

126 (92.9) 240 (177) 315 (232.3) 396 (292.1)

* S-Series connectors are used with O-Ring Face Seals (ORFS). ** L-Series connectors are used with 37° flare. Torque values for metric port connections (Metric face-seal ports and stud ends)

Metric tube Outside Diameter (OD) mm (in) Metric thread

S-Series *

M10 x 1 M12 x 1.5 M14 x 1.5 M16 x 1.5 M18 x 1.5 M20 x 1.5 M22 x 1.5 M26 x 1.5 M27 x 1.2 M33 x 2 M42 x 2 M48 x 2

– 4 (0.157) 5 (0.197) 7 (0.276) 8 (0.315) 10 (0.394) 12 (0.472) – 16 (0.630) 20 (0.787) 25 (0.984) 32 (1.260)

Ferrous

Non-Ferrous

L-Series **

S-Series N·m (lb ft) ± 10%

L-Series N·m (lb ft) ± 10%

S-Series N·m (lb ft) ± 10%

L-Series N·m (lb ft) ± 10%

4 (0.157) 6 (0.236) 7 (0.276) 9 (0.354) 11 (0.433) – 14 (0.551) 18 (0.709) – 23 (0.906) 30 (1.181) 36 (1.417)

– 47 (34.7) 63 (46.5) 84 (62) 105 (77.4) 147 (108.4) 158 (116.5) – 210 (154.9) 400 (295) 525 (387.2) 630 (464.7)

21 (15.5) 32 (23.6) 53 (39.1) 63 (46.5) 84 (62) – 147 (108.4) 210 (154.9)

– 28 (20.7) 38 (28) 50 (36.9) 63 (46.5) 88 (64.9) 95 (70.1) – 126 (92.9) 240 (177) 315 (232.3) 396 (292.1)

12.5 (9.2) 19 (14) 32 (23.6) 38 (28) 50 (36.9) – 88 (64.9) 126 (92.9) – 240 (177) 315 (232.3) 396 (292.1)

* S-Series connectors are used with O-Ring Face Seals (ORFS). ** L-Series connectors are used with 37° flare.

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400 (295) 525 (387.2) 630 (464.7)

INTRODUCTION

Torque values for Inch O-Ring Boss (ORB) port non-adjustable connections

SAE dash size

UN/UNF thread size

Inch tube OD mm (in)

2 3 4 5 6 8 10 12 14 16 20 24 32

5/16-24 3/8-24 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

3.18 (0.125) 4.76 (0.187) 6.35 (0.250) 7.94 (0.313) 9.52 (0.375) 12.7 (0.500) 15.88 (0.625) 19.05 (0.750) 22.22 (0.875) 25.4 (1.000) 31.75 (1.250) 38.1 (1.500) 50.8 (2.000)

S-Series * NonFerrous Ferrous N·m (lb ft) N·m (lb ft) ± 10% ± 10%

L-Series ** NonFerrous Ferrous N·m (lb ft) N·m (lb ft) ± 10% ± 10%

– 15.5 (11.4) 37 (27.3) 42 (31) 47 (34.7) 89 (65.6) 121 (89.2) 178 (131.3) 225 (166) 283 (208.7) 300 (221.3) 388 (286.2) 388 (286.2)

8.5 (6.3) 10.5 (7.7) 19 (14) 26 (19.2) 32 (23.6) 53 (39.1) 63 (46.5) 100 (73.8) 131 (96.6) 156 (115.1) 210 (154.9) 220 (162.3) 315 (232.3)

– 9.3 (6.9) 22 (16.2) 25 (18.4) 28 (20.7) 53 (39.1) 73 (53.8) 107 (78.9) 135 (99.6) 170 (125.4) 180 (132.8) 233 (171.9) 233 (171.9)

5 (3.7) 6.3 (4.6) 11.5 (8.5) 15.5 (11.4) 19 (14) 32 (23.6) 38 (28) 60 (44.3) 79 (58.3) 94 (69.3) 126 (92.9) 132 (97.4) 189 (139.4)

* S-Series connectors are used with O-Ring Face Seals (ORFS). ** L-Series connectors are used with 37° flare. Torque values for inch O-Ring Boss (ORB) port adjustable connections

SAE dash size

UN/UNF thread size

Inch tube OD mm (in)

2 3 4 5 6 8 10 12 14 16 20 24 32

5/16-24 3/8-24 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

3.18 (0.125) 4.76 (0.187) 6.35 (0.250) 7.94 (0.313) 9.52 (0.375) 12.7 (0.500) 15.88 (0.625) 19.05 (0.750) 22.22 (0.875) 25.4 (1.000) 31.75 (1.250) 38.1 (1.500) 50.8 (2.000)

S-Series * NonFerrous Ferrous N·m (lb ft) N·m (lb ft) ± 10% ± 10%

L-Series ** NonFerrous Ferrous N·m (lb ft) N·m (lb ft) ± 10% ± 10%

– 10.5 (7.7) 21 (15.5) 42 (31) 47 (34.7) 89 (65.6) 121 (89.2) 178 (131.3) 225 (166) 285 (210.2) 300 (221.3) 388 (286.2) 388 (286.2)

8.5 (6.3) 10.5 (7.7) 19 (14) 26 (19.2) 32 (23.6) 53 (39.1) 63 (46.5) 100 (73.8) 131 (96.6) 156 (115.1) 210 (154.9) 220 (162.3) 315 (232.3)

* S-Series connectors are used with O-Ring Face Seals (ORFS). ** L-Series connectors are used with 37° flare.

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– 9.3 (6.9) 21 (15.5) 25 (18.4) 28 (20.7) 53 (39.1) 73 (53.8) 107 (78.9) 135 (99.6) 170 (125.4) 180 (132.8) 233 (171.9) 233 (171.9)

5 (3.7) 6.3 (4.6) 11.5 (8.5) 15.5 (11.4) 19 (14) 32 (23.6) 38 (28) 60 (44.3) 79 (58.3) 94 (69.3) 126 (92.9) 132 (97.4) 189 (139.4)

INTRODUCTION

Torque values for inch O-Ring Boss (ORB) port plugs

SAE dash size

UN/UNF thread size

2 3 4 5 6 8 10 12 14 16 20 24 32

5/16-24 3/8-24 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

Ferrous External hex Internal hex N·m (lb ft) N·m (lb ft) ± 10% ± 10% 7.5 (5.5) 14.5 (10.7) 21 (15.5) 28 (20.7) 47 (34.7) 89 (65.6) 116 (85.6) 176 (129.8) 247 (182.2) 284 (209.5) 357 (263.3) 441 (325.3) 536 (395.3)

12.5 (9.2) 21 (15.5) 37 (27.3) 42 (31) 47 (34.7) 89 (65.6) 116 (85.6) 176 (129.8) 247 (182.2) 284 (209.5) 357 (263.3) 441 (325.3) 536 (395.3)

Non-Ferrous N·m (lb ft) ± 10% 7.5 (5.5) 12.5 (9.2) 22 (16.2) 25 (18.4) 28 (20.7) 53 (39.1) 70 (51.6) 106 (78.2) 148 (109.2) 170 (125.4) 214 (157.8) 265 (195.5) 322 (237.5)

Torque values for four-bolt flange connections (Metric Screws, Class 10.9)

Metric size mm

Imperial size in

Screw code 61

Code 61 N·m (lb ft) ± 10%

13 19 25

1/2 3/4 1

M8 x 1.25 M10 x 1.5 M10 x 1.5

34 (25.1) 74 (54.6) 74 (54.6)

1-1/4

M10 x 1.5

74 (54.6)

38 51 64 76 89 102 127

1-1/2 2 2-1/2 3 3-1/2 4 5

M12 x 1.75 M12 x 1.75 M12 x 1.75 M16 x 2 M16 x 2 M16 x 2 M16 x 2

137 (101) 137 (101) 137 (101) 310 (228.6) 310 (228.6) 310 (228.6) 310 (228.6)

Screw code 62

Code 62 N·m (lb ft) ± 10%

M8 x 1.25 M10 x 1.5 M12 x 1.75 M12 x 1.75 M14 x 1.5 M16 x 2 M20 x 2.5 M24 x 3 M30 x 3.5 – – –

34 (25.1) 74 (54.6) 137 (101) 137 (101) 189 (139.4) 310 (228.6) 575 (424.1) 575 (424.1) 680 (501.5) – – –

Screw code 62

Code 62 N·m (lb ft) ± 10%

M8 x 1.25 M10 x 1.5 M12 x 1.75 M12 x 1.75 M14 x 1.5 M16 x 2 M20 x 2.5 M24 x 3 M30 x 3.5 – – –

29 (21.4) 57(42) 100 (73.8) 100 (73.8) 160 (118) 250 (184.4) 500 (368.8) 575 (424.1) 680 (501.5) – – –

Torque values for four-bolt flange connections (Metric Screws, Class 8.8)

Metric size mm

Imperial size in

Screw code 61

Code 61 N·m (lb ft) ± 10%

13 19 25

1/2 3/4 1

M8 x 1.25 M10 x 1.5 M10 x 1.5

29 (21.4) 57(42) 57(42)

1-1/4

M10 x 1.5

57(42)

38 51 64 76 89 102 127

1-1/2 2 2-1/2 3 3-1/2 4 5

M12 x 1.75 M12 x 1.75 M12 x 1.75 M16 x 2 M16 x 2 M16 x 2 M16 x 2

100 (73.8) 100 (73.8) 100 (73.8) 250 (184.4) 250 (184.4) 250 (184.4) 250 (184.4)

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INTRODUCTION

Torque values for four-bolt flange connections (Inch Screws, Grade 8)

Metric size mm

Imperial size in

Screw code 61

Code 61 N·m (lb ft) ± 10%

Screw code 62

Code 62 N·m (lb ft) ± 10%

13 19 25 32 38 51 64 76 89 102 127

1/2 3/4 1 1-1/4 1-1/2 2 2-1/2 3 3-1/2 4 5

5/16-18 3/8-16 3/8-16 7/16-14 1/2-13 1/2-13 1/2-13 5/8-11 5/8-11 5/8-11 5/8-11

34 (25.1) 63 (46.5) 63 (46.5) 97 (71.5) 158 (116.5) 158 (116.5) 158 (116.5) 310 (228.6) 310 (228.6) 310 (228.6) 310 (228.6)

5/16-18 3/8-16 7/16-14 1/2-13 5/8-11 3/4-10 – – – – –

34 (25.1) 63 (46.5) 97 (71.5) 158 (116.5) 310 (228.6) 473 (348.9) – – – – –

Tapered thread connection tightening

British Standard Pipe Taper (BSPT) thread size (inch)

National Pipe Thread Fuel (NPTF) thread size (inch)

1/8-28 1/4-19 3/8-19 1/2-14 3/4-14 1-11 1-1/4-11 1-1/2-11 2-11

1/8-27 1/4-18 3/8-18 1/2-14 3/4-14 1-11 1/2 1-1/4-11 1/2 1-1/2-11 1/2 2-11 1/2

Turns from finger tight 2 2 2 2 2 1.5 1.5 1.5 1.5

3 3 3 3 3 2.5 2.5 2.5 2.5

Torque values for banjo bolt connections (Copper washer style)

Bolt thread (metric)

Hex size (mm)

Torque N·m (lb ft) ± 10%

M8 x 1.25 M10 x 1.25 M12 x 1.5 M14 x 1.5 M16 x 1.5 M18 x 1.5 M20 x 1.5 M22 x 1.5 M24 x 1.5

13 17 17 19 22 24 27 32 32

13 (9.6) 16 (11.8) 40 (29.5) 45 (33.2) 48 (35.4) 50 (36.9) 73 (53.8) 73 (53.8) 73 (53.8)

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INTRODUCTION

Torque values for O-Ring Face Seals (ORFS) connections

SAE dash size

UN/UNF thread size

4 5 6 8 10 12 14 16 20 24

9/16-18 5/8-18 11/16-16 13/16-16 1-14 1-3/16-12 1-5/16-12 1-7/16-12 1-11/16-12 2-12

Inch tube OD (mm)

Metric tube OD (mm)

Hex size (mm) (Reference only)

* Swivel nut torque N·m (lb ft) ± 10%

** Swivel nut torque N·m (lb ft) ± 10%

6.35 7.94 9.52 12.7 15.88 19.05 22.23 25.4 31.75 38.1

6 8 10 12 16 20 22 25 30 38

17 19 22 24 30 36 41 41 50 60

27 (19.9) 34 (25.1) 44 (32.5) 65 (47.9) 100 (73.8) 150 (110.6) 163 (120.2) 210 (154.9) *** 280 (206.5) *** 375 (276.6) ***

27 (19.9) 34 (25.1) 44 (32.5) 65 (47.9) 100 (73.8) 131 (96.6) 131 (96.6) 131 (96.9) 178 (131.3) 210 (154.9)

* High/Medium-pressure applications > 50 bar (725 psi). ** Low-pressure applications < 50 bar (725 psi). *** It is recommended to use a four-bolt flange connection instead of O-Ring Face Seals (ORFS) sizes "16" and up. Torque values for 37° flare connections - Joint Industry Council (JIC)

SAE dash size

UN/UNF thread size

Metric tube OD (mm)

Inch tube OD (mm)

Swivel nut torque N·m (lb ft) ± 10%

2 3 4 5 6 8 10 12 14 16 20 24 32

5/16-24 3/8-24 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

– – 6 8 10 12 16 20 – 25 30/32 38 50

3.18 4.76 6.35 7.94 9.52 12.7 15.88 19.05 22.22 25.4 31.75 38.1 50.8

8.25 (6.1) 11.5 (8.5) 15.5 (11.4) 20 (14.8) 25 (18.4) 52 (38.4) 81 (59.7) 112 (82.6) 133 (98.1) 155 (114.3) 180 (132.8) 225 (166) 348 (256.7)

Torque values for 30° flare, 60° cone connections

Nominal size (mm)

British Standard Pipe Parallel (BSPP) thread size

Hex size (mm)

Swivel nut torque N·m (lb ft) ± 10%

5, 6, 6.3 8, 9, 10 12, 12.5 15, 16, 19 25 31.5, 32 38 50, 51

G 1/4 G 3/8 G 1/2 G 3/4 G1 G 1-1/4 G 1-1/2 G2

17 19 22 30 36 46 50 65

25 (18.4) 34 (25.1) 64 (47.2) 132 (97.4) 196 (144.6) 225 (166) 255 (188.1) 316 (223.1)

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INTRODUCTION

Special tools 84271105 Bearing extractor of the sprayer hydraulic motor.

84271105

84271106

84271107

84271106 Hydraulic motor bearing beater

84271107 Gear fixing pin extractor.

84400046 Deutsch terminal retraction tool.

BRIL12CE0085A0A

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INTRODUCTION

380002422 Service cable â&#x20AC;&#x201C; NAVII and GPS.

380003052 Installation tool for the metal retainer rail.

380003052

380003053

380003054

380003053 Installation device for the metal retainer rail.

380003054 Hub retainer installation tool.

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INTRODUCTION

380003306 Cab lift cradle (Use with 380003353).

380003306

380003312 Bearing lock nut extractor.

BRAG12PUALL025

BRAG12PUALL026

BRAG12PUALL027

380003313 Bearing cup installer.

380003314 Retainer installer.

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INTRODUCTION

380003353 Cab lift frame (Universal).

380003353

380040220 DPA5 adapter â&#x20AC;&#x201C; Electronic Service Tool (EST) connectivity kit.

Additional tools required Multimeter Fluke 88 digital multi-meter

RAIL13SP01281AB

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INTRODUCTION

Back probe extension wire set

NOTE: Obtain direct from SPX â&#x20AC;&#x201C; OTC 233788, or FNH00550

RAIL13SP01282AA

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INTRODUCTION

General specification Tire and rim repair WARNING Explosion hazard! Do not remove, install, or make repairs to a tire on a wheel rim. Take the tire and rim to a tire shop where persons with special training and special safety tools are available. Failure to comply could result in death or serious injury. W0365A

Always have a qualified tire mechanic service the tires and rims on this machine. If the tire has lost all air pressure, take the tire and rim to a tire shop for service. The use of correct equipment and correct procedures will prevent accidents. Explosive separation of the tire can cause serious injury.

RCIL08CCH014AAB

RCIL08CCH015AAB

Tire installation To get the traction and cleaning action of the lugs, the tires must be installed on the wheels so the tread is turning as shown. Do not try to remove, repair or install a tire on a rim. This should be done by a qualified technician.

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INTRODUCTION

Tire inflation procedure Do not inflate a tire that has had a complete loss of air. If the tire has lost all air pressure, have a qualified tire mechanic service the tire. To add air to a partly inflated tire, use the following procedure: 1. Use an air hose with a remote shutoff valve and a self-locking air chuck. 2. Stand behind the tread of the tire and make sure all persons are away from the side of the tire before you start to add air. 3. Inflate the tire to the recommended air pressure. DO NOT inflate the tire more than the recommended pressure.

Tire inflation examples For maximum sprayer performance, always adjust the tire pressure to the recommended range to conform with the actual load on the tires. Use the tire and load and inflation charts to match the tire pressure to the machine weight. This example shows the cross section of a tire inflated for maximum load but with a minimum load on the tire. The tire tread is not making full contact with the ground which will give poor performance.

RCIL08CCH012AAB

RCIL08CCH013AAB

This example shows the cross section of a tire with the inflated pressure correctly adjusted to the load on the tire. The tire tread is making full contact with the ground which will give maximum performance.

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INTRODUCTION

Capacities Fluid and lubricants System Grease fittings (all)

Wheel hubs (per unit)

Motor

Multiplier gear box

Cooling system

Hydraulic system Air-conditioner compressor Air-conditioning system Fuel tank Fuel system and tank

Recommended fluid

Quantity

International specification

NEW HOLLAND AMBRA GR-9 MULTI-PURPOSE GREASE grease

As needed

NLGI 2, NH 710A

Oil NEW HOLLAND AMBRA HYPOIDE 140 GEAR LUBE

1.1 L (0.3 US gal)

Oil NEW HOLLAND AMBRA MASTERGOLD™ HSP ENGINE OIL CI-4 SAE 15W-40

16.0 L (4.2 US gal)(without filter) 17.0 L (4.5 US gal)(with filter)

Oil NEW HOLLAND AMBRA HYPOIDE 140 GEAR LUBE

2.84 L (0.75 US gal)

* 50% demineralized water + 50% NEW HOLLAND AMBRA ACTIFULL™ OT EXTENDED LIFE COOLANT

60.0 L (15.9 US gal)

OAT Glycol ASTM D3306

NEW HOLLAND AMBRA HI TECH 68 Oil

Reservoir : 105 L (27,5 US gal) Top up: 195 L (52 US gal) With IntelliHeight: 200 L (53 US gal)

PAG SP20 Oil

285 mL (1.20 US cup)

HFC R134A gas Diesel No 2 ** Additive CNH

1.9 kg (4.2 lb) 305 L (81 US gal) 1% of the fuel tank capacity

SAE 85W-140, API GL-5, NH 504A SAE 15W-40, API CI-4, ACEA E7, NH 330H SAE 85W-140, API GL-5, NH 504A

NOTE: * If demineralized water is not available, the water must have the following characteristics: Solids 340 ppm

Sulphates 100 ppm

Chlorine 40 ppm

pH 5.5 - 9.0

NOTE: ** The tank and fuel system additive is available in the following packages: PN 71104731 ( 1 L package), PN 71104732 ( 5 L package), PN 71104733 ( 20 L package), and PN 71104734 ( 2000 L package). See your NEW HOLLAND dealer to purchase the correct package that best suits your application, machine, and/or fuel storage tank.

Engine oil The correct engine oil viscosity grade is dependent upon ambient temperature. Refer to the chart when selecting the oil for your machine engine. NOTE: In areas where prolonged periods of extreme temperatures are encountered, local lubricant practices are acceptable, such as the use of SAE 5W30 in extreme low temperatures or SAE 50 in extreme high temperatures.

SS09J076

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SERVICE MANUAL Engine SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Engine - 10

[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 [10.216] Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 [10.206] Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 [10.202] Air cleaners and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 [10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6 [10.310] Aftercooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7 [10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8

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Engine - 10 Engine and crankcase - 001

SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Engine - 10 Engine and crankcase - 001

TECHNICAL DATA Engine Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Engine Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Service instruction - Valve cover access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Remove - Air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Install - Air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Vibration isolators Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

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Engine - Engine and crankcase

Engine - Torque

SOIL17SP00450AA

Reference (1) (2) (3)

Description Motor mount bolts Engine air tube clamps Fan bolts

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Torque Values 310 – 380 N·m (229 – 280 lb ft) 16 – 18 N·m (12 – 13 lb ft) 9 – 11 N·m (80 – 97 lb in)

Engine - Engine and crankcase

Engine - Remove 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

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: Engine hood â&#x20AC;&#x201C; Removal Engine hood - Remove (90.105) Prior operation: Oil reservoir â&#x20AC;&#x201C; Removal Oil reservoir - Remove (35.300) 1. On the right-hand side of the machine, remove the cover (1) from the battery compartment.

SOIL17SP00401AA

SOIL17SP00403AA

2. Disconnect both battery cables from the batteries. Start with the negative cable.

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Engine - Engine and crankcase

3. Close the valve (1) to cut the fuel supply.

SOIL17SP00473AA

SOIL17SP00452AA

SOIL17SP00466AA

SOIL16SP00049AA

4. Disconnect the hoses (1) to (4) from the deaeration tank. NOTE: Label the position of these hoses to facilitate their reconnection. NOTICE: Cover the connection points to avoid the entry of dirt.

5. Remove cap screws (1). 6. Remove the deaeration tank (2) together with the cradle (3).

7. Disconnect the air filter restriction sensor (1).

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Engine - Engine and crankcase

8. Loosen the clamp that secures the air tube at the end of the filter housing (1). 9. Loosen the fastening clamp at the turbocharger (2). 10. Remove the air duct (3). NOTICE: Cover the connection points to avoid the entry of dirt.

SOIL16SP00049AA

SOIL16SP00041AA

SOIL17SP00456AA

11. Remove the bolts that secure the air filter housing (1), installed under the rails (2). 12. Remove the complete filter assembly. Unseat the duct (3) from the support plate (4).

13. Loosen the clamp (1). Remove the tube (2) of the muffler (3). 14. Loosen the nuts of the clamp that secures the muffler (4). Remove the muffler (3).

15. Remove cap screws (1). 16. Remove the muffler cradle (2).

SOIL16SP00050AA

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Engine - Engine and crankcase

17. Remove the following ducts: • Interconnection of the intercooler and the intake manifold (1). • Interconnection of the turbocharger and the intercooler (2). • Interconnection of the engine and the radiator (3). • Interconnection of the turbocharger and the muffler (4). NOTICE: Cover the connection points to avoid the entry of dirt. SOIL16SP00039AA

SOIL17SP00462AA

SOIL16SP00040AA

SOIL16SP00042AA

18. Loosen the hose clamp at the engine (1). Loosen the clamps that secure the hose to the cradle (2). Remove the hose (3) from the cradle.

19. With a suitable lifting device, support the cradle assembly (1). NOTE: Also use the eye bolts (2) for lifting. 20. Remove the bolts (3) on both sides of the cradle (1). 21. Remove the cradle (1).

22. Remove cap screws (1). 23. Remove the radiator fan shield (2).

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Engine - Engine and crankcase

24. Loosen the bolts that secure the coolant overflow tank cradle (1). Remove the cradle.

SOIL17SP00459AA

SOIL17SP00463AA

SOIL17SP00464AA

SOIL16SP00048AA

25. Remove the bolts (1) and washers (2) that secure the fan shroud (3) on both sides. Move the fan shroud so that you can access the bolts of the helix.

26. Remove the bolts (1) that secure the radiator fan.

27. Disconnect the heater hose (1). NOTICE: Cover the connection points to avoid the entry of dirt.

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Engine - Engine and crankcase

28. Disconnect the alternator cables, in this order: • Ground (1). • Positive (2). • Exciter (3).

SOIL16SP00034AA

SOIL16SP00047AA

SOIL16SP00036AA

SOIL16SP00035AA

29. Disconnect the hoses (1), (2), and (3) secured on the engine, at the bottom of the radiator. NOTICE: Cover the connection points to avoid the entry of dirt.

30. Disconnect the cable (1) and the wiring harness (2) from the cold start relay (3).

31. Disconnect the starter motor cables, in this order: • Negative (1). • Ground (2). • Positive (3).

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Engine - Engine and crankcase

32. Remove the radiator fan (1).

SOIL16SP00055AA

SOIL16SP00031AA

SOIL16SP00038AA

SOIL16SP00037AA

33. Disconnect the positive cable from the auxiliary cold start device (1).

34. Remove the hardware that secures the hoses of the air-conditioning compressor to the frame of the machine, to allow the removal of the compressor. 35. Remove cap screws (1) e (2). 36. Remove the screw (3). 37. Remove the compressor (4) and the belts (5). Pay attention to the weight of the component. NOTICE: Handle the compressor safely, so as to not damage the refrigerant fluid hoses.

38. Disconnect the fuel hoses (1) and (2). NOTICE: Cover the connection points to avoid the entry of dirt. 39. Disconnect the connectors (3) to (6) from the main wiring harness. 40. Remove the clamps (7) to detach the main wiring harness from the engine.

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Engine - Engine and crankcase

41. Remove the handrail assembly (1) on the left-hand side of the machine.

SOIL16SP00046AA

SOIL16SP00043AA

SOIL16SP00044AA

SOIL16SP00045AA

42. Mount a suitable lifting device on an overhead crane. 43. Connect the lift chains to the engine hoist eyelets (1).

44. Remove the bolts (1) from the front pads.

45. Remove the bolts (1) from the rear pads. 46. Lift the engine. Remove the engine through the lefthand side of the machine.

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Engine - Engine and crankcase

Engine - Install 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

Prior operation: Engine - Remove (10.001) 1. Position the engine on the cradle of the machine. Lift and move through the left-hand side of the machine.

SOIL16SP00064AA

SOIL16SP00046AA

SOIL16SP00045AA

2. Install the handrail assembly (1) on the left-hand side of the machine.

3. Install the bolts (1) of the rear pads. Tighten slightly.

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Engine - Engine and crankcase

4. Install the bolts (1) of the front pads. Tighten slightly. 5. Torque the bolts of the front and rear pads to 234 – 260 N·m (173 – 192 lb ft) to finalize the attachment.

SOIL16SP00044AA

SOIL16SP00043AA

SOIL16SP00037AA

SOIL16SP00038AA

6. Disconnect the lift device from the eyelets (1).

7. Install the clamps (1) at proper points to attach the main wiring harness properly to the engine. 8. Connect the connectors (2) to (5) of the main wiring harness. 9. Connect the fuel hoses (6) and (7).

10. Install the air-conditioning compressor (1) on the cradle (2). Install the bolt and nut (3). NOTE: Do not fully tighten the nut (3). 11. Install the belt (4). 12. Adjust the tilt of the compressor (1) to obtain the correct tension of the belt (4). Install and tighten the bolts (5) and (6). 13. Fully tighten the nut (3). NOTE: Check whether the belt (4) is correctly tensioned. 14. Secure the compressor hoses at the proper points on the frame of the machine. Install the original fasteners.

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Engine - Engine and crankcase

15. Apply LOCTITE® 7649™ PRIMER N and LOCTITE® 243™ to the threads of the radiator fan fastening bolts (1). 16. Position the bolts (1) on the radiator fan. 17. Install the radiator fan on the engine. Tighten the bolts (1) to a torque of 52 – 61 N·m (38 – 45 lb ft)

SOIL17SP00464AA

SOIL17SP00463AA

18. Position the fan shroud (1) in its housing. Install the washers (2) and the fastening bolts (3) of the fan (1) on both sides.

19. Position the coolant reservoir (1). Install the fastening bolts (2)

SOIL17SP00459AA

SOIL16SP00042AA

20. Install the radiator fan shield (1) with the bolts (2).

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Engine - Engine and crankcase

21. Correctly route and then connect the positive cable from the auxiliary cold start device (1).

SOIL16SP00031AA

SOIL16SP00035AA

SOIL16SP00036AA

SOIL16SP00047AA

22. Connect the starter motor cables, in this order: • Ground (1). • Negative (2). • Positive (3).

23. Connect the cable (1) and the wiring harness (2) to the cold start relay (3).

24. Connect the hoses (1), (2), and (3) to the engine, at the bottom of the radiator.

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Engine - Engine and crankcase

25. Connect the alternator cables, in this order: • Ground (1). • Exciter (2). • Positive (3).

SOIL16SP00034AA

SOIL16SP00048AA

SOIL16SP00040AA

SOIL16SP00039AA

26. Connect the heater hose (1).

27. Suspend the cradle assemble (1) over the engine. NOTE: Use the eye bolts (2) for lifting. 28. Lower the cradle (1). Secure to the radiator frame. Install the bolts (3) on both sides.

29. Install the following ducts: • Interconnection of the intercooler and the intake manifold (1). • Interconnection of the turbocharger and the intercooler (2). • Interconnection of the engine and the radiator (3). • Interconnection of the turbocharger and the muffler (4).

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Engine - Engine and crankcase

30. Install the muffler cradle (1) with the bolts (2).

SOIL16SP00050AA

SOIL16SP00041AA

SOIL16SP00049AA

SOIL17SP00456AA

31. Position the entire air filter assembly (1) over the rails (2). Fit the duct (3) on the support plate (4) 32. Attach the air filter compartment (1). Install the bolts underneath the rails (2).

33. Install the air duct (1) to interconnect the filter compartment and the turbocharger. 34. Connect the air filter restriction sensor (2)

35. Position the muffler tube (1) in its housing. Position the clamps (2) and their nuts (3) to attach the muffler. 36. Position the tube (4) at the end of the muffler. Secure the tube with the tube clamp (5).

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Engine - Engine and crankcase

37. Install the deaeration tank (1) and the cradle (2). Install the bolts (3) to assemble.

SOIL16SP00052AA

SOIL17SP00452AA

SOIL17SP00465AA

SOIL17SP00403AA

38. Connect the hoses (1) to (4) to the deaeration tank.

39. Open the fuel supply valve (1). 40. Install the casing that masks the fuel tank (2).

41. Connect both battery cables from the batteries. Start with the positive cables.

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Engine - Engine and crankcase

42. Install the cover (1) of the battery compartment.

SOIL17SP00401AA

Next operation: Oil reservoir - Install (35.300) Next operation: Engine hood - Install (90.105)

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Engine - Engine and crankcase

Engine - Service instruction - Valve cover access 1. Open the access latch (1) of the engine hood.

RAIL13SP04628AA

SOIL16SP00073AA

RAIL13SP04639AA

2. Tip the parts (2) and (3) of the engine hood

3. Remove the hood support bracket.

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Engine - Engine and crankcase

4. Disconnect the electric connector of the air filter restriction sensor (1). 5. Remove the 90Â° hose (2) connecting the air intake tube to the air filter housing.

RAIL13SP04640AA

RAIL13SP04643AA

6. Loosen the hose clamp securing the air inlet tube to the air filter housing.

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Engine - Engine and crankcase

7. Remove the bolts securing the air filter housing to the support frame.

RAIL13SP04642AA

RAIL13SP04645AA

RAIL13SP04644AA

8. Remove the air filter housing and intake tube from the machine.

9. Loosen the clamp securing the crossover tube.

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Engine - Engine and crankcase

10. Loosen the clamp securing the breather hose to the breather on top of the valve cover.

RAIL13SP04637AA

11. Remove the crossover tube.

RAIL13SP04646AA

RAIL13SP04648AA

12. Loosen the clamp (1) securing the 90Â° hose connecting the air intake tube to the turbo. 13. Rotate the 90Â° hose so the inlet is up (2), out of the way for the valve cover removal.

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Engine - Engine and crankcase

14. Remove the two nuts securing the harness to the valve cover and move the harness up, out of the way.

RAIL13SP04647AA

RAIL13SP04649AA

15. Remove the nuts securing the valve cover to the head and remove the valve cover.

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Engine - Engine and crankcase

Engine - Remove - Air filter housing 1. Open the access latch (1) of the engine hood.

RAIL13SP04628AA

SOIL16SP00073AA

RAIL13SP04639AA

2. Tip the parts (2) and (3) of the engine hood.

3. Remove the hood support bracket.

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Engine - Engine and crankcase

4. Disconnect the electric connector of the air filter restriction sensor (1). 5. Remove the 90Â° hose (2) connecting the air intake tube to the air filter housing.

RAIL13SP04640AA

RAIL13SP04643AA

6. Loosen the hose clamp securing the air inlet tube to the air filter housing.

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Engine - Engine and crankcase

7. Remove the bolts securing the air filter housing to the support frame.

RAIL13SP04642AA

RAIL13SP04645AA

8. Remove the air filter housing and intake tube from the machine.

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Engine - Engine and crankcase

Engine - Install - Air filter housing 1. Install the air filter housing on the machine.

RAIL13SP04645AA

RAIL13SP04642AA

2. Position the air filter housing on the cradle frame and install the bolts.

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Engine - Engine and crankcase

3. Position the air intake tube on the air filter housing and secure the clamp.

RAIL13SP04643AA

RAIL13SP04640AA

RAIL13SP04639AA

4. Install the 90Â° hose (2) that connects the air intake tube on the air filter housing. 5. Connect the electric connector of the air filter restriction sensor (1).

6. Install the hood support cradle.

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Engine - Engine and crankcase

7. Close the parts (2) and (3) of the engine hood.

SOIL16SP00073AA

RAIL13SP04628AA

8. Close the access latch (1) of the engine hood.

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Engine - Engine and crankcase

Vibration isolators - Remove Engine isolator mount removal NOTICE: If replacing hardware, must use the hardware noted in this Machineâ&#x20AC;&#x2122;s Parts Manual. 1. Remove the nut and washer from the isolator being removed.

RAIL13SP01245AA

RAIL13SP01246AA

RAIL13SP01250AA

1. If removing an engine to frame isolator, attach a proper chain to the end (front or back) of the engine of the isolator being changed. Lift the engine high enough to not have any weight on the isolator. 2. If you remove the engine frame isolator on the frame with a suitable jack (1), lift the corner of the engine frame so that the engine frame is high enough that no weight is on the isolator.

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Engine - Engine and crankcase

CAUTION Avoid injury! Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear. Failure to comply could result in minor or moderate injury. C0145A

Remove isolator mounting hardware and isolator bolt. Then remove the isolator. RAIL13SP01248AB

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Engine - Engine and crankcase

Vibration isolators - Install 1.

Install the isolator. Install and tighten isolator mounting hardware. Put isolator bolt in place. RAIL13SP01248AB

RAIL13SP01246AA

RAIL13SP01250AA

RAIL13SP01245AA

NOTE: Do not install isolator nut at this time. 2.

If installing an engine to frame isolator, lower the chain.

3. If you install the engine frame onto the frame isolator, lower the jack (1).

4. Install washer and nut. Torque to 310 – 380 N·m (229 – 280 lb ft).

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Index Engine - 10 Engine and crankcase - 001 Engine - Install - Air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine - Remove - Air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine - Service instruction - Valve cover access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Vibration isolators - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Vibration isolators - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Engine - 10 Fuel tanks - 216

SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Engine - 10 Fuel tanks - 216

SERVICE Fuel tank Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Engine - Fuel tanks

Fuel tank - Drain fluid WARNING Fuel vapors are explosive and flammable. Do not smoke while handling fuel. Keep fuel away from flames or sparks. Shut off engine and remove key before servicing. Always work in a well-ventilated area. Clean up spilled fuel immediately. Failure to comply could result in death or serious injury. W0904A

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

NOTE: The machine should be parked on a flat surface. 1. Position a suitable collection container under the fuel tank. 2. Close the valve (1). 3. Reinstall the drain plug (2). 4. After the oil has completely drained, reinstall the plug (2). 5. Store the collection container properly.

SOIL17SP00465AA

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Engine - Fuel tanks

Fuel tank - Remove 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

WARNING Heavy object! The following instruction requires two people. Failure to comply could result in death or serious injury. W1270A

Prior operation: Drain the fuel Fuel tank - Drain fluid (10.216) Prior operation: Front hood Front shield - Remove - Front hood (90.105) 1. Disconnect the suction hose (1) and the return hose (2) at the bottom of the fuel tank. NOTICE: Cover the connection points to avoid the entry of dirt.

SOIL17SP00468AA

SOIL17SP00474AA

2. Disconnect the electric wiring harness from the fuel level sensor connector (1).

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Engine - Fuel tanks

3. On both sides of the fuel tank, remove the bolts (1) and the shims (2). 4. With the help of an assistant, remove the fuel tank by hand.

SOIL16SP00070AA

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Engine - Fuel tanks

Fuel tank - Install 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

WARNING Heavy object! The following instruction requires two people. Failure to comply could result in death or serious injury. W1270A

1. With the help of an assistant, position the fuel tank (1) on the front cradle of the machine (2).

SOIL17SP00455AA

SOIL16SP00070AA

SOIL17SP00474AA

2. Secure the fuel tank on both the sides. Install the shims (1) and the bolts (2).

3. Connect the electric wiring harness to the fuel level sensor connector (1).

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Engine - Fuel tanks

4. Connect the suction hose (1) and the return hose (2) at the bottom of the fuel tank. NOTE: If the fuel supply valve is closed, open the fuel supply valve.

SOIL17SP00468AA

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Index Engine - 10 Fuel tanks - 216 Fuel tank - Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel tank - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel tank - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Engine - 10 Fuel filters - 206

SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Engine - 10 Fuel filters - 206

SERVICE Fuel filters Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Fuel-water separator filter Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Engine - Fuel filters

Fuel filters - Replace WARNING Fuel vapors are explosive and flammable. Do not smoke while handling fuel. Keep fuel away from flames or sparks. Shut off engine and remove key before servicing. Always work in a well-ventilated area. Clean up spilled fuel immediately. Failure to comply could result in death or serious injury. W0904A

1. Clean the fuel filter head. 2. The element (1) is the one-piece type, threaded onto the cradle. Remove by hand, or use a filter wrench. 3. Fill a new filter with clean fuel. Apply a film of fuel to the seal ring. 4. Install the filter. Tighten the filter by hand until the seal ring touches the head, then tighten 1/4 a 1/2 turn.

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SOIL16SP00352AA

CUIL16TC00172AA

Engine - Fuel filters

Fuel-water separator filter - Drain fluid WARNING Fuel vapors are explosive and flammable. Do not smoke while handling fuel. Keep fuel away from flames or sparks. Shut off engine and remove key before servicing. Always work in a well-ventilated area. Clean up spilled fuel immediately. Failure to comply could result in death or serious injury. W0904A

NOTE: The prefilter (1) is installed on the left-hand side of the machine, between the product tank and the radiator group. 1. Open the drain valve (2). Let the fluid drain into a collection container 2. When fuel free of water starts to come out through the orifice, close the valve (2). 3. Discard the mixture collected in accordance with the environmental regulations in force.

SOIL16SP00348AA

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Engine - Fuel filters

Fuel-water separator filter - Replace WARNING Fuel vapors are explosive and flammable. Do not smoke while handling fuel. Keep fuel away from flames or sparks. Shut off engine and remove key before servicing. Always work in a well-ventilated area. Clean up spilled fuel immediately. Failure to comply could result in death or serious injury. W0904A

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

1. Close the valve (1) to cut the fuel supply.

SOIL16SP00063AA

SOIL16SP00348AA

SOIL16SP00356AA

2. Disconnect the fuel suction lines connected to the adapter (1). NOTICE: Cover the connection points to avoid the entry of dirt. 3. Drain out all of the fluid in the pre-filter. See the procedure Fuel-water separator filter - Drain fluid (10.206)

4. Fit the special wrench (1) in the mounting collar (2). 5. Turn the wrench (1) to remove the cover (3).

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Engine - Fuel filters

6. Remove the filter element (1). Discard the filter element. 7. Lightly lubricate the seal ring (2). NOTE: If the ring (2) is worn, deformed, or dried out, replace the component. 8. Install a new filter element.

SOIL16SP00357AA

SOIL16SP00356AA

SOIL16SP00348AA

9. Assemble the cover (1). Use the wrench (2) to tighten slightly.

10. Connect the fuel suction lines to the adapter (1). 11. Remove the cap (2). Fill with clean fuel up to the maximum mark on the cover (3). 12. Reinstall the cover (2). NOTE: If it is not possible to put fuel into the pre-filter through the top opening, activate the priming pump (4) manually. Suction fuel from the tank until the fuel reaches the maximum mark on the cover (3).

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Index Engine - 10 Fuel filters - 206 Fuel filters - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel-water separator filter - Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel-water separator filter - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Engine - 10 Air cleaners and lines - 202

SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Engine - 10 Air cleaners and lines - 202

FUNCTIONAL DATA Air cleaner Overview - Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Air cleaner Test - Restriction sensor switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Engine - Air cleaners and lines

Air cleaner - Overview - Filters Engine air filter elements The engine is equipped with a two-stage air filter system consisting of a primary filter and a secondary filter. The primary filter is a high capacity filter designed to provide optimum protection to the engine. The outer element is the primary air cleaner and the inner element is the secondary (safety) air cleaner. When servicing air cleaners, inspect all ducts between the air cleaner housing and engine intake for air leaks that would allow dirt to enter the engine. See the Operator’s Manual for regularly scheduled filter replacement intervals. The secondary (inner) filter gives extra protection to the engine if there is damage to the primary filter. NOTICE: The primary element and the secondary element must be replaced, not cleaned. It is important the correct air filter elements are used as engine failure can be caused by incorrect filter elements or improper service. When the air filter service monitor on the instrument cluster illuminates, the primary filter element needs replacement. NOTICE: Operation should not continue with a restricted/ plugged air filter or engine damage can occur. If the air filter service monitor illuminates with frequency, or after the primary filter has been replaced, check the following items for service: • Secondary filter element • Restriction indicator switch • Grill screen

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Engine - Air cleaners and lines

Air cleaner - Test - Restriction sensor switch Prior operation: If you replace hardware, use the hardware noted in this Machineâ&#x20AC;&#x2122;s Parts Manual.

Restriction indicator switch removal 1. Remove the wiring harness connector (1) from the switch. Remove the switch (2).

SOIL16SP00049AA

RAIL13SP01266AA

RAIL13SP01267AA

Restriction indicator switch testing 1. Install the test leads of a multimeter to the switch terminals. 2. Set the multimeter to ohms or continuity testing. The multimeter should show an open circuit. 3. If the multimeter shows a closed circuit, replace the switch.

4. Connect the switch to a vacuum hand pump as shown. Use the hand pump to slowly and carefully apply vacuum to the switch. The multimeter should show a closed circuit at approximately 50.8 mm Hg (2.0 in Hg) of vacuum. If the switch does not close at 50.8 mm Hg (2.0 in Hg) of vacuum or closes before 45.7 mm Hg (1.8 in Hg) of vacuum replace the switch and go to the Installation.

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Engine - Air cleaners and lines

Restriction indicator switch installation 1. Install the switch (1). Connect the wiring harness (2). NOTICE: Hand tighten only. 3.4 NÂˇm (30 lb in).

The maximum torque is

SOIL16SP00049AA

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Index Engine - 10 Air cleaners and lines - 202 Air cleaner - Overview - Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air cleaner - Test - Restriction sensor switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Engine - 10 Intake and exhaust manifolds and muffler - 254

SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Engine - 10 Intake and exhaust manifolds and muffler - 254

SERVICE Exhaust pipes Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Exhaust pipes - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Exhaust muffler Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Engine - Intake and exhaust manifolds and muffler

Exhaust pipes - Remove 1. Open the access latch (1) of the engine hood.

RAIL13SP04628AA

SOIL16SP00073AA

SOIL16SP00074AA

2. Tip the parts (2) and (3) of the engine hood

3. Loosen the clamp (1). 4. Remove the exhaust tube (2).

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Engine - Intake and exhaust manifolds and muffler

Exhaust pipes - Install 1. Fit the exhaust tube (1) on the muffler (2) in the position shown. 2. Attach the exhaust pipe (1) with the clamp (3).

SOIL16SP00074AA

SOIL16SP00073AA

PIIL17SP00164AA

3. Close the parts (2) and (3) of the engine hood.

4. Close the engine hood access latch (1).

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Engine - Intake and exhaust manifolds and muffler

Exhaust muffler - Remove Prior operation: Remove the exhaust tube Exhaust pipes - Remove (10.254) 1. Loosen the clamp (1). 2. Disconnect the gas duct (2).

SOIL16SP00067AA

SOIL16SP00068AA

3. Loosen the retaining nuts on the clamp that secures the muffler (1). 4. Remove the muffler (2).

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Engine - Intake and exhaust manifolds and muffler

Exhaust muffler - Install 1. Secure the muffler (1) to the cradles (2) and (3) at the position shown. Install the clamps (4) to secure the muffler.

SOIL16SP00068AA

SOIL16SP00067AA

2. Connect the gas duct (1) to the muffler (2). Secure the duct with the clamp (3).

Next operation: Install the exhaust tube Exhaust pipes - Install (10.254)

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Index Engine - 10 Intake and exhaust manifolds and muffler - 254 Exhaust pipes - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust muffler - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust muffler - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust pipes - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Engine - 10 Engine cooling system - 400

SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Engine - 10 Engine cooling system - 400

SERVICE Engine cooling system Service instruction - Cooling package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Cleaning - Cooling package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Radiator Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Expansion tank Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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Engine - Engine cooling system

Engine cooling system - Service instruction - Cooling package 1. The air conditioning condenser (1) and the hydraulic oil cooler (4) may be removed and installed without removing the front engine hood from the machine. Remove the hood in order to remove the air cooler (2) or the radiator (3). NOTE: Shown with cleanout panel removed.

RAIL13SP01816BA

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Engine - Engine cooling system

Engine cooling system - Cleaning - Cooling package NOTE: If replacing hardware, must use the hardware noted in this Machineâ&#x20AC;&#x2122;s Parts Manual. 1. Remove the hood grills. Please see Engine hood Remove (90.105) . 2. Remove clean out doors on both sides of the machine. (Right-hand side shown) 3. Clean dirt and dust from all grille screens, A/C condenser, charge air cooler, oil cooler and the radiator with compressed air or water. NOTICE: Be careful not to bend or damage the fins during cleaning.

RAIL13SP01817BA

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Engine - Engine cooling system

4. Install clean out doors on both sides of machine. Install bolts and torque bolts to 14 – 16 N·m (10 – 12 lb ft). 5. Install engine hood grills. Please see Engine hood Install (90.105) .

RAIL13SP01817BA

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Engine - Engine cooling system

Radiator - Drain fluid WARNING Hot liquid under pressure! Service when cool. Failure to comply could result in death or serious injury. W1187A

NOTE: The machine should be parked on a flat surface. 1. Connect a hose to the drain fitting (1) at the base of the radiator. Place the other end of the hose into a clean and suitable collection container. 2. Open the drain connection valve (1). 3. After the fluid has completely drained out, close the drain fitting (1). 4. Disconnect the drain hose. 5. Store the collection container properly.

SOIL16SP00066AA

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Engine - Engine cooling system

Radiator - Remove 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

Prior operation: – Engine hood fairing – Removal Engine hood - Remove - Engine casing (90.105) Prior operation: Aftercooler – Removal Aftercooler - Remove (10.310) 1. Disconnect the hoses (1) to (4) from the deaeration tank. NOTE: Label the position of these hoses to facilitate their reconnection. NOTICE: Cover the connection points to avoid the entry of dirt.

SOIL17SP00452AA

SOIL16SP00052AA

2. Remove the bolts (1). 3. Remove the deaeration tank (2) together with the cradle (3).

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Engine - Engine cooling system

4. Disconnect the following ducts: • Air intake (1). • Interconnection (2) of the intercooler and the intake manifold. • Interconnection (3) the turbocharger and the intercooler. • Interconnection (4) the engine and the radiator. NOTICE: Cover the connection points to avoid the entry of dirt. SOIL16SP00088AA

SOIL16SP00089AA

SOIL16SP00090AA

SOIL16SP00091AA

5. Loosen the bolts (2) to remove the expansion tank (1).

6. Remove the bolts (1). 7. Remove the radiator fan shield (2).

8. Remove the bolts (1) that secure the radiator fan. 9. Remove the radiator fan (2).

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Engine - Engine cooling system

10. Disconnect the hose (1) at the base of the radiator. NOTICE: Cover the connection points to avoid the entry of dirt.

SOIL16SP00092AA

SOIL16SP00093AA

SOIL16SP00094AA

11. Attach two lifting cables on the sides of the radiator frame. 12. Support the radiator assembly with a block and tackle.

13. Remove the bolts (1). 14. Remove the radiator assembly from the machine.

15. Remove the casing from the radiator (1).

SOIL16SP00096AA

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Engine - Engine cooling system

Radiator - Install 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

1. Install the radiator casing (1) with the bolts (2).

SOIL16SP00096AA

SOIL16SP00095AA

SOIL16SP00094AA

2. Position the radiator assembly in the housing of the radiators group.

3. Secure the radiator assembly to the frame (1) with the bolts (2). 4. Remove the lifting eyes attached to the radiator.

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Engine - Engine cooling system

5. Connect the lower hose (1) to the radiator.

SOIL16SP00092AA

SOIL16SP00091AA

SOIL16SP00090AA

SOIL16SP00089AA

6. Apply LOCTITE® 7649™ PRIMER N and LOCTITE® 243™ to the threads of the radiator fan fastening bolts (1). 7. Position the bolts (1) on the radiator fan. 8. Install the radiator fan on the engine. Tighten the bolts (1) to a torque of 52 – 61 N·m (38 – 45 lb ft).

9. Install the radiator fan shield (1) with the bolts (2).

10. Install the expansion tank (1) with the bolts (2).

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Engine - Engine cooling system

11. Connect the following ducts: • Air intake (1). • Interconnection (2) of the intercooler and the intake manifold. • Interconnection (3) the turbocharger and the intercooler. • Interconnection (4) the engine and the radiator.

SOIL16SP00088AA

SOIL16SP00052AA

12. Install the deaeration tank (1) and the cradle (2). Install the bolts (3) to assemble.

13. Connect the hoses (1) to (4) to the deaeration tank.

SOIL16SP00051AA

Next operation: Aftercooler – Install – Aftercooler - Install (10.310) Next operation: Engine casing – Install Engine hood - Install - Engine casing (90.105)

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Engine - Engine cooling system

Expansion tank - Remove 1. Loosen the hose clamp (1). Remove the hose clamp. Drain the coolant into a clean collection container 2. Remove the fastening bolts from the cradle of the coolant overflow tank (2). Remove the tank.

SOIL17SP00467AA

3. Dispose of the coolant collected in accordance with the environmental regulations in effect.

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Engine - Engine cooling system

Expansion tank - Install 1. Position the coolant reservoir (1). Install the fastening bolts (2). 2. Install the hose (3). Secure the clamp.

SOIL17SP00467AA

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Index Engine - 10 Engine cooling system - 400 Engine cooling system - Cleaning - Cooling package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine cooling system - Service instruction - Cooling package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Expansion tank - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Expansion tank - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radiator - Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radiator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radiator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Engine - 10 Aftercooler - 310

SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Engine - 10 Aftercooler - 310

SERVICE Aftercooler - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Engine - Aftercooler

Aftercooler - Remove 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

1. Remove the side shields (1). 2. Remove the front shield (2).

SOIL16SP00058AA

SOIL16SP00060AA

SOIL16SP00059AA

3. Remove the bottom bolts (1).

4. Use bolts to attach two hoist eyes into the holes (1). 5. Attach lift straps to the attached eyes. Support the aftercooler assembly with a block and tackle. 6. Loosen the front clamps (2) of the side ducts of the aftercooler. 7. Remove cap screws (3). 8. Pull the aftercooler assembly forward to disconnect the sides ducts. Then remove from the machine.

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Engine - Aftercooler

Aftercooler - Install 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

1. Use the hoist to position the aftercooler assembly against the hydraulic oil radiator. NOTE: Make sure that the side ducts (1) fully fit onto the air intakes (2).

SOIL16SP00061AA

SOIL16SP00059AA

SOIL16SP00060AA

2. Install the top bolts (1). 3. Tighten the clamps (2). Secure the side ducts of the aftercooler. 4. Remove the hoist eyes attached to the assembly.

5. Install the screws (1).

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Engine - Aftercooler

6. Start the engine and check: â&#x20AC;˘ The function of the aftercooler. â&#x20AC;˘ If there are any leaks in the circuit. 7. Install the front shield (1). 8. Install the side shields (2).

SOIL16SP00058AA

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Index Engine - 10 Aftercooler - 310 Aftercooler - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Aftercooler - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Engine - 10 Engine lubrication system - 304

SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Engine - 10 Engine lubrication system - 304

SERVICE Engine oil filter Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Engine - Engine lubrication system

Engine oil filter - Replace NOTE: For a better oil flow, this procedure must be performed with the engine at operating temperature. 1. Place a suitable collection container below the sump drain plug (1). 2. Remove the plug (1). When the oil has completely drained, reinstall the plug.

SOIL16SP00353AA

SOIL16SP00354AA

SOIL16SP00073AA

SOIL16SP00355AA

3. Clean the area around the oil filter (1). 4. The element (1) is the one-piece type, threaded onto the cradle. Remove by hand, or use a filter wrench. 5. Fill a new filter with clean oil. Apply a film of oil to the seal ring. 6. Install the filter. Tighten the filter by hand until the seal ring touches the head, then tighten 1/4 a 1/2 turn.

7. Open the latch (1). 8. Tip the parts (2) and (3) of the engine hood.

9. Remove the oil filler nozzle cap (1). 10. Fill the crankcase with new recommended oil, in the correct amount. See Capacities Fluid and lubricants 11. Reinstall the cover (1). 12. Check the oil level through the dipstick.

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Index Engine - 10 Engine lubrication system - 304 Engine oil filter - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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CNH Industrial Latin America LTDA, Av. Jerome Case, 1801, Aparecidinha - Socoraba (SP) - Brasil, CEP:18087-220

SERVICE - Technical Publications & Tools

CNH Industrial Latin America LTDA 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 the time of publication, but are subject to change without notice. Availability of some models and equipment builds varies according to the country in which the equipment is being used. For exact information about any particular product, please consult your NEW HOLLAND dealer. NEW HOLLAND is a trademark registered in the United States and many other countries, owned or licensed to CNH Industrial N.V., its subsidiaries or affiliates. Any trademarks referred to herein, in association with goods and/or services of companies, other than owned by or licensed to CNH Industrial N.V., its subsidiaries or affiliates, are the property of those respective companies.

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SERVICE MANUAL Power coupling SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Power coupling - 19

[19.121] Pump-drive assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.1

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Power coupling - 19 Pump-drive assembly - 121

SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Power coupling - 19 Pump-drive assembly - 121

TECHNICAL DATA Pump-drive assembly - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Pump-drive assembly Pump-drive assembly - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Pump-drive assembly Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Remove - Pump drive gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Disassemble - Pump drive gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Assemble - Pump drive gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Install - Pump drive gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Change fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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Power coupling - Pump-drive assembly

Pump-drive assembly - Torque

SOIL17SP00502FA

Reference (1)

Torque 52 – 61 N·m (38 – 45 lb ft)

Reference (2)

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Torque 27 – 41 N·m (20 – 30 lb ft)

Power coupling - Pump-drive assembly

Pump-drive assembly - General specification

SOIL17SP00501FA

Location Transmission Ratio Outer spline shaft

Inner spline shaft

Rated Power Mounting flange

Assembled on the diesel engine flywheel (1) 1.40 : 1 1 Quantity 29 # of tines Pitch 12 / 24 Turning direction Counter-clockwise 2 Quantity 14 # of tines Pitch 12 / 24 Turning direction Counter-clockwise Pressure angle 30Â° 400 Hp 12 bolts

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Power coupling - Pump-drive assembly

Pump-drive assembly - Overview

SOIL17SP00501FA

The gearbox (1) is responsible for driving the variable flow pumps (2) and (3). The tandem pump (2) generates hydraulic flow to activate the wheel motors and the active suspension cylinders, while the pump (3) acts specifically on the wheel steering and track adjustment systems.

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Power coupling - Pump-drive assembly

SOIL18SP00176FA

Item 1 2 3 4 5 6 7

Details Filling port Mounting flange Inner spline shaft Level sight glass Drain port Drive plate Outer spline shaft

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Power coupling - Pump-drive assembly

Pump-drive assembly - Drain fluid WARNING Hot liquid under pressure! Service when cool. Failure to comply could result in death or serious injury. W1187A

NOTE: The machine should be parked on a flat surface. 1. Position a suitable collection container under the drive box of the pumps. 2. Reinstall the drain plug (1). 3. After the oil has completely drained, reinstall the plug (1). 4. Store the collection container properly.

SOIL17SP00469AA

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Power coupling - Pump-drive assembly

Pump-drive assembly - Remove - Pump drive gearbox Prior operation: Engine hood - Remove - Engine casing (90.105) NOTE: If replacing hardware, must use the hardware noted in this Machineâ&#x20AC;&#x2122;s Parts Manual. 1. Unplug the harness connectors.

RAIL13SP04950AA

RAIL13SP04952AA

RAIL13SP04953AA

2. Unplug the connector from the harness.

3. Unplug the harness connectors.

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Power coupling - Pump-drive assembly

4. Label and disconnect the four hoses.

RAIL13SP04954AA

RAIL13SP04955AA

RAIL13SP04957AA

5. Label and disconnect the two hoses.

6. Label and disconnect the hoses as shown.

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Power coupling - Pump-drive assembly

7. Label and disconnect the hoses as shown.

RAIL13SP04958AA

SOIL17SP00571AA

8. Support the hydrostatic pump (1) with the gear pump (2) of the left-hand side (1). With a lift strap and a crane-type hydraulic winch, remove the mounting bolts and remove the pumps from the pump drive gearbox (3). NOTE: The auxiliary pumps do not need to be separated from the hydrostatic pumps.

9. Support the hydrostatic pumps (1) with the variable pump (2). With a lift strap and a crane-type hydraulic winch, remove the mounting bolts and remove the pumps from the pump drive gearbox (3). NOTE: The auxiliary pumps do not need to be separated from the hydrostatic pumps.

10. Remove the drain plug (1) and drain the oil from the pump drive gearbox housing into a suitable size container. Reinstall and tighten the plug.

RAIL13SP04964AA

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Power coupling - Pump-drive assembly

11. Remove the upper mounting bolts that secure the pump drive gearbox on the motor.

RAIL13SP04960AA

RAIL13SP04961AA

RAIL13SP04962AA

12. Install two clamps (1) and position lift straps (2) on the pump drive gearbox (3) as shown.

13. Support the motor (1) with a suitable floor jack (2).

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Power coupling - Pump-drive assembly

14. Remove the mount to frame mounting bolts.

RAIL13SP04963AA

RAIL13SP04965AA

RAIL13SP01516AA

15. Remove the bolts (1) securing the pump drive to the mounting bracket.

16. Loosen the bolts (2) that secure the housing to the motor at the mounting bracket. 17. Remove the lower mounting bolts (1) that secure the pump drive gearbox on the motor.

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Power coupling - Pump-drive assembly

18. Separate the pump drive gearbox from the motor housing (1) of the motor (2). Remove the pump drive gearbox from the machine.

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

RAIL13SP04966AA

RAIL13SP04967AA

19. With the pump drive gearbox and the adapter housing removed, inspect the pump drive flexplate for excessive wear or damage. Replace as required.

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Power coupling - Pump-drive assembly

Pump-drive assembly - Disassemble - Pump drive gearbox 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

1. To access the input shaft retaining ring, remove expansion plug (1). Remove retaining ring (2) from input drive shaft (3) and slide shaft out of the engine adapter side. NOTE: The expansion plug must be replaced anytime it is removed. NOTE: Use a rubber mallet to remove the shaft from the input gear.

RAIL13SP01519AA

RAIL13SP01520AA

RAIL13SP01521AA

2. Remove pump pad mounting bolts (1). Carefully pry pump pads away from housing evenly to avoid damaging the pilot. Remove pump pads from housing. NOTE: To avoid oil leaks, all O-rings are to be replaced any time a pump pad is removed.

3. Place the pump drive gearbox on a flat surface with the pump pads facing upward. Remove the socket head cap screws. Use cap screws (1) in threaded separating holes to split housing halves. Lightly tap on the output housing with a rubber mallet to release the bearings and the gears from the bearing orifices.

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Power coupling - Pump-drive assembly

4. Lift the output housing (1) half off. Be careful not to lift any of the gears.

RAIL13SP01522AA

RAIL13SP01523AA

RAIL13SP01524AA

RAIL13SP01525AA

5. Evenly lift the gears and bearings (1) from the housing (2). NOTE: The gears and bearings can be removed by hand.

6. Drive the input seal (1) out towards the engine adapter.

7. Remove bearings from gears. Use a gear puller or arbor press. NOTE: Bearings MUST be replaced any time they have been removed from the gear.

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Power coupling - Pump-drive assembly

8. Remove the bolts (1) from the engine adapter housing (2). Remove the adapter from the pump drive gearbox (3). 9. Clean the two halves of the housing of the pump drive gear. Inspect the two halves of the housing and the gears for excessive wear or damage. Replace as required.

RAIL13SP01526AA

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Power coupling - Pump-drive assembly

Pump-drive assembly - Assemble - Pump drive gearbox 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

1. Connect the adaptor housing (1) in the pump drive gearbox housing (2). Secure with the bolts (3). NOTE: Align the word â&#x20AC;&#x153;TOPâ&#x20AC;? (4) on the adaptor housing with the top of the pump drive gearbox housing for correct installation.

RAIL13SP01526AA

RAIL13SP01527AA

RAIL13SP01522AA

2. Install bearing onto the gear with shield (1) facing the gear and the open ball bearing facing out. NOTE: For proper oil flow it is mandatory that the bearing shield is facing toward the gear.

3. The gears have retaining ring grooves (1) on the output side and a seal lip on the input side. 4. Install the gears in the input half of the pump drive gearbox housing with the side of the gear retaining ring grooves facing upward. NOTE: Apply a coat of oil to the outside of the bearing to allow gear and bearing to slide into housing easier.

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Power coupling - Pump-drive assembly

5. Put approximately one 3.00 mm (0.12 in) drop of LOCTITEÂŽ 587 along the sealing surface of the input half of the pump drive gearbox housing. NOTICE: Use sealant sparingly. Over applying may cause excessive sealant to break loose inside gear box and cause internal damage.

RAIL13SP01528AA

RAIL13SP01529AA

RAIL13SP01530AA

RAIL13SP01531AA

6. Place the output half of the pump drive gearbox housing together with the input pump drive gearbox housing. Both housings must be oriented in the same direction for bolt holes to line up properly. Install the housing bolts.

7. Replace the O-rings (1) on the pump pads (2).

8. Install the pump pads (1) in the groove housing (2).

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Power coupling - Pump-drive assembly

9. Install input drive shaft (1). Install retaining ring (2) and expansion plug (3).

RAIL13SP01519AA

RAIL13SP01532AA

10. Turn over the assembled gear box to install the input seal. Apply a small coat of oil to the gear surface to allow the seal to properly seat. Apply a thin coat of LOCTITEÂŽ 609 to the seal O.D. and press into place, 1.50 mm (0.06 in) below flush with the gear. NOTICE: Pressing the seal too far will create a leak or possibly block oil to the bearings. NOTICE: Do not use sharp objects for pressing in seals. Press only on the outer edge of the seal to keep from bending or damaging the seal casing.

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Power coupling - Pump-drive assembly

Pump-drive assembly - Install - Pump drive gearbox 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

Prior operation: Pump drive gearbox, see Pump-drive assembly - Assemble - Pump drive gearbox (19.121) 1. Coat the inside groove on the flexplate of the pump drive gearbox with LOCTITE® ANTI-SEIZE compound.

RAIL13SP04967AA

RAIL13SP04966AA

RAIL13SP01516AA

2. Put a light coat of LOCTITE® ANTI-SEIZE compound on the spline of the pump drive shaft. NOTE: Use alignment dowels in the housing holes to prevent damage to the seal when you install the pump drive gearbox. 3. Install a suitable lifting device on the pump drive gearbox. Lift and position the gearbox in its housing. 4. Rotate the drive to line up the splined shaft with the flexplate.

5. Install the bolts that secure the adaptor housing on the motor (install all of the lower bolts) 6. Torque to 40.7 N·m (30 lb ft) .

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Power coupling - Pump-drive assembly

7. Install the bolts (1) that secure the pump drive gearbox onto the mounting bracket. 8. Tighten the bolts (2) that secure the housing of the pump drive gearbox onto the mounting bracket. 9. Lower engine down so mounts are in place on frame. 10. Tighten screws to 219.6 – 242.7 N·m (162 – 179 lb ft) .

RAIL13SP04965AA

RAIL13SP04963AA

RAIL13SP04962AA

11. Install the bolt and assembly the nut to the bolt securing the rear engine mount to frame. Do both sides. NOTE: Be sure the engine support frame is centered by checking engine fan to fan shroud clearance. 12. Torque to 310 – 380 N·m (229 – 280 lb ft) .

13. Remove the jack that supports the engine (1).

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Power coupling - Pump-drive assembly

14. Remove the lift straps (1) and the clamps (2).

RAIL13SP04961AA

SOIL17SP00571AA

15. Install the hydrostatic pumps (1) with the variable pump (2) of the right-hand side with a lift strap and a crane-type hydraulic jack beside the pump drive gearbox (3). 16. Torque the mounting bolts to 67.8 – 75 N·m (50 – 55 lb ft)

17. Install the hydrostatic pumps (1) with the gear pump (2) of the left-hand side with a lift strap and a cranetype hydraulic jack beside the pump drive gearbox (3). 18. Torque the mounting bolts to 67.8 – 75 N·m (50 – 55 lb ft)

19. Connect the hoses as labeled during disassembly.

RAIL13SP04958AA

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Power coupling - Pump-drive assembly

20. Connect the hoses as labeled during disassembly.

RAIL13SP04957AA

RAIL13SP04955AA

RAIL13SP04954AA

21. Connect the hoses as labeled during disassembly.

22. Connect the hoses as labeled during disassembly.

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Power coupling - Pump-drive assembly

23. Connect the wiring harness connectors.

RAIL13SP04953AA

RAIL13SP04952AA

RAIL13SP04950AA

24. Connect the harness connector.

25. Connect the harness connector.

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Power coupling - Pump-drive assembly

26. Remove the fill plug (1).

SOIL17SP00471AA

SOIL17SP00470AA

27. Fill the gearbox (1) with NEW HOLLAND AMBRA HYPOIDE SSL GEAR OIL oil, until the level is visible through the indicator (2).

28. Install the fill plug. 29. Install hydraulic tank and plumbing. Please see Oil reservoir - Install (35.300) . 30. Fill the hydraulic tank. Please see Oil reservoir Drain fluid (35.300) . NOTE: Pump drive lubricant must be replaced after initial 100 h of operation after repair or replacement of pump drive. Follow normal maintenance schedule there after. 31. Bleed the air and any impurities from the system by using the following procedure. 32. Install a new in-tank return filter on the auxiliary hydraulic circuit. 33. Start the engine and run at 1500 RPM with the vehicle in neutral for a minimum of 20 min to filter and warm the hydraulic oil prior to any operation. 34. Run the machine for at least 1 h under light load to complete the hydraulic oil filtration. 35. Shut down machine and check for leaks. NOTICE: See the Initial start-up procedure for hydraulic pumps and motors in Pump and motor components - Service instruction - Motor or pump replacement start-up (29.218).

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Power coupling - Pump-drive assembly

Pump-drive assembly - Change fluid NOTE: The machine should be parked on a flat surface. 1. Open the latch (1).

RAIL13SP04628AA

SOIL16SP00073AA

SOIL17SP00471AA

2. Tip the parts (2) of the engine hood.

3. Remove the fill plug (1).

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Power coupling - Pump-drive assembly

4. Fill the gearbox (1) with NEW HOLLAND AMBRA HYPOIDE SSL GEAR OIL oil, until the level is visible through the indicator (2). NOTE: Use a filling funnel.

SOIL17SP00470AA

5. Reinstall the plug (1).

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Index Power coupling - 19 Pump-drive assembly - 121 Pump-drive assembly - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump-drive assembly - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump-drive assembly - Assemble - Pump drive gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump-drive assembly - Change fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump-drive assembly - Disassemble - Pump drive gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump-drive assembly - Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump-drive assembly - Install - Pump drive gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump-drive assembly - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump-drive assembly - Remove - Pump drive gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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CNH Industrial Latin America LTDA, Av. Jerome Case, 1801, Aparecidinha - Socoraba (SP) - Brasil, CEP:18087-220

SERVICE - Technical Publications & Tools

48149953 12/06/2018 EN

SERVICE MANUAL Front axle system SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Front axle system - 25

[25.100] Powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1 [25.108] Final drive hub, steering knuckles, and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.2 [25.122] Axle suspension control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.3

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Front axle system - 25 Powered front axle - 100

SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Front axle system - 25 Powered front axle - 100

TECHNICAL DATA Four-Wheel Drive (4WD) axle General specification - Track adjustment cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 General specification - Suspension cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Four-Wheel Drive (4WD) axle - Torque - Suspension cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

FUNCTIONAL DATA Powered front axle Exploded view - Suspension cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SERVICE Powered front axle Remove - Axle extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Replace - Slide plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Install - Axle extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Axle suspension Remove - Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Install - Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Remove - Trailing link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Disassemble - Trailing link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Assemble - Trailing link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Install - Trailing link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Remove - Upper suspension and steering arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Disassemble - Upper suspension and steering arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Assemble - Upper suspension and steering arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Install - Upper suspension and steering arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

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Front axle system - Powered front axle

Four-Wheel Drive (4WD) axle - General specification - Track adjustment cylinder

SOIL18SP00170AA

Type Location Quantity Test pressure Operating pressure Cracking pressure Collapsed length Extended length Stroke Connect

Dual-acting At the front of the shaft (1) (2) 22408.0 kPa (3250.0 psi) 18960.6 kPa (2750.0 psi) 81358.1 kPa (11800.0 psi) 619.00 mm (24.37 in) 1016.00 mm (40.00 in) 397.00 mm (15.63 in) 9/16-18 in

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Front axle system - Powered front axle

Four-Wheel Drive (4WD) axle - Torque

SOIL17SP00503FA

Reference (1)

Torque 690 N·m (509 lb ft)

Reference (2)

Torque 475 N·m (350 lb ft)

Four-Wheel Drive (4WD) axle - General specification - Suspension cylinder Suspension cylinder (1)

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Front axle system - Powered front axle

SOIL17SP00503FA

Type Location Quantity Outer diameter of the fastening terminals Collapsed length Extended length Stroke Connect

Dual-acting On the wheel mounting bracket (2) 63.50 mm (2.50 in) 414.00 mm (16.30 in) 668.00 mm (26.30 in) 254.00 mm (10.00 in) 7/16-20 in

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Front axle system - Powered front axle

Four-Wheel Drive (4WD) axle - Torque - Suspension cylinder

SOIL18SP00171AA

Reference (1)

Torque 61 N·m (45 lb ft)

Reference (2)

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Torque 237 N·m (175 lb ft)

Front axle system - Powered front axle

Powered front axle - Exploded view - Suspension cylinder

SOIL16SP00167FA

Item (1) (2) (3) (4) (5) (6) (7) (8)

Description Rod Seal O-ring Backup ring Flashing Retainer Cylinder guide Backup ring

Item (9) (10) (11) (12) (13) (14) (15) (16)

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Description O-ring O-ring Backup ring Wear ring Retainer Piston Nut Liner

Front axle system - Powered front axle

Powered front axle - Remove - Axle extension 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

WARNING Escaping fluid! The hydraulic tank is a pressurized system. Vent tank slowly by loosening the breather before performing work on the hydraulic system. Failure to comply could result in death or serious injury. W1047A

Prior operation: If replacing hardware, must use the hardware noted in this Machineâ&#x20AC;&#x2122;s Parts Manual. Prior operation: Clean all of the connections to be removed with a degreaser and brush before you loosen the connections. Prior operation: Immediately cap or plug any hydraulic connection that is opened with clean, threaded caps and plugs. Prior operation: Front and rear axle removal procedures are the same except where noted. Prior operation: Fully extend the axle. See Operator Manual. Prior operation: Park the machine on solid, level surface. 1. Shut down the engine and remove the key (1).

SOIL17SP00472AA

RAIL13SP01856AA

2. Place wheel chocks (1) at the front and rear of the axle, opposite the tire to be removed.

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Front axle system - Powered front axle

3. Use a heavy duty service jack (1) to lift the machine. NOTICE: Hydraulic jack used for lifting must have a rating of 10 ton or more. Use a proper jack stand (2) to support the machine. ( 15 ton jackstand shown)

RAIL13SP01857BA

RAIL13SP01914AA

RAIL15SP00386AA

4. Using strap and suitable overhead lifting device secure the fender and fender brackets. Remove four bolts and remove the fender and brackets as a unit.

Slowly open the breather (1) to release the pressure from the hydraulic reservoir.

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Front axle system - Powered front axle

6. Remove hydraulic line from the brake caliper.

RAIL13SP01915AA

RAIL13SP01863AA

RAIL13SP01916AA

RAIL13SP01917AA

7. Remove the parking brake line from the hub.

8. Disconnect the two hydraulic lines to the shock absorber. NOTE: Front axle only for machines equipped with active suspension 9. Remove wheel motor. Please see Motor - Remove Wheel motor (29.218) . NOTE: Hydraulic hoses on motor do not need to be disconnected from motor for axle removal. NOTICE: If the hydraulic lines are not removed the wheel motor must be properly supported to prevent damage to the hydraulic lines. 10. Remove wheel. See Front wheels - Remove (44.511) and Rear wheel - Remove (44.520). 11. Remove inside slide bar support bracket bolt and replace with longer bolt. Do not fully tighten longer bolt. NOTE: his is to allow bracket to drop down without removing, so opposite end can be removed from bushing.

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Front axle system - Powered front axle

12. Use a chain to support the adjustment cylinder and the slide bar once the bolts have been removed. Remove axle cylinder adjustment bolt (1), slide bar axle bolt (2), cotter pin, steering cylinder castle nut and bolt (3). NOTE: Steering castle nut and bolt on front axle only.

RAIL13SP01918AA

RAIL13SP01919AA

RAIL13SP01920AA

13. Remove the bushings, the adjustment cylinder, and the slide bar. boom.

14. Attach a suitable lifting device to the shaft and slide the shaft out of the beam. NOTE: Attach as shown for proper balance.

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Front axle system - Powered front axle

Powered front axle - Replace - Slide plate Prior operation: Remove the axle. Refer to the Powered front axle - Remove - Axle extension (25.100) 1. Remove the four nuts and bolts (2) that secure the slide plates (1) inside the beam.

RAIL13SP01921AA

RAIL13SP01922AA

RAIL13SP01921AA

2. Inspect the slide plates (1) for damage or excessive wear. Replace the plate components as necessary.

3. Install the slide plate (1) on the frame beam. Secure the slide plates with bolts and nuts (2).

Next operation: Install the axle. Please see Powered front axle - Install - Axle extension (25.100) .

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Front axle system - Powered front axle

Powered front axle - Install - Axle extension 1. Attach a proper lifting device to the axle. Slide the axle into the beam.

RAIL13SP01920AA

RAIL13SP01918AA

RAIL13SP01923AA

RAIL13SP01916AA

2. Use chain to support adjustment cylinder and slide bar once bolts are removed. Install the axle cylinder adjustment screw (1), the slide bar axle bolt (2), the steering cylinder bolt cotter pin, (3), the castle nut (4), and the cotter pin (5). Torque the steering cylinder castle nut to 393 – 419 N·m (290 – 309 lb ft). Install cotter pin and bend tabs over the nut. Remove chain used to support adjustment cylinder and slide bar. NOTE: The steering castle nut and bolt are used only on the front axle. NOTE: If needed, tighten castle nut to allow for cotter pin installation. 3. Support the slide bar support cradle with a C-clamp (1) and remove the bolt. Install original bolt and torque to standard specifications. 4. Install wheel. (44.511) .

Please see Front wheels - Install

5. Install hydraulic lines onto active suspension cylinder. NOTE: Front axle only for machines equipped with active suspension

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Front axle system - Powered front axle

6. Install the park brake line from the torque hub.

RAIL13SP01863AA

RAIL13SP01915AA

RAIL13SP01914AA

7. Attach service brake hose to brake caliper and tighten fitting. NOTE: Front axle only.

8. Install fender mounting bracket assembly. screws to 74.6 NÂˇm (55 lb ft) .

Tighten

9. Bleed service brakes. Please see Brake caliper Service instruction - Brake bleeding procedure (33.202) . NOTE: Front axle only. 10. Raise the machine and remove jackstand and remove the hydraulic jack from under the machine. 11. Adjust axle to proper setting. See Operator Manual.

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Front axle system - Powered front axle

Axle suspension - Remove - Spring Prior operation: Place the machine on a smooth, level surface. Perform the procedure on one wheel at a time-complete the procedure entirely before repeating on other wheels. Prior operation: Power wash machine around area to be worked on. NOTE: If replacing hardware, must use the hardware noted in this Machineâ&#x20AC;&#x2122;s Parts Manual.

Spring removal 1.

Slowly loosen the breather cap (1) until the pressure is bled from the hydraulic tank to remove the pressure from the hydraulic tank. 2. Remove the wheel. (44.511).

See Front wheels - Remove

RAIL15SP00386AA

RAIL13SP01869AA

RAIL13SP01870AA

3. Remove two nuts from top of cylinder rod end. NOTE: Secure the lower trailing arm with proper lifting device before removing the two top nuts on hydraulic cylinder.

4. Clean all connections to be removed with an aerosol degreaser and brush before loosening. Repeat flush with aerosol degreaser with fitting backed out 2-3 turns. NOTICE: Immediately cap and plug any connection that is opened, with clean threaded caps and plugs Remove two hydraulic hoses from cylinder elbows.

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Front axle system - Powered front axle

5. Remove lower cylinder nut and bolt (1). Remove the two bolts from the lower shock mount (2) and remove mount (3) and cylinder (4). NOTE: Secure cylinder from falling after removing lower mount.

RAIL13SP01871AA

RAIL13SP01872BA

6. Secure spring from falling. Slowly lower the trailing arm and remove the spring. NOTICE: The spring is very heavy, be sure to have assistance in its removal.

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Front axle system - Powered front axle

Axle suspension - Install - Spring 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

Set spring adapters (1) into place and bend tabs (2) over trailing link and upper suspension arm. Lift the spring (3) into place and rest onto spring adapters. Raise the lower trailing link (4) to hold spring in place.

RAIL13SP01872BA

RAIL13SP01869AA

2. Slide cylinder in from underside with components installed in this order: A. Cylinder B. Spring washer (not shown, underneath) C. Retainer washer (not shown, underneath) D. Pilot bushing - long shock (not shown, underneath) Slide the cylinder rod into the upper suspension arm and install the following components: E. Spring washer F.

Urethane bushing - (red)

G. Retainer washer H. Spring washer I.

Two nuts

Tighten to compress the rubber and urethane to achieve a dimension of 17 mm (0.67 in) from the top of the cylinder rod to the top of the jam nut.

NOTE: Apply anti-seize to the cylinder rod end threads before you install the nuts.

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Front axle system - Powered front axle

3. Apply thread sealant primer and removable LOCTITE® 243™ -31 onto bolts and nut prior to installing. Install the lower shock bracket (1) with two bolts (2). Install the lower cylinder nut and the bolt (3) and torque to 292 – 332 N·m (215 – 245 lb ft).

RAIL13SP01871AA

RAIL13SP01870AA

RAIL15SP00386AA

4. Install two hydraulic hoses onto lower cylinder end and tighten to specifications NOTE: Only on the front axles. 5. Install the wheel. Front wheels - Install (44.511)

6. Close the hydraulic reservoir breather (1).

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DANGER Unexpected machine movement! Air in the hydraulic system could cause unexpected machine movement. Purge the air from the hydraulic system after any hydraulic system maintenance or repair. Failure to comply will result in death or serious injury. D0054A

NOTE: Step 7 to 10 are only required if the spring installed was a front axle spring. 7. Start the engine and run in neutral at a maximum of 1500 RPM. 8. Allow the engine to run at 1500 RPM with the vehicle in neutral for a minimum of 20 min to filter and warm the hydraulic oil prior to any operation. 9. Run the machine for at least 1 h under light load to complete the hydraulic oil filtration. 10. Shut down the machine and check for leaks.

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Front axle system - Powered front axle

Axle suspension - Remove - Trailing link NOTICE: If replacing hardware, must use the hardware noted in this Machineâ&#x20AC;&#x2122;s Parts Manual. 1. Remove the wheel. See Front wheels - Remove (44.511) in this section. 2. Remove brake caliper and brake rotor. See. Brake caliper - Remove (33.202) 3. Remove the wheel motor. See. Product pump hydraulic motor - Remove (35.911) 4. Remove the spring. Please see Axle suspension Remove - Spring (25.100) . 5. Remove four bolts (1) and outer end cap (2). Remove nut (3) and set screw (4).

RAIL13SP01873AA

RAIL13SP01874AA

RAIL13SP01875AA

6. Remove the four bolts (1) and inner end cap (2).

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

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Front axle system - Powered front axle

Axle suspension - Disassemble - Trailing link 1. Remove seals (1) from trailing link.

RAIL13SP01876AA

RAIL13SP01877AA

RAIL13SP01878AA

2. Remove the sleeve bearings (2) and grease zerks (3) from trailing link.

3. Bend tabs up and remove spring adapter.

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Front axle system - Powered front axle

Axle suspension - Assemble - Trailing link 1. Align the grease holes (1) in the bushings with the grease zerk holes in the upper suspension arm. Install the bushings (2) on the trailing link. Use a suspension bushing installer to install the bushings. Apply primer and LOCTITEÂŽ 243-31 prior to installing grease zerks (3) and caps. Point grease zerk (4) to the inside of casting parallel to shaft +/- 30Â° . NOTE: Bushings must be pre-lubricated using grade #2, lithium 12 grease so all pockets on shaft side of bushings are filled and the remaining surface is coated. RAIL13SP01877AA

RAIL13SP01876AA

2. Install seals (5) into trailing link. NOTE: Lubricate the seal lip before you slide it through the shaft.

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Axle suspension - Install - Trailing link NOTE: Check bearings for wear and replace if necessary. 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

Grease the shaft (1) on both seal lips. Install trailing link (2) onto suspension arm (3). Align the machined slot (4) on the shaft with the adjustment screw (5) on the suspension arm. Slide shaft into trailing link and suspension arm. RAIL13SP01879AB

RAIL13SP01880AA

RAIL13SP01881AA

RAIL13SP01874AA

2. Insert a combination of machine bushing shims (7) to achieve minimum clearance between the trailing link and the upper suspension arm. (Inside shim shown. Insert shims to both sides of suspension arm.)

3. Seal the surface between the caps and the trailing link with G-flex flexible caulk. (Do both sides.)

4. Install inner end cap (1) and four bolts (2). Use G-Flex caulk to seal dust cap. NOTE: Use LOCTITEÂŽ on four dust cap bolts, per the specification.

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5. Use LOCTITEÂŽ on four dust cap bolts, per the specification NOTE: Grease zerks. See lubrication chart 6. Install planetary gear hub. Please see Planetary drive and hub - Install (25.108) . 7. Install the spring. Please see Axle suspension - Install - Spring (25.100) . 8. Install the wheel motor. Please see Motor - Install Wheel motor (29.218) . 9. Install brake rotor and brake caliper. Please see Brake caliper - Install (33.202) . 10. Install wheel. (44.511) .

Please see Front wheels - Install

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RAIL13SP01873AA

Front axle system - Powered front axle

Axle suspension - Remove - Upper suspension and steering arm NOTE: If replacing hardware, must use the hardware noted in this Machineâ&#x20AC;&#x2122;s Parts Manual. 1. Remove the fender. Please see Powered front axle Remove - Axle extension (25.100) . 2. Remove the wheel. Please see Front wheels - Remove (44.511) . 3. Remove brake caliper and brake rotor. Please see Brake caliper - Remove (33.202) . 4. Remove the wheel motor. Please see Motor - Remove - Wheel motor (29.218) . 5. Remove the spring. Please see Axle suspension Remove - Spring (25.100) . 6. Remove the trailing link. Please see Axle suspension - Remove - Upper suspension and steering arm (25.100) . 7.

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

Support upper suspension arm with proper lifting device. 8. Remove two nuts and bolts from fender bracket.

RAIL13SP01882AA

RAIL13SP01883AA

9. Remove cotter pin (1), slotted nut (2), washer (3), steering bolt (4) and spring bushings in between cylinder clevis (5) and steering arm (6).

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Front axle system - Powered front axle

10. Once the bolt is removed, tap the cylinder clevis (1) on the bottom and top. This moves the bushings to make the clearance to separate the cylinder clevis from the steering arm.

RAIL13SP01884AA

RAIL13SP01885AA

RAIL13SP01886AA

RAIL13SP01887AA

11. Remove two nuts, washers, and bolts from the steering arm.

12.

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

Secure upper suspension arm with proper lifting device prior to removing bolt. Remove bolt (1), washer (2), cover plate washer (3) from upper suspension arm. Remove suspension arm.

13. Inspect thrust washer for wear and replace if necessary.

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Axle suspension - Disassemble - Upper suspension and steering arm Upper suspension arm disassembly 1. Remove the upper suspension. See Axle suspension - Remove - Upper suspension and steering arm (25.100). 2. Remove bearings (1) from upper suspension arm (2). Remove grease zerk (3) and cap.

RAIL13SP01888AA

RAIL13SP01889AA

RAIL13SP01890AA

3. Remove the adapter from the upper suspension arm by bending the tabs over.

4. Remove the two nuts (4) and rubber stop (5).

Steering arm disassembly

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Remove seal (1), and self aligning bearing (2) from steering arm (3).

RAIL13SP01892AA

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Axle suspension - Assemble - Upper suspension and steering arm Upper suspension arm assembly 1. Install the adapter onto the upper suspension arm and secure by bending the tabs over.

RAIL13SP01889AA

RAIL13SP01888AA

RAIL13SP01891AA

RAIL13SP01890AA

2. Install bushings (1) into upper suspension arm using the TY1001 Suspension Bushing installer. Bushings must be pre-lubricated using grade No. 2, lithium 12 grease so that all pockets (2) on shaft side of bushing are filled and remaining surface is coated. Grease holes (3) in bushings must line up with grease zerk holes in upper suspension arm. Install grease zerk (4) and cap.

3. Install set screw and lock nut.

4. Install rubber stop (1) and secure with two nuts (2).

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Steering arm assembly 1. Clean bore in steering arm and outer surface of spherical bearing with solvent. Apply primer to bearing and bore surfaces, allow to dry. Apply LOCTITE® to outer surfaces of spherical bearing and press fit into bores.

RAIL13SP01893AA

RAIL13SP01894AA

RAIL13SP01895AA

RAIL13SP01896AA

2. Bearing should be located 0.500 – 3.500 mm (0.020 – 0.138 in) from either face of steering arm.

3. Install seal (1) into steering arm (2) as shown to ensure grease purges up through thrust washer (3). Install bushings (4) into counterbore on steering arm.

4. Install seal with proper size driver until the face seats just below the surface. 5. Install Upper Suspension Arm and Wheel. Axle suspension - Install - Upper suspension and steering arm (25.100) and Front wheels - Install (44.511)

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Axle suspension - Install - Upper suspension and steering arm 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

1. Pre-lubricate thrust washer (1) with clean grease prior to assembly. Install onto spindle.

RAIL13SP01897AA

RAIL13SP01898AA

RAIL13SP01899AA

2. Install the bushings and seal (1) onto the steering arm. Pre-lubricate seal with clean grease prior to assembly. NOTE: Apply anti-seize to bushings prior to installing.

3. Pre-lubricate the top of the seat of the steering arm thrust washer (1) with clean grease prior to assembly. Grease spindle then slide steering arm onto spindle. NOTICE: Use caution when installing steering arm to spindle. DO NOT roll seal. Temporary support steering arm prior to installation of upper suspension arm.

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4. Secure upper suspension arm with proper lifting device prior to installing. Seal surface between upper suspension arm and steering arm with G-flex flexible caulk.

RAIL13SP01900AA

RAIL13SP01901AA

RAIL13SP01902AA

RAIL13SP01903AA

5. Secure upper suspension arm with proper lifting device prior to installing. 1.

Install upper suspension arm

Install axle shim spacer

Install cover plate washer

Install flat washer

Install bolt. Apply primer and LOCTITE® to bolt threads and torque to 556 – 597 N·m (410 – 440 lb ft)

NOTE: Install axle shim spacer as needed to obtain 0.254 – 2.032 mm (0.01 – 0.08 in) of free play in the assembly. 6. Install two bolts (1) through steering arm and upper suspension arm. Secure with two washers (2) and two lock nuts (3), and torque to 556 – 597 N·m (410 – 440 lb ft) uncap and apply grease to zerk (4) until grease purges from assembly. Reinstall cap.

7. Install steering cylinder (1) onto steering arm (2). Install spring bushings (3) on top and bottom of steering arm as shown.

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8. Secure steering arm and cylinder with bolt (1), washer (2), castle nut (3), and cotter pin (4). Torque nut and bolt to 393 – 419 N·m (290 – 309 lb ft) or until next available hole alignment. NOTE: To keep cotter pin in place, bend over both legs one up and one down.

RAIL13SP01883AA

RAIL13SP01891AA

9. Install lockset bolt (1) and nut (2) into upper suspension arm. NOTE: Apply anti-seize to end threads and install. 10. Install upper suspension arm. 11. Install the spring. Please see Axle suspension - Install - Spring (25.100) . 12. Install planetary gear hub. Please see Planetary drive and hub - Install (25.108) . 13. Install the wheel motor. Please see Motor - Install Wheel motor (29.218) . 14. Install brake rotor and brake caliper. Brake caliper - Install (33.202) . 15. Install wheel. (44.511) .

Please see

Please see Front wheels - Install

16. Install the fender. Please see Powered front axle Install - Axle extension (25.100) .

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Index Front axle system - 25 Powered front axle - 100 Axle suspension - Assemble - Trailing link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axle suspension - Assemble - Upper suspension and steering arm . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axle suspension - Disassemble - Trailing link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axle suspension - Disassemble - Upper suspension and steering arm . . . . . . . . . . . . . . . . . . . . . . . .

Axle suspension - Install - Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axle suspension - Install - Trailing link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axle suspension - Install - Upper suspension and steering arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axle suspension - Remove - Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axle suspension - Remove - Trailing link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axle suspension - Remove - Upper suspension and steering arm . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Four-Wheel Drive (4WD) axle - Torque - Suspension cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Four-Wheel Drive (4WD) axle - General specification - Suspension cylinder . . . . . . . . . . . . . . . . . . .

Four-Wheel Drive (4WD) axle - General specification - Track adjustment cylinder . . . . . . . . . . . . . . .

Four-Wheel Drive (4WD) axle - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Powered front axle - Exploded view - Suspension cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Powered front axle - Install - Axle extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Powered front axle - Remove - Axle extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Powered front axle - Replace - Slide plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Front axle system - 25 Final drive hub, steering knuckles, and shafts - 108

SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Front axle system - 25 Final drive hub, steering knuckles, and shafts - 108

SERVICE Planetary drive and hub Test - Roll, leak and brake test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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Planetary drive and hub - Test - Roll, leak and brake test Planetary gear hub units should always have roll, leak and brake tests before disassembly and after assembly to make sure that the unit’s gears, bearings and seals are working properly. The following information briefly outlines what to look for when performing these tests. NOTE: he brake must be released before performing the roll test. This can be accomplished by pressurizing the brake using the brake leak test procedure below.

The leak test (main unit) The purpose of a leak test is to make sure the unit is airtight. A leak in the system will be indicated by a fall on the pressure gauge reading on the leak-checking fitting after the unit has been pressurized and allowed to equalize. Leaks will most likely occur at the pipe plugs, the main seal or wherever O-rings or gaskets are located. The exact location of a leak can usually be detected by brushing a soap and water solution around the main seal and where the O-rings or gaskets meet the exterior of the unit, then checking for air bubbles. If a leak is detected in a seal, O-ring or gasket, the part must be replaced, and the unit rechecked. Leak test at 98.6 kPa (14 psi) for 20 min.

The brake test Input brake Static torque: 565 N·m (417 lb ft) Full release pressure: 18.27 bar (265 psi). Maximum pressure: 103 bar (1494 psi) If brake does not release at the full release pressure, brake has to be inspected, repaired or replaced. NOTE: When applying release pressure, make sure that the two motor mounting bolts are installed to provide extra bolt clamp. If applying a release pressure near the maximum, use the hydraulic motor or something with a SAE “C” pilot to help stabilize the mounting adapter.

The roll test The purpose of the roll test is to determine if the hub gears are rotating freely and properly. The gears should rotate when applying constant torque to the gearbox input. If the gears have more drag at certain points, and are not rolling freely they should be examined for improper installation or defects. Some gear packages roll more difficult than others. Do not be concerned if the gears roll hard as long as they roll with consistency.

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Front axle system - Final drive hub, steering knuckles, and shafts

Planetary drive and hub - Remove 1. Remove the wheel. Please see Front wheels - Remove (44.511) . 2. Remove the brake line from the planetary gear hub. NOTE: Clean all connections to be removed with an aerosol degreaser and brush before loosening. Repeat flush with aerosol degreaser with fitting backed out 2-3 turns. Immediately cap or plug any connection opened with clean, threaded caps and plugs. 3. Remove brake caliper and rotor. Please see Brake caliper - Remove (33.202) . 4. Remove wheel motor. Please see Motor - Remove Wheel motor (29.218) .

RAIL13SP01863AA

RAIL13SP01864AA

RAIL13SP01865AA

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

Place a mark on the hub and trailing link to aid in proper assembly. (So rotation is not off location.) 6. Attach a proper lifting device to the planetary gear hub and remove bolts (quantity. 18) from planetary gear hub. 7. Remove the planetary gear hub (1) from the machine.

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Planetary drive and hub - Disassemble Prior operation: Perform roll check, leak check and brake check if applicable prior to disassembling the unit. Refer to Planetary drive and hub - Test - Roll, leak and brake test (25.108) for procedure.

Planetary gear hub main disassembly

RCPH11BEN376FAU

1. Drain oil from unit. 2. Place the planetary gear hub on a bench with the cover side down. 3. Remove the mounting adapter (2) by removing the four countersunk bolts (1). NOTE: The spring force from the brake will force the mounting adapter (2) out. Gradually loosen each bolt so that the mounting adapter remains aligned during the disassembly. 4. Remove thrust washer (3) from the mounting adapter (2) counterbore or from the end of the coupling (5). 5. Remove the O-ring (12) from the mounting adapter. 6. Remove coupling (5). 7. Remove retaining ring (4) from the coupling (5) bore. 8. Remove the belleville spring (6) from the back of the piston (7). 9. Slowly and carefully add light air pressure to the brake port of the spindle (16) until the brake piston (7) is forced out of the spindle bore. Remove the piston. 10. Remove the O-ring (12) and the backup ring (8) from the piston groove (7). 48149953 12/06/2018

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Front axle system - Final drive hub, steering knuckles, and shafts

11. Remove the brake friction plate stack (9) from the spindle (16). NOTE: Try to keep the friction plates in the same order by removing them all together and then banding them together until re-assembly. 12. Remove the brake retaining ring (11), O-ring (13) and backup ring (10) from the spindle (16) bore. 13. Remove the input shaft (14). 14. Turn over the planetary gear hub so that the cover is up. 15. Remove the cover retaining ring (6) by prying the open end of the retaining ring out of the groove with a screwdriver. Then grasp the loose end with pliers and pull the retaining ring completely out of the groove. 16. Remove the cover (5) from the unit. This can be done by pulling the cover with a tool that attaches to the drain plug holes or by using a long metal rod to tap it out from the other side. NOTE: Be careful not to lose the cover thrust washer when removing the cover. 17. Remove the O-ring (4) from the cover. RCPH11BEN375FAU

RCPH11BEN374FAU

18. Remove the input sun gear (3). 19. Remove the input carrier sub-assembly (2) from the hub/spindle sub-assembly (1). 20. Remove 15 bolts (6) that fasten the bearing carrier (5) to the hub/spindle sub-assembly (1). NOTE: Heat may need to be applied to loosen the LoctiteÂŽ applied during assembly. 21. Before removing mark each output planet shaft (2) and planet shaft hole of the hub/spindle sub-assembly so that the shaft can be reassembled into the same hole. 22. Using the tapped hole remove each output planet shaft (2). Do not lose the half-moon shims (3) that are on the back of the planet shaft. Keep each shim set with its respective output planet shaft. 23. Using a soft metal rod, tap the main bearing cone (4) from the bearing carrier (5).

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Front axle system - Final drive hub, steering knuckles, and shafts

24. Push the three output planet sub-assemblies (1) towards the center of the hub/spindle sub-assembly (2).

RCPH11BEN373BAU

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Front axle system - Final drive hub, steering knuckles, and shafts

RCPH11BEN372FAU

25. Pull the hub sub-assembly (5) off the spindle. NOTE: This may require a hoist to break the seal loose. 26. Slide each output planet sub-assembly (6) out of the spindle window. Place each sub-assembly with its respective planet shaft (2) and shim set (3) so that they are matched for re-assembly. 27. Remove the output planet bearing cones (1). 28. Use a soft steel rod to tap out the output planet bearing cups (2). 29. Remove the cup spacer (4) and the retaining ring (3). 30. Repeat for the other two output planet sub-assemblies. 31. Remove the main bearing cone (7) from the spindle.

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Planetary gear hub disassembly 32. Remove the main seal (1). NOTE: The main seal should not be reused when reassembling the unit. 33. Using a soft steel rod and a hammer, tap out the main bearing cups (2). 34. Use stud removal tool to remove the 10 double-threaded wheel studs (3).

RCPH11BEN371FAU

NOTE: Heat may need to be applied to loosen the LoctiteÂŽ applied during assembly.

Planetary gear hub input carrier disassembly

RCPH11BEN370EAU

35. Using a punch, drive the roll pin (3) into the planet shaft (6). 36. Slide the planet shaft (5) from the carrier (2). 37. Using a punch, remove the roll pin (3)from the planet shaft (6). NOTE: The used roll pins should be replaced during reassembly. 38. Slide out the planet gear (7) from carrier (2). Remove the 16 needle rollers (5) from the planet gear bore.

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39. Remove the two thrust washers (4) from the carrier (2). 40. Repeat steps 1 through 5 for the other two planet gears. 41. Remove the retainer ring (7). 42. Remove output sun gear (1) from the carrier.

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Planetary drive and hub - Assemble Planetary gear hub input carrier assembly

RCPH11BEN370EAU

1. Install the output sun gear (1) on the spline of the cradle (2). 2. Install the retaining ring (8) into the groove in the output sun gear (1) on the other end of the cradle (2). 3. Apply a liberal coat of grease to the bore of one input planet gear (6). 4. Line the inside of the planet gear (6) with 16 needle rollers (5). NOTE: The last roller installed must be installed end wise. That is, the end of the last roller must be placed in between the ends of the two rollers, which form the space, and then slid, parallel to the other rollers, into place. 5. Apply a coat of grease to two thrust washers (4). Place the thrust washers against the sides of the carrier (2) internal walls so that the thrust washer tang sits in the groove in the carrier and the thrust washer bore lines up with the planet shaft bores of the carrier. 6. Carefully slide the planet gear (6) with the needle rollers (5) between the thrust washer (4) in the carrier (2). 7. Slide the planet shaft (7) into the planet shaft bore of the carrier and through the thrust washer (4) and the planet gear (6) bores. Install the planet shaft so that the roll pin hole lines up with the corresponding hole in the carrier. 8. Using a small rod, line up the roll pin hole of the carrier (2) with the roll pinhole in the planet shaft (7). 48149953 12/06/2018

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Front axle system - Final drive hub, steering knuckles, and shafts

9. Drive a roll pin (3) into the roll pin hole of the carrier (2) until it is flush with the outside of the carrier. NOTE: Be sure not to hit the planet gear (6) when driving in the roll pins (3). 10. Repeat steps 3 through 9 for the other two planet gears (6).

Planetary gear hub assembly 11. Position the hub (3) on a workbench with the retaining ring groove upward. 12. Install the main bearing cup (2). 13. Turn over the hub (3) and press in the other main bearing cup (2) in the same manner. 14. Apply LOCTITEÂŽ 272â&#x201E;˘ to the shorter length threads of the 10 double-threaded studs (4). 15. Install the 10 threaded studs in the hub (3).

RCPH11BEN371FAU

Planetary gear hub main assembly

RCPH11BEN372FAU

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Front axle system - Final drive hub, steering knuckles, and shafts

16. Set the spindle (7) on the bench with the flange down. 17. Tap the main bearing cone (6) onto the spindle (8) until it is about 6 mm (0.24 in) below the planet gear windows. 18. Install snap ring (3) into an output planet gear (2). 19. Put the spacer (4) into the bore of the output planet gear (2). Take note of where the numbers are stamped on the output planet gear and make sure that the spacer in on that side of retaining ring (3). 20. Press in the output planet bearing cup (1) so that it is fully seated against the spacer (4). boom. 21. Turn over the output planet gear (2) and press in an output planet bearing cup (1) in the same manner. 22. Place an output planet bearing cone (5) into each end of the output planet gear and slide the subassembly into one of the planet gear windows in the spindle (7). 23. Repeat 18 through 22 for the other two output planet gears. 24. Clean the seal ring inner bore and seal surface (2) of the hub spindle (1). 25. Insert the inner seal ring (3) into a suitable seal tool (4). Be careful not to scratch the seal surface. 26. Liberally apply alcohol to the seal ring inner diameter and to the hub spindle surface (2).

RAIL16SP00202AA

RAIL16SP00204AA

27. Press the seal ring onto the hub spindle (1) until the ring bottoms on the flange face (5).

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Front axle system - Final drive hub, steering knuckles, and shafts

28. Clean the seal bore in the hub housing (1). 29. Start the outer seal (2) into the housing (1).

RAIL16SP00205AA

RAIL16SP00206AA

RAIL16SP00207AA

30. Place a suitable hub seal installer (3) into the spindle housing (1).

31. Press outer seal into hub housing until the hub seal installer stops on the housing.

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Front axle system - Final drive hub, steering knuckles, and shafts

32. Push the output planet gear sub-assemblies (1) into the center of the spindle (2) as far as they will go. NOTICE: Take extra precautions to ensure that the hub is aligned during assembly. Failure to align the seal may cause an oil leak.

RCPH11BEN373BAU

33. Place the bearing carrier (5) on the bench with the counter bored holes facing down. 34. Press the main bearing cone (4) into the bearing carrier. 35. Apply a film of P-80 THIX lubricant to the ID of the main seal that is in the hub sub-assembly. NOTE: Proceed to the next step immediately, P-80 will dry after only a few minutes. 36. Making sure that the studs are pointed up, very carefully lower the hub sub-assembly over the spindle until the main bearing cup (4) starts to contact its respective bearing cone.

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RCPH11BEN374FAU

Front axle system - Final drive hub, steering knuckles, and shafts

37. Place the bearing carrier (5) with the bearing cone (4) onto the top of the spindle (1) to keep the hub subassembly aligned to the spindle. 38. Press the hub sub-assembly onto the spindle (1) by pressing down on the bearing carrier (5). An arbor press or hydraulic press (as long as the pressure is very low) maybe used to press down on the bearing carrier. NOTE: Take extreme caution to ensure that the hub subassembly is being pressed squarely onto the spindle. 39. Remove the bearing carrier (5) and set aside. 40. Using a long metal rod, reach through the area between the output Planet sub-assemblies and tap the front of the main bearing cone (4) on the spindle to ensure that it is fully seated against its shoulder. NOTE: Do not strike bearing roller cage with metal rod. 41. Line up the bore of the planet sub-assembly with the planet shaft hole in the spindle (1). Insert a planet shaft (2) so that the tapped holes are clocked towards the center of the spindle. 42. Tap the back of the planet shaft (7) to make sure it is seated all the way down. NOTE: If the output planet sub-assemblies were properly marked and none of the parts were replaced and they are assembled into the same planet shaft hole, the following two steps can be skipped. 43. Use a depth micrometer to gage the amount that the planet shaft (2) face is recessed below the spindle (1). 44. Stack the half moon shims (3) to the thickness measured in the previous step plus .05 mm (0.002 in). 45. Place the shim stack onto the back of the planet shaft (2). 46. Repeat steps 35 through 39 for the other two output planet gear sub-assemblies. 47. Apply a heavy film of assembly oil to the main bearing cones (4) both on the spindle (1) and on the bearing carrier (5). 48. Install the bearing carrier (5) onto the top of the spindle (1). 49. Apply LOCTITE® 272™ to the threads of the 15 bearing carrier bolts (6). 50. Install the bearing carrier bolts (6) and in a star pattern torque to 54 – 61 N·m (40 – 45 lb ft).

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Front axle system - Final drive hub, steering knuckles, and shafts

51. Install the carrier sub-assembly (2) into the hub/spindle sub-assembly (1). 52. Install the input sun gear (3) into mesh in the center of the input carrier sub-assembly (2). 53. Apply a coat of grease to the cover thrust washer (5) and place the thrust washer into the counterbore in the cover (6). 54. Apply a coat of grease to the cover O-ring (4) and place it into the O-ring groove on the outside diameter of the cover (6). 55. Place cover (6) into the end of the hub/spindle subassembly. A rubber mallet may be used to help push the cover O-ring (4) onto its surface. NOTE: Keep the cover aligned to avoid cutting the O-ring on the retaining ring groove. 56. Install the cover retaining ring (9) into the retaining ring groove of the hub/spindle sub-assembly. 57. If the drain plugs (7) or ID tag (8) are not installed in the cover, do so at this time. 58. Turn over the planetary gear hub unit. Install the brake retaining ring (11) into the bore of the spindle.

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RCPH11BEN375FAU

Front axle system - Final drive hub, steering knuckles, and shafts

RCPH11BEN376FAU

59. Install the brake O-ring (10) and the backup ring (13) into the groove in the spindle so that the O-ring is on top of the backup ring. 60. Install the input shaft (14) so that the smaller diameter splines engage the input sun gear (not shown). 61. Install the coupling retaining ring (4) into the groove in the orifice of the coupling (5). 62. Install the coupling (5) onto the end of the input shaft (14) such that the end with the external splines is down. 63. Stack the friction plates (9) so that the stator splines engage into the spindle splines, and the rotor splines engage the coupling splines (5). NOTE: The friction plates must be placed in the same way they were when removed. Stack four stators, then a rotor, and then a stator and keep alternating until all the rotors are used. Then install the remaining two stators. NOTE: The stator plates have three missing spline teeth. Line these teeth up with three cross holes that are drilled in the spindle. 64. Place the piston O-ring (2) and the back-up ring (8) onto the brake piston (7) so that the O-ring is on the same side as the nose of the piston. 65. Apply a layer of grease to the piston O-ring (12) and back-up ring (8) as well as the brake O-ring (10) and back-up ring (13) in the spindle. 66. Install the brake piston (7) into the bore of the spindle. A rubber mallet may be used to help force the piston into the bore. 48149953 12/06/2018

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Front axle system - Final drive hub, steering knuckles, and shafts

67. Place the belleville spring (6) into the counterbore in the back of the brake piston (7) so that the high side of the belleville spring is at the ID. 68. Apply a layer of grease to the mounting adapter O-ring (12) and install into the groove in the mounting adapter (2). 69. Apply a layer of grease to the thrust washer (3) and install into the counterbore of the mounting adapter (2). 70. Install the mounting adapter (12) into the end of the spindle. 71. Fasten the mounting adapter (12) to the spindle with the four countersunk bolts (1). NOTE: Gradually tighten the countersunk bolts so that there is even pressure on the belleville spring. 72. Torque the countersunk bolts (1) to 16 NÂˇm (12 lb ft). 73. Install brake pressure plug (15) into the brake port if not already installed. 74. Perform roll check, leak check and brake check to help ensure proper assembly. See Planetary drive and hub - Test - Roll, leak and brake test (25.108) for the procedure. 75. Fill the unit half full with oil.

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Front axle system - Final drive hub, steering knuckles, and shafts

Planetary gear hub assembly drawing

RCPH11BEN425GAU

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Front axle system - Final drive hub, steering knuckles, and shafts

Planetary drive and hub - Install NOTE: The front and back planetary gear hubs are not identical. If replacing the planetary gear hub make sure you have the correct part. 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

Use proper lifting device and install planetary gear hub (1) onto the suspension trailing link (2).

RAIL13SP01865AA

RAIL13SP01866AC

RAIL13SP01867AA

2. Apply LOCTITE® 7649™ PRIMER N and LOCTITE® 242® onto the threads of the 18 bolts. Tighten and then torque to 271.16 N·m (200.00 lb ft). Use the illustration for torque sequence.

3. Apply LOCTITE® 7649™ PRIMER N and LOCTITE® 242® onto the threads of the two wheel motor bolts (1). Install the wheel motor (2) onto the planetary gear hub. Torque the two bolts to 118 – 132 N·m (87 – 97 lb ft). 4. NOTICE: If the planetary gear hub has too much lubricant in it will cause damage. Check the hub lubrication level. boom.

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Front axle system - Final drive hub, steering knuckles, and shafts

5. Install hydraulic lines to wheel motor. Please see Motor - Install - Wheel motor (29.218) . 6. Install brake line to planetary gear hub.

RAIL13SP01863AA

RAIL13SP01868AA

7. Install two hose clamps and secure hoses with plastic ties. 8. Install brake rotor and brake caliper. Please see Brake caliper - Install (33.202) . 9. Install wheel. NOTICE: Hub lubricant must be replaced after initial 50 h of operation after repair or replacement of hub. Follow normal maintenance schedule there after.

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Index Front axle system - 25 Final drive hub, steering knuckles, and shafts - 108 Planetary drive and hub - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Planetary drive and hub - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Planetary drive and hub - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Planetary drive and hub - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Planetary drive and hub - Test - Roll, leak and brake test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Front axle system - 25 Axle suspension control - 122

SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Front axle system - 25 Axle suspension control - 122

FUNCTIONAL DATA Axle suspension cylinder Overview - Active suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Axle suspension cylinder Remove - Active suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install - Active suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Front axle system - Axle suspension control

Axle suspension cylinder - Overview - Active suspension Active suspension is an option for this machine. This option will keep the front wheels in contact with the ground, increasing traction when climbing steep hills and slopes. Hydraulic cylinders (1) are mounted to each front strut with the rod end of the cylinders connected into the drive system of the front wheel motors. As one of the front wheels starts to slip or loose traction, drive pressure drops for that wheel motor (2) and the other increases. When the opposite side increases, the pressure will retract the cylinder of the non-slipping wheel, collapsing the suspension which in turn forces the slipping wheel to the ground.

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RAIL13SP01399AA

Front axle system - Axle suspension control

Axle suspension cylinder - Remove - Active suspension Prior operation: If replacing hardware, must use the hardware noted in this Machineâ&#x20AC;&#x2122;s Parts Manual. Prior operation: It is not necessary to remove the suspension spring to remove shock absorber/suspension cylinder. Prior operation: Power wash entire machine, especially around area to be worked on. 1.

Remove the pressure from the hydraulic tank by slowly loosening the breather cap until pressure is bled from the hydraulic tank. Tighten breather. NOTE: This is only required if working on the front suspension cylinders.

RAIL13SP01405AA

RAIL13SP01580AA

RAIL13SP01581AA

2. NOTE: The hydraulic lines are only on the front suspension cylinders. NOTE: Clean all connections to be removed with an aerosol degreaser and brush before loosening. Repeat flush with aerosol degreaser with fitting backed out 2-3 turns. NOTICE: Immediately cap or plug any connection opened with clean, threaded caps and plugs. Disconnect hydraulic lines (1) and remove bolts (2) from the lower area of the shock absorber. 3. Remove the nuts from the upper shock absorber/suspension cylinder mount and remove the cylinder through the lower mount area. NOTE: There is no overhaul for the rear shock absorber.

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Front axle system - Axle suspension control

Axle suspension cylinder - Install - Active suspension 1. Install the shock through the lower shock mount area and apply BN 55077 anti-seize to the threads. Install the nuts on the upper mount and tighten to compress rubber and urethane to achieve the correct dimension. Install and tighten jam nut. â&#x20AC;˘ Front suspension cylinder - compress the urethane bushing 3 mm (0.118 in) (A). â&#x20AC;˘ Rear shock absorber - 4 mm (0.157 in) (B).

RAIL13SP01581AA

RAIL13SP01580AA

RAIL13SP01404AA

2. Install bolts (1) and hydraulic lines (2).

NOTE: This step is only required if installing a front suspension cylinder.

4. Install a new in-tank return filter on the auxiliary hydraulic circuit. 5. Start the engine and run in neutral at a minimum of 1500 RPM. 6. While driving the machine depress the traction assist pedal to cycle the cylinder five times to move any air and debris to the tank. 7. Allow the engine to run at 1500 RPM with the vehicle in neutral for a minimum of 20 min to filter and warm the hydraulic oil prior to any operation. 8. Run the machine for at least 1 h under light load to complete the hydraulic oil filtration. 9. Shut down machine and check for leaks.

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Index Front axle system - 25 Axle suspension control - 122 Axle suspension cylinder - Install - Active suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axle suspension cylinder - Overview - Active suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axle suspension cylinder - Remove - Active suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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CNH Industrial Latin America LTDA, Av. Jerome Case, 1801, Aparecidinha - Socoraba (SP) - Brasil, CEP:18087-220

SERVICE - Technical Publications & Tools

48149953 12/06/2018 EN

SERVICE MANUAL Rear axle system SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Rear axle system - 27

[27.100] Powered rear axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.1 [27.124] Final drive hub, steering knuckles, and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.2

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Rear axle system - 27 Powered rear axle - 100

SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Rear axle system - 27 Powered rear axle - 100

SERVICE Powered rear axle Remove - Axle extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Replace - Axle liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install - Axle extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Axle suspension Remove - Trailing link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Remove - Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Install - Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Remove - Trailing link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Disassemble - Trailing link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Assemble - Trailing link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Install - Trailing link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

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Rear axle system - Powered rear axle

Powered rear axle - Remove - Axle extension 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: If replacing hardware, must use the hardware noted in this Machineâ&#x20AC;&#x2122;s Parts Manual. Prior operation: Clean all connections to be removed with an aerosol degreaser and brush before loosening. Repeat flush with aerosol degreaser with fitting backed out 2-3 turns. Prior operation: Immediately cap or plug any hydraulic connection that is opened with clean, threaded caps and plugs. Prior operation: Front and rear axle removal procedures are the same except where noted. Prior operation: Fully extend the axle. See Operator Manual. Prior operation: Park the machine on solid, level surface. 1. Shut down the engine and remove the key (1).

SOIL17SP00593FA

RAIL13SP01856AA

2. Place wheel chocks in front and rear of tire on opposite axle of tire to be removed.

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Rear axle system - Powered rear axle

3. Use a heavy duty service jack (1) to lift the machine. NOTICE: The hydraulic jack (2) used for lifting must have a nominal capacity of 10 ton or more. Support machine using a proper jack stand. ( 15 ton jackstand shown)

RAIL13SP01857BA

RAIL13SP01914AA

RAIL15SP00386AA

4. Using strap and suitable overhead lifting device secure the fender and fender brackets. 5. Remove four bolts and remove the fender and brackets as a unit.

Slowly open the breather (1) to release pressure from the hydraulic reservoir.

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Rear axle system - Powered rear axle

7. Remove hydraulic line from the brake caliper.

RAIL13SP01915AA

RAIL13SP01863AA

RAIL13SP01916AA

RAIL13SP01917AA

8. Remove the park brake line from the torque hub.

9. NOTE: Front axle only for machines equipped with active suspension. Disconnect the two hydraulic lines to the shock absorber. 10. Remove wheel motor. Please see Motor - Remove Wheel motor (29.218) . NOTE: Hydraulic hoses on motor do not need to be disconnected from motor for axle removal. NOTICE: If the hydraulic lines are not removed the wheel motor must be properly supported to prevent damage to the hydraulic lines. 11. Remove wheel. Please see Rear wheel - Remove (44.520) . 12. Remove inside slide bar support bracket bolt and replace with longer bolt. Do not fully tighten longer bolt. NOTE: his is to allow bracket to drop down without removing, so opposite end can be removed from bushing.

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Rear axle system - Powered rear axle

13. Use chain to support adjustment cylinder and slide bar once bolts are removed. Remove axle cylinder adjustment bolt (1), slide bar axle bolt (2), cotter pin, steering cylinder castle nut and bolt (3). NOTE: Steering castle nut and bolt on front axle only.

RAIL13SP01918AA

RAIL13SP01919AA

RAIL13SP01920AA

14. Remove the bushings, the adjustment cylinder, and the slide bar.

15. Attach a proper lifting device to axle as shown for proper balance and slide axle out of beam.

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Rear axle system - Powered rear axle

Powered rear axle - Replace - Axle liners 1. Remove the axle. Please see Powered rear axle Remove - Axle extension (27.100) . 2. Remove the four nuts and bolts (2) that secure the slide plates of the shaft (1) inside the beam.

RAIL13SP01921AA

RAIL13SP01922AA

RAIL13SP01921AA

3. Inspect the slide plates (1) for damage or excessive wear. Replace the slide plates as needed.

4. Install the slide plates (1) on the frame beam. Secure the slide plates with bolts and retaining nuts (2).

5. Install the axle. Please see Powered rear axle - Install - Axle extension (27.100) .

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Rear axle system - Powered rear axle

Powered rear axle - Install - Axle extension 1. Attach a proper lifting device to the axle. Slide the axle into the beam.

RAIL13SP01920AA

RAIL13SP01918AA

RAIL13SP01923AA

RAIL13SP01916AA

2. Use chain to support adjustment cylinder and slide bar once bolts are removed. 3. Install the axle cylinder adjustment screw (1), the slide bar axle bolt (2), the steering cylinder bolt cotter pin, (3), the castle nut (4), and the cotter pin (5). Torque the steering cylinder castle nut to 393 – 419 N·m (290 – 309 lb ft). Install cotter pin and bend tabs over the nut. NOTE: If needed, tighten castle nut to allow for cotter pin installation. NOTE: The steering castle nut and bolt are used only on the front axle 4. Remove chain used to support adjustment cylinder and slide bar. 5. Support the slide bar support cradle with a C-clamp (1) and remove the bolt. Install original bolt and torque to standard specifications. 6. Install wheel. See. Rear wheel - Install (44.520)

7. Install hydraulic lines onto active suspension cylinder. NOTE: Front axle only for machines equipped with active suspension.

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Rear axle system - Powered rear axle

8. Install the park brake line from the torque hub.

RAIL13SP01863AA

RAIL13SP01915AA

RAIL13SP01914AA

9. Attach service brake hose to brake caliper and tighten fitting. NOTE: Front axle only.

10. Install fender mounting bracket assembly. Tighten screws to 74.6 NÂˇm (55 lb ft) . 11. Raise the machine and remove jackstand and remove the hydraulic jack from under the machine. 12. Adjust axle to proper setting. See Operator Manual.

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Rear axle system - Powered rear axle

Axle suspension - Remove - Trailing link NOTE: If replacing hardware, must use the hardware noted in this Machineâ&#x20AC;&#x2122;s Parts Manual. 1. Remove the wheel. Please see Rear wheel - Remove (44.520) . 2. Remove brake caliper and brake rotor. Please see Brake caliper - Remove (33.202) . 3. Remove the wheel motor. Please see Pump - Remove - Product pump (63.100) . 4. Remove the spring. Please see Axle suspension Remove - Spring (25.100) . 5. Remove four bolts (1) and outer end cap (2). Remove nut (3) and set screw (4).

RAIL13SP01873AA

RAIL13SP01874AA

RAIL13SP01875AA

6. Remove the four bolts (1) and inner end cap (2).

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

Before removing the shaft, support trailing link with proper lifting device. Use the suspension pin remover to remove the shaft (1). Then separate the trailing arm (2) from the suspension arm (3).

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Rear axle system - Powered rear axle

Spring removal WARNING Escaping fluid! The hydraulic tank is a pressurized system. Vent tank slowly by loosening the breather before performing work on the hydraulic system. Failure to comply could result in death or serious injury. W1047A

1. Slowly open the breather (1) to release pressure from the hydraulic reservoir. 2. Remove the wheel.

RAIL15SP00386AA

RAIL13SP01869AA

3. Remove two nuts from top of cylinder rod end. NOTICE: Secure the lower trailing arm with proper lifting device before removing the two top nuts on hydraulic cylinder.

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Rear axle system - Powered rear axle

RAIL13SP01870AA

RAIL13SP01871AA

RAIL13SP01872BA

5. Remove lower cylinder nut and bolt (1). Remove the two bolts from the lower shock mount (2) and remove mount (3) and cylinder (4). NOTICE: Secure cylinder from falling after removing lower mount.

6. Secure spring from falling. Slowly lower the trailing arm and remove the spring. NOTICE: The spring is very heavy, be sure to have assistance in its removal.

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Rear axle system - Powered rear axle

Axle suspension - Install - Spring 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

RAIL13SP01872BA

RAIL13SP01869AA

Urethane bushing - (red)

G. Retainer washer H. Spring washer I.

Two nuts

Tighten to compress the rubber and urethane to achieve a dimension of 17 mm (0.67 in) from the top of the cylinder rod to the top of the jam nut.

NOTE: Apply anti-seize to the cylinder rod end threads before you install the nuts.

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Rear axle system - Powered rear axle

RAIL13SP01871AA

RAIL13SP01870AA

RAIL15SP00386AA

4. Install two hydraulic hoses onto lower cylinder end and tighten to specifications. NOTE: Only on the front axles. 5. Install the wheel.

6. Close the hydraulic reservoir breather (1).

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Rear axle system - Powered rear axle

Axle suspension - Remove - Trailing link NOTE: If replacing hardware, must use the hardware noted in this Machineâ&#x20AC;&#x2122;s Parts Manual. 1. Remove the wheel. (44.520)

See.

Rear wheel - Remove

2. Remove brake caliper and brake rotor. See. Brake caliper - Remove (33.202) 3. Remove wheel motor. See. Product pump hydraulic motor - Remove (35.911) 4. Remove the spring. See. Axle suspension - Remove - Spring (27.100) 5. Remove four bolts (1) and outer end cap (2). Remove nut (3) and set screw (4).

RAIL13SP01873AA

RAIL13SP01874AA

RAIL13SP01875AA

6. Remove the four bolts (1) and inner end cap (2).

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

Before removing the shaft, support trailing link with proper lifting device. Use TY1002 Suspension Pin Remover to remove the shaft (1) then separate trailing arm (2) from suspension arm (3). NOTE: Tool number TY1002 is sold through CNH parts system

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Rear axle system - Powered rear axle

Axle suspension - Disassemble - Trailing link 1. Remove seals (1) from trailing link.

RAIL13SP01876AA

RAIL13SP01877AA

RAIL13SP01878AA

2. Remove the sleeve bearings (2) and grease zerks (3) from trailing link.

3. Bend tabs up and remove spring adapter.

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Rear axle system - Powered rear axle

Axle suspension - Assemble - Trailing link 1. Align the grease holes (1) in the bushings with the grease zerk holes in the upper suspension arm. Install the bushings (2) on the trailing link. Use the suspension bushing installer to install the bushings. Apply primer and LOCTITEÂŽ 243-31 prior to installing grease zerks (3) and caps. Point grease zerk (4) to the inside of casting parallel to shaft +/- 30Â°. NOTE: Bushings must be pre-lubricated using grade #2, lithium 12 grease so all pockets on shaft side of bushings are filled and the remaining surface is coated. RAIL13SP01877AA

RAIL13SP01876AA

2. Install seals (5) into trailing link. NOTE: Lubricate the seal lip before you slide it through the shaft.

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Rear axle system - Powered rear axle

Axle suspension - Install - Trailing link 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

NOTE: Check bearings for wear and replace if necessary. 1. Grease the shaft (1) on both seal lips. Install the trailing link (2) onto the suspension arm (3). Align the machined slot (4) on the shaft with the adjustment screw (5) on the suspension arm. Slide shaft into trailing link and suspension arm.

RAIL13SP01879AB

RAIL13SP01880AA

RAIL13SP01881AA

2. Insert a combination of bushing shims (6) to achieve minimum clearance between the trailing link and the upper suspension arm. (Inside shim shown. Insert shims to both sides of suspension arm.)

3. Seal the surface between the caps and the trailing link with G-flex flexible caulk. (Do both sides.)

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Rear axle system - Powered rear axle

4. Install inner end cap (1) and four bolts (2). Use G-Flex caulk to seal dust cap. NOTE: Use primer and LOCTITEÂŽ on four dust cap bolts per specification.

RAIL13SP01874AA

RAIL13SP01873AA

5. Install outer dust cap (3) and four bolts (4). Tighten set screw (5) and tighten lock set screw in position with nut (6). Use G-Flex caulk to seal dust cap. NOTE: Use primer and LOCTITEÂŽ on four dust cap bolts per specification. NOTE: Grease zerks. See lubrication chart 6. Install planetary gear hub. Please see Final drive hub, steering knuckles, and shafts - Install (27.124) . 7. Install the spring. See Axle suspension - Install Spring (25.100). 8. Install the wheel motor. See Motor - Install - Wheel motor (29.218). 9. Install brake rotor and brake caliper. See brake rotor installation and brake caliper installation in Brake caliper - Install (33.202). 10. Install wheel. (44.520) .

Please see Rear wheel - Install

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Index Rear axle system - 27 Powered rear axle - 100 Axle suspension - Assemble - Trailing link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axle suspension - Disassemble - Trailing link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axle suspension - Install - Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axle suspension - Install - Trailing link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axle suspension - Remove - Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axle suspension - Remove - Trailing link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Powered rear axle - Install - Axle extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Powered rear axle - Remove - Axle extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Powered rear axle - Replace - Axle liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Rear axle system - 27 Final drive hub, steering knuckles, and shafts - 124

SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Rear axle system - 27 Final drive hub, steering knuckles, and shafts - 124

SERVICE Final drive hub, steering knuckles, and shafts Test - Roll, leak and brake test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Test - Roll, leak and brake test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

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Rear axle system - Final drive hub, steering knuckles, and shafts

Final drive hub, steering knuckles, and shafts - Test - Roll, leak and brake test Planetary gear hub units should always have roll, leak and brake tests before disassembly and after assembly to make sure that the unit’s gears, bearings and seals are working properly. The following information briefly outlines what to look for when performing these tests. NOTE: The brake must be released before performing the roll test. This can be accomplished by pressurizing the brake using the brake leak test procedure below.

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Rear axle system - Final drive hub, steering knuckles, and shafts

Final drive hub, steering knuckles, and shafts - Install NOTE: The front and back planetary gear hubs are not identical. If replacing the planetary gear hub make sure you have the correct part 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

Use proper lifting device and install planetary gear hub (1) onto the suspension trailing link (2).

RAIL13SP01865AA

RAIL13SP01866AB

RAIL13SP01867AA

2. Apply LOCTITE® 7649™ PRIMER N and LOCTITE® 242® onto the threads of the 18 bolts. Tighten and then torque to 271.16 N·m (200.00 lb ft). NOTE: Use the illustration for torque sequence.

3. Apply LOCTITE® 7649™ PRIMER N and LOCTITE® 242® onto the threads of the two wheel motor bolts (1). Install the wheel motor (2) onto the planetary gear hub. Torque the two bolts to 118 – 132 N·m (87 – 97 lb ft). Check the hub lubrication level. NOTICE: If the planetary gear hub has too much lubricant in it will cause damage.

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Rear axle system - Final drive hub, steering knuckles, and shafts

4. Install hydraulic lines to wheel motor. Please see Motor - Install - Wheel motor (29.218) . Install brake line to planetary gear hub.

RAIL13SP01863AA

RAIL13SP01868AA

5. Install two hose clamps and secure hoses with plastic ties. 6. Install brake rotor and brake caliper. Please see Brake caliper - Install (33.202) . 7. Install wheel. NOTICE: Hub lubricant must be replaced after initial 50 h of operation after repair or replacement of hub. Follow normal maintenance schedule there after.

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Rear axle system - Final drive hub, steering knuckles, and shafts

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Rear axle system - Final drive hub, steering knuckles, and shafts

Final drive hub, steering knuckles, and shafts - Remove 1. Remove the wheel. Please see Rear wheel - Remove (44.520) . 2. Remove the brake line from the planetary gear hub. NOTE: Clean all connections to be removed with an aerosol degreaser and brush before loosening. Repeat flush with aerosol degreaser with fitting backed out 2-3 turns. Immediately cap or plug any connection that is opened with clean, threaded caps and plugs 3. Remove brake caliper and rotor. Please see Brake caliper - Remove (33.202) . 4. Remove wheel motor. See Motor - Remove - Wheel motor (29.218).

RAIL13SP01863AA

RAIL13SP01864AA

RAIL13SP01865AA

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

Place a mark on the hub and trailing link to aid in proper assembly. (So rotation is not off location.) 6. Attach a proper lifting device to the planetary gear hub and remove bolts (qty. 18) from planetary gear hub. 7. Remove the planetary gear hub (1) from the machine.

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Rear axle system - Final drive hub, steering knuckles, and shafts

Final drive hub, steering knuckles, and shafts - Disassemble Prior operation: Perform roll check, leak check and brake check if applicable prior to disassembling the unit. See Final drive hub, steering knuckles, and shafts - Test - Roll, leak and brake test (27.124) for the procedure.

Planetary gear hub main disassembly

RCPH11BEN376FAU

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Rear axle system - Final drive hub, steering knuckles, and shafts

RCPH11BEN374FAU

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Rear axle system - Final drive hub, steering knuckles, and shafts

24. Push the three output planet sub-assemblies (1) towards the center of the hub/spindle sub-assembly (2).

RCPH11BEN373BAU

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Rear axle system - Final drive hub, steering knuckles, and shafts

RCPH11BEN372FAU

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Rear axle system - Final drive hub, steering knuckles, and shafts

RCPH11BEN371FAU

NOTE: Heat may need to be applied to loosen the LoctiteÂŽ applied during assembly.

Planetary gear hub input carrier disassembly

RCPH11BEN370EAU

35. Using a punch, drive the roll pin (3) into the planet shaft (7). 36. Slide the planet shaft (6) from the carrier (2). 37. Using a punch, remove the roll pin (3)from the planet shaft (6). NOTE: The used roll pins should be replaced during reassembly. 38. Slide out the planet gear (7) from carrier (2). Remove the 16 needle rollers (5) from the planet gear bore.

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39. Remove the two thrust washers (4) from the carrier (2). 40. Repeat steps 1 through 5 for the other two planet gears. 41. Remove the retainer ring (8). 42. Remove the output sun gear (1) from the cradle (2).

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Final drive hub, steering knuckles, and shafts - Assemble Planetary gear hub input carrier assembly

RCPH11BEN370EAU

1. Install the output sun gear (1) on the spline of the cradle (2). 2. Install the retaining ring (8) into the groove in the output sun gear (1) on the other end of the cradle (2). 3. Apply a liberal coat of grease to the bore of one input planet gear (7). 4. Line the inside of the planet gear (7) with 16 needle rollers (5). NOTE: The last roller installed must be installed end wise. That is, the end of the last roller must be placed in between the ends of the two rollers, which form the space, and then slid, parallel to the other rollers, into place. 5. Apply a coat of grease to two thrust washers (4). Install the thrust washers against the sides of the inner walls of the cradle (2) so that the thrust washer tab sits in the groove in the cradle and the thrust washer orifice lines up with the planetary shaft orifices of the cradle. 6. Carefully slide the planet gear (7) with the needle rollers (5) between the thrust washer (4) in the carrier (2). 7. Slide the planetary shaft (6) into the orifice of the planetary shaft of the cradle (2) through the thrust washer (4) and into the orifices of the planetary gear (7). Install the planetary shaft so that the roll pin hole lines up with the corresponding hole in the cradle (2). 8. Using a small rod, line up the roll pin hole of the carrier (2) with the roll pinhole in the planet shaft (6). 48149953 12/06/2018

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Rear axle system - Final drive hub, steering knuckles, and shafts

9. Drive a roll pin (3) into the roll pin hole of the carrier (2) until it is flush with the outside of the carrier. NOTE: Be sure not to hit the planet gear (7) when driving in the roll pins (3). 10. Repeat steps 3 through 9 for the other two planet gears (6).

Planetary gear hub assembly 11. Adjust the hub (3) on a workbench with the retaining ring groove (2) upward. 12. Press the main bearing cup (2) and fit it into place. 13. Turn over the hub (3) and press in the other main bearing cup (2) in the same manner. 14. Apply LOCTITEÂŽ 272â&#x201E;˘ to the shorter length threads of the 10 double-threaded studs (4). 15. Use a stud driver to install the 10 double-threaded studs into the hub (3).

RCPH11BEN371FAU

Planetary gear hub main assembly

RCPH11BEN372FAU

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Rear axle system - Final drive hub, steering knuckles, and shafts

16. Set the spindle (7) on the bench with the flange down. 17. Tap the main bearing cone (6) onto the spindle (8) until it is about 6 mm (0.24 in) below the planet gear windows. 18. Install snap ring (3) into an output planet gear (2). 19. Put the spacer (4) into the bore of the output planet gear (2). Take note of where the numbers are stamped on the output planet gear and make sure that the spacer in on that side of retaining ring (3). 20. Press in the output planet bearing cup (1) so that it is fully seated against the spacer (4). 21. Turn over the output planet gear (2) and press in an output planet bearing cup (1) in the same manner. 22. Place an output planet bearing cone (5) into each end of the output planet gear and slide the subassembly into one of the planet gear windows in the spindle (7). 23. Repeat 18 through 22 for the other two output planet gears. 24. Clean the seal ring inner bore and seal surface (2) of the hub spindle (1). 25. Insert the inner seal ring (3). Be careful not to scratch the seal surface. 26. Liberally apply alcohol to the seal ring inner diameter and to the hub spindle surface (2).

RAIL16SP00202AA

RAIL16SP00204AA

27. Press the seal ring onto the hub spindle (1) until the ring bottoms on the flange face (5).

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Rear axle system - Final drive hub, steering knuckles, and shafts

28. Clean the seal bore in the hub housing (1). 29. Start the outer seal (2) into the housing (1).

RAIL16SP00205AA

RAIL16SP00206AA

RAIL16SP00207AA

30. Place the hub seal installer (3) into the spindle housing (1).

31. Press outer seal into hub housing until the hub seal installer stops on the housing.

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Rear axle system - Final drive hub, steering knuckles, and shafts

RCPH11BEN373BAU

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RCPH11BEN374FAU

Rear axle system - Final drive hub, steering knuckles, and shafts

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Rear axle system - Final drive hub, steering knuckles, and shafts

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RCPH11BEN375FAU

Rear axle system - Final drive hub, steering knuckles, and shafts

RCPH11BEN376FAU

59. Install the brake O-ring (10) and the backup ring (13) into the groove in the spindle so that the O-ring is on top of the backup ring. 60. Install the input shaft (14) so that the smaller diameter grooves engage the input sun gear (not shown). 61. Install the coupling retaining ring (4) into the groove in the orifice of the coupling (5). 62. Install the coupling (5) onto the end of the input shaft (14) so that the end with the external grooves is down. 63. Stack the friction plates (9) so that the stator splines engage into the spindle splines and the rotor splines engage the coupling splines (5). NOTE: The friction plates must be placed in the same way they were when removed. Stack four stators, then a rotor, and then a stator and keep alternating until all the rotors are used. Then install the remaining two stators. NOTE: The stator plates have three missing spline teeth. Line these teeth up with three cross holes that are drilled in the spindle. 64. Place the piston O-ring (2) and the back-up ring (8) onto the brake piston (7) so that the O-ring is on the same side as the nose of the piston. 65. Apply a layer of grease to the piston O-ring (12) and back-up ring (8) as well as the brake O-ring (10) and back-up ring (13) in the spindle. 66. Install the brake piston (7) into the bore of the spindle. A rubber mallet may be used to help force the piston into the bore.

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Rear axle system - Final drive hub, steering knuckles, and shafts

67. Place the belleville spring (6) into the counterbore in the back of the brake piston (7) so that the high side of the belleville spring is at the ID. 68. Apply a layer of grease to the mounting adapter O-ring (12) and install into the groove in the mounting adapter (2). 69. Apply a layer of grease to the thrust washer (3) and install into the counterbore of the mounting adapter (2). 70. Install the mounting adapter (12) into the end of the spindle. 71. Fasten the mounting adapter (12) to the spindle with the four countersunk bolts (1). NOTE: Gradually tighten the countersunk bolts so that there is even pressure on the belleville spring. 72. Torque the countersunk bolts (1) to 16 NÂˇm (12 lb ft). 73. Install brake pressure plug (15) into the brake port if not already installed. 74. Perform roll check, leak check and brake check to help ensure proper assembly. Refer to Final drive hub, steering knuckles, and shafts - Test - Roll, leak and brake test (27.124) for procedure. 75. Fill the unit half full with oil.

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Rear axle system - Final drive hub, steering knuckles, and shafts

Planetary gear hub assembly drawing

RCPH11BEN425GAU

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Rear axle system - Final drive hub, steering knuckles, and shafts

Final drive hub, steering knuckles, and shafts - Install NOTE: The front and back planetary gear hubs are not identical. If replacing the planetary gear hub make sure you have the correct part 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

Use proper lifting device and install planetary gear hub (1) onto the suspension trailing link (2).

RAIL13SP01865AA

RAIL13SP01866AB

RAIL13SP01867AA

2. Apply LOCTITE® 7649™ PRIMER N and LOCTITE® 242® onto the threads of the 18 bolts. Tighten and then torque to 271.16 N·m (200.00 lb ft). NOTE: Use the illustration for torque sequence.

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Rear axle system - Final drive hub, steering knuckles, and shafts

5. Install hydraulic lines to wheel motor. Please see Motor - Install - Wheel motor (29.218) . Install brake line to planetary gear hub.

RAIL13SP01863AA

RAIL13SP01868AA

6. Install two hose clamps and secure hoses with plastic ties. 7. Install brake rotor and brake caliper. Please see Brake caliper - Install (33.202) . 8. Install wheel. NOTICE: Hub lubricant must be replaced after initial 50 h of operation after repair or replacement of hub. Follow normal maintenance schedule there after.

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Index Rear axle system - 27 Final drive hub, steering knuckles, and shafts - 124 Final drive hub, steering knuckles, and shafts - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Final drive hub, steering knuckles, and shafts - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Final drive hub, steering knuckles, and shafts - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Final drive hub, steering knuckles, and shafts - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Final drive hub, steering knuckles, and shafts - Test - Roll, leak and brake test . . . . . . . . . . . . . . . . .

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CNH Industrial Latin America LTDA, Av. Jerome Case, 1801, Aparecidinha - Socoraba (SP) - Brasil, CEP:18087-220

SERVICE - Technical Publications & Tools

48149953 12/06/2018 EN

SERVICE MANUAL Hydrostatic drive SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Hydrostatic drive - 29

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

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Hydrostatic drive - 29 Pump and motor components - 218

SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Hydrostatic drive - 29 Pump and motor components - 218

TECHNICAL DATA Hydrostatic system feed pump General specification - Hydrostatic pump with control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 General specification - Hydrostatic pump without control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Motor General specification - Wheel motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

FUNCTIONAL DATA Pump and motor components Dynamic description - Drive circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Overview - Drive circuit troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Hydrostatic system feed pump Overview - Hydrostatic pump with control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Overview - Hydrostatic pump without control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Motor Overview - Wheel motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Pump valves Dynamic description - Neutral bypass valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

SERVICE Pump and motor components Service instruction - Motor or pump replacement start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Service instruction - Start-up procedure after replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Pump Remove - Hydrostatic pump - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Install - Hydrostatic pump - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Motor Test - Wheel motor case drain test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Test - Verification of wheel motor shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Remove - Wheel motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Install - Wheel motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Motor valves Remove - Motor control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Install - Motor control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

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Pump valves Disassemble - Neutral bypass valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Assemble - Neutral bypass valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Pump valves - Remove - Neutral bypass valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Install - Neutral bypass valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

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Hydrostatic drive - Pump and motor components

Hydrostatic system feed pump - General specification - Hydrostatic pump with control module General specifications

SOIL17SP00501FA

Brand Pump type Location

Rexroth A4VG axial pistons variable pump with control module Mounted on the multiplier gearbox (1) Offset (Vg) 56 cm³/rev # of tines Pressure angle Outer splined shaft Pitch Turning direction # of tines Pressure angle Inner splined shaft Pitch Turning direction General specifications Maximum operating speed 3600 RPM Intermittent continuous rotation 4500 RPM 2 screws Mounting flange Guide diameter: 127 mm Charge pump displacement 15,1 cm³/rev (Vg) Oil viscosity 47 mm²/s at 40° 7 mm²/s @ 100° Maximum Working temperature range Minimum Valve pressure Pressure range 400 bar@ 450 bar settings

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14 30° 12 / 24 Counter-clockwise 11 30° 16 / 32 Counter-clockwise

90 °C -25 °C

Hydrostatic drive - Pump and motor components

Connector Terminals Nominal voltage Control module

Control chain Limit chain Nominal resistance at 20 Â°C Timesheet Work cycle

DEUTSCH 2 pins, DT04-2P 460 - 202 - 16141 12 V Minimum displacement (Vg 0) Maximum displacement (Vg max) 1,54 A 5,5 ÎŠ 100 Hz 100%

Ports

SOIL18SP00178FA

Item A and B T1 T2 Ma and Mb R S X1 and X2 G Ps Ps Mh

Details Work ports Filling port Drain port Ports for diagnostics (pressure check of ports A and B) Air bleed port Suction port Pressure control ports Pressure port for auxiliary circuit Pressure control port Port for charge pump pressure check Port for measurement of high pressure

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400 mA 1200 mA

Hydrostatic drive - Pump and motor components

Hydrostatic system feed pump - General specification - Hydrostatic pump without control module General specifications

SOIL17SP00501FA

Brand Pump type Location

Rexroth Axial pistons variable pump A4VG Mounted on the multiplier gearbox (1) Offset (Vg) 56 cm³/rev # of tines Pressure angle Outer spline shaft Pitch Turning direction # of tines Pressure angle Inner spline shaft Pitch Turning direction General specifications Maximum working speed 3600 RPM Intermittent continuous rotation 4500 RPM 2 screws Mounting flange Guide diameter: 127 mm Charge pump displacement 15,1 cm³/rev (Vg) Oil viscosity 47 mm²/s at 40 °C 7 mm²/s @ 100 °C Maximum Working temperature range Minimum Valve pressure Pressure range 400 bar@ 450 bar settings

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14 30° 12 / 24 Counter-clockwise 13 30° 16 / 32 Counter-clockwise

90 °C -25 °C

Hydrostatic drive - Pump and motor components

Ports

SOIL18SP00182FA

Item A and B T1 T2 Ma and Mb R S X1 and X2 G Ps Fa Mh

Details Work ports Filling port Drain port Diagnostics ports (check the pressure of ports A and B) Air bleed port Suction port Pressure control ports Pressure port for auxiliary circuit Pressure control port Charge pump pressure check port High-pressure measurement port

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Hydrostatic drive - Pump and motor components

Motor - General specification - Wheel motor General specifications

SOIL17SP00490AA

Brand Type Location

Axle Type

Offset (Vg) Control type Pressure Mounting flange

Rexroth A6V variable pistons hydraulic motor with HZ and ED control Mounted on the wheel hub assembly (1) Outer spline DIN 5480 30 mm Reference diameter 2 mm Module (tooth size) 14 # of tines 9g Grade Pressure angle 30° Turning direction Bi - directional Maximum 55 cm³/rev Minimum 19,55 cm³/rev HD2 400 bar@ 450 bar 2 screws

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Hydrostatic drive - Pump and motor components

Ports

SOIL17SP00505FA

Item A and B G X T1 T2 M1

Details Work ports Pressure and timing control port Pilot pressure port Drain port Drain port Pressure measurement port

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Hydrostatic drive - Pump and motor components

Pump and motor components - Dynamic description - Drive circuit The drive circuit contains hydraulic and electrical components. The hydraulic components include hydraulic pumps, hydraulic motors, motor control valve (MCV), shunt valve, and a park brake valve. The electric components used in the system are the power train control module (PCM), position sensor (FNR lever control potentiometer) , speed potentiometer, neutral switch, reverse switch, and various relay coils that control the hydraulic components.

Drive system (Overview) The right hand console has two drive control components, a position sensor and a potentiometer. The hydrostatic control lever assembly contains the position sensor and the speed control knob contains the potentiometer. Both are wired to the power train control module. As the hydrostatic control lever is moved, the power train control module receives a voltage signal from both components simultaneously. The power train control module converts the signal into a current (milli-amp) signal. For the schematic above, the milli-amp signal from the power train control module (PCM) is sent to an electronic proportional valve (EP) on each pump.

Operation After you release the parking brake to start the PCM, 5V is sent to the position sensor and to the speed potentiometer. Even when there is no propulsion, the PCM checks the feedback signals for an expected value. If this value is not met, an error code is displayed. The hydrostatic control lever is attached to a position sensor. As the control lever is moved to a forward or reverse position, the output signal changes. Rotating the ground speed pot has the same effect, the output signal changes. The PCM sees these changes and sends individual signals to each of the hydrostatic pumps and the motor control valve (MCV). Each hydrostat has its own signal to control displacement and pump rotational direction. The MCV controls wheel motor displacement changes. Note that the PCM requires an engine rpm signal to send a signal to the MCV. This is input via the vehicle's CAN system. When the control lever is moved forward, this signal is sent from the controller to the hydrostatic pumps. Once the lever is moved all the way forward, the pumps have moved from minimum displacement to maximum. Additionally, the MCV receives a signal to change displacement of the wheel motors to achieve the required speed, approximately 11 mph. If the speed pot has been moved from minimum position to any other, the controller will now increase the signal to the MCV to shift the wheel motors however much is required. The amount of wheel motor shift is determined by the software in the PCM.

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Hydrostatic drive - Pump and motor components

Hydraulic component schematics

RAIL13SP01382FA

A. B.

Hydrostatic lever Drivetrain control module â&#x20AC;&#x201C;

Motor control valve (MCV)

D. E.

Wheel Motors Hydrostatic pumps \ electronic proportional valves (EP)

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Hydrostatic drive - Pump and motor components

Hydrostatic pumps

SOIL17SP00504FA

The hydrostatic pumps (1) are connected to a multiplier gear box, which is connected to the rear of the engine. The pumps are driven by the diesel engine and supply hydraulic pressure to the wheel motors. The gear pump (product pump) (2) supplies oil for the product pump circuit. The variable pump (3) supplies oil to the steering system, service brakes, width of the shaft, and hydraulic boom. The gear and pressure compensation pumps are each mounted to one of the hydrostatic pumps.

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Hydrostatic drive - Pump and motor components

Pump and motor components - Overview - Drive circuit troubleshooting Symptom Machine will not move

Possible cause Hydraulic oil level low Park brake switch is ON Park brake failed to release Neutral safety switch out of adjustment or faulty Power train control module fuse faulty Power train control module relay faulty Power train control module faulty Power train control module wiring faulty Park brake switch faulty

Corrective action Fill hydraulic tank to proper level Turn off park brake switch Release park brake Adjust or replace neutral safety switch

Test power train control module. Repair or replace as required

Test park brake valve and park brake valve. Repair or replace faulty Park brake valve faulty component Test motor control valve. Replace if Motor control valve is faulty required Shunt valve is faulty Test shunt valve. Replace if required Suction strainers clogged Clean or replace suction strainer Test hydrostatic pump. Replace Hydrostatic pump failure hydrostatic pump if required Pump drive is faulty Repair or replace Machine only operates in one EDC wiring faulty Test the EDC. Repair or replace faulty direction (forward or reverse) component EDC coil faulty Adjust multifunction valve. Replace High pressure relief valves are faulty multifunction valve if required Test power train control module. Power train control module is faulty Replace if required Drive system will not maintain a Motor control valve wiring faulty Test motor control valve. Repair or constant speed replace faulty component Motor control valve faulty Test speed control knob. Replace if Speed control knob faulty required The machine wants to move when in Neutral switch out of adjustment Adjust neutral safety switch the neutral position Neutral safety switch faulty Test neutral safety switch Shunt valve faulty Repair or replace valve Park brake will not engage or Wiring faulty disengage Switch faulty Test park brake system. Repair or replace faulty component Fuse faulty Park brake valve faulty Machine will not slow down or stop Service brake switch faulty Test service brake. Repair or replace properly Service brake valve faulty faulty component Service brake wiring faulty Axles will not extend or retract Axle adjustment switch faulty properly In/out switch faulty Test axle adjust. Repair or replace faulty component In/out solenoid faulty Wiring faulty

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Hydrostatic drive - Pump and motor components

Symptom Drive system sluggish or erratic

Possible cause Brakes not fully released Hydraulic oil level low Hydraulic filter clogged Power train control module not calibrated Power train control module is faulty Planetary gear hub has incorrect oil level Low, fluctuating or no charge pressure

Motor control valve is faulty Planetary gear hub failure Wheel motor failure Speed control knob faulty Motor control valve is faulty Wheel motor/planetary gear hub noisy

Planetary gear hub has incorrect oil level Low oil level in reservoir Air in system Check pump inlet pressure Wheel motor or planetary gear hub loose Planetary gear hub failure

Machine pulls to one side

Wheel motor failure Traction control switch is faulty Load share coil faulty Hydraulic filter clogged Planetary gear hub failure Wheel motor failure Low, fluctuating or no charge pressure Hydrostatic pump failure

Machine wants to move when in neutral

Shunt valve is faulty Neutral safety switch out of adjustment Neutral safety switch is faulty

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Corrective action Release brake. If brakes fail to release Fill hydraulic tank to proper level Replace hydraulic filters Test power train control module Test power train control module. Replace if faulty Adjust oil level Check and adjust charge relief valve Repair or replace charge pump Repair or replace hydrostatic pump Test motor control valve. Replace if required Properly jack the suspected planetary gear hub and perform the planetary gear hub roll test Test wheel motor. Replace if required Test speed control knob. Replace if required Test motor control valve. Replace if required Adjust oil level Fill hydraulic tank to proper level Fix leak in hydraulic system Inspect inlet filter and replace if necessary Tighten wheel motor or planetary gear hub Properly jack the suspected planetary gear hub and perform the planetary gear hub roll test Test wheel motor. Replace if required Replace switch Repair or replace load share coil Replace filter Test planetary gear hub Test wheel motor Check and adjust charge relief valve Repair or replace charge pump Test hydrostatic pumps. Repair or replace hydrostatic pump if required Repair or replace valve Adjust switch Replace neutral switch

Hydrostatic drive - Pump and motor components

Hydrostatic system feed pump - Overview - Hydrostatic pump with control module General view

SOIL18SP00177FA

Item 1 2 3 4 5 6

Details Outer splined shaft Mounting flange Charge pump filter Control module Pressure cut off valve Inner splined shaft

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Hydrostatic drive - Pump and motor components

Hydrostatic system feed pump - Overview - Hydrostatic pump without control module General view

SOIL18SP00181FA

Item 1 2 3 4 5 6

Details Outer spline shaft Mounting flange Charge pump filter High-pressure valve Pressure cut off valve Inner spline shaft

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Hydrostatic drive - Pump and motor components

Motor - Overview - Wheel motor General view

SOIL18SP00185FA

Item 1 2

Details Outer spline shaft Mounting flange

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Hydrostatic drive - Pump and motor components

Pump valves - Dynamic description - Neutral bypass valve This component is used as a safety device. It prevents any unwanted movement occurring from a faulty signal from the Power-train Control Module (PCM) or EDC any time the machine is in neutral. The shunt valve is located on top of the left-hand pump and on the bottom of the right hand hydrostatic pump. The electrical coil located on the shunt valve is energized by a signal from the neutral safety switch. This shifts the cartridge inside the valve to block the oil path to the hydraulic tank, allowing the hydraulic signal from the EDC valve to act on the pump displacement controls. In its normal state (not energized), the oil passes through the shunt valve and will eventually return to the hydraulic tank. RCPH11BEN457BAU

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Hydrostatic drive - Pump and motor components

Pump and motor components - Service instruction - Motor or pump replacement start-up WARNING Stay clear! The steering tires will move automatically during this procedure. ALWAYS make sure the work area is clear of bystanders and domestic animals before starting this procedure. Know the full area of movement of the machine. Do not permit anyone to enter the area of movement during this procedure. Failure to comply could result in death or serious injury. W0066A

NOTE: When testing full system pressure, a second person is required in the cab to apply service brakes and to turn the machine “OFF” if needed. NOTE: The hydraulic system must cleaned and thoroughly flushed. Fill pump and or motor cases with clean oil. The following start-up procedure should always be followed when starting-up a new installation or when restarting an installation in which either the hydrostatic pump or wheel motor had been removed. 1. Disconnect the parking brake quick disconnect and install brake bleed fitting. Please see Parking brake or parking lock - Overview - Solenoid valve (33.110) . NOTE: This allows the parking brake switch to be disengaged, which in turn, provides the 12 V signal to the power train control module. This procedure will allow the machine to think it can propel, or at least attempt to propel, as the parking brakes within the planetaries are still applied. 2. Properly anchor the machine with suitable chain to a immovable object, so it will not move unexpectedly.

RAIL13SP01385AA

RAIL13SP01388AA

3. The charge pressure readings of the pumps are measured after the filter, at the Fa (1) diagnostic port. Install a 50 – 100 bar ( 600 – 1000 psi) pressure gauge at Fa diagnostic port (1).

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Hydrostatic drive - Pump and motor components

4. Locate the electronic proportional valve (EP) mounted on top of the left hydrostatic pump. Disconnect both the forward and reverse connectors at the electronic proportional valve (EP) until after initial start-up to ensure the pump remains in neutral position. 5. Using the starter “Jog” or slowly rotate engine until charge pressure reaches 3 bar (44 psi) or more. Start the engine and run at idle, until charge pressure has been established. 6. Once charge pressure has been established, increase speed to high idle. The charge pressure should be 27 – 29 bar (392 – 420 psi). If the charge pressure is inadequate, shut down the engine and determine the cause of the inadequate pressure. See. Pump - Pressure test - Patriot 3240 charge pressure test and adjustment (29.218) 7. Shut down the engine and connect the electronic proportional valve (EP) forward and reverse connectors. 8. Start the engine, checking to be certain the pump remains in neutral. With the engine running at high engine idle ( 2260 RPM), slowly check for forward and reverse machine operation. NOTE: Charge pressure may slightly decrease during forward or reverse operation. Continue to cycle slowly between forward and reverse for at least 5 min. 9. Shut down the engine, remove gauge and connect park brake hose assembly. 10. Check hydraulic tank level and add filtered fluid if needed.

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RAIL13SP01397AA

Hydrostatic drive - Pump and motor components

Pump and motor components - Service instruction - Start-up procedure after replacement WARNING Avoid injury! Performing the following procedure may require the machine be disabled (work function disconnected, wheels raised off the ground, etc.). Failure to comply could result in death or serious injury. W0992A

WARNING Overturning hazard! Always try to park the machine on firm level ground. Avoid parking on slopes. Block the wheels in both directions. Failure to comply could result in death or serious injury. W0051A

NOTE: The following start-up procedure should always be followed when starting-up a new installation or when restarting an installation in which either the hydrostatic pump or wheel motor had been removed. 1. Properly anchor the machine so it will not move unexpectedly or raise the machine so all four wheels are off the ground and properly support the machine with jackstands. 2. Install a 50 bar (725 psi) (1) pressure gauge in the charge pressure gauge port (2) to monitor the charge pressure during start-up.

RCPH11BEN434BAU

RCPH11BEN446BAU

3. Disconnect the EDC at the pump control until after initial start-up to ensure the pump remains in its neutral position. 4. Using the starter â&#x20AC;&#x153;Jogâ&#x20AC;? or slowly rotate engine until charge pressure starts to rise. Start the engine and run at idle, until charge pressure has been established. 5. Once charge pressure has been established, increase speed to normal operating RPM. Charge pressure should be as indicated in the pump model code (located on the manufacturers name plate secured to the pump or motor). If charge pressure is inadequate, shut down and determine cause for improper pressure.

6. Shut down the engine and connect the EDC.

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Hydrostatic drive - Pump and motor components

7. Start the engine, checking to be certain the pump remains in neutral. With the engine running at high engine idle 2260 RPM, slowly check for forward and reverse machine operation. NOTE: Charge pressure may slightly decrease during forward or reverse operation. Continue to cycle slowly between forward and reverse for at least five minutes. 8. Shut down the engine, remove gauges, and plug the ports. 9. Check hydraulic tank level and add filtered fluid if needed.

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Hydrostatic drive - Pump and motor components

Pump - Remove - Hydrostatic pump Prior operation: If replacing hardware must use the hardware noted in this Machineâ&#x20AC;&#x2122;s Parts Catalog. Prior operation: The hydrostatic pump tests can be found in hydraulic troubleshooting in Pump and motor components - Overview - Drive circuit troubleshooting (29.218). Prior operation: Clean all connections to be removed with an aerosol degreaser and brush before loosening. Repeat flush with aerosol degreaser with fitting backed out 2-3 turns. Prior operation: Cap or plug any connection that is opened with clean caps and plugs. Prior operation: Some oil may still be in hoses, drain into proper container. Prior operation: Tag and label all hoses prior to removal. 1. Disconnect the negative cable on the batteries (1).

SOIL17SP00403AA

RAIL13SP04848AA

2. Remove the engine hood and cowling for overhead crane access when removing the hydraulic pumps. See the engine hood in Engine hood - Remove (90.105). 3. Power wash area around hydraulic pumps.

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Hydrostatic drive - Pump and motor components

4. With the right hand boom cradled and the left hand boom properly supported, support the center section with the proper support stand. 5. Drain hydraulic tank. Please see Pump-drive assembly - Drain fluid (19.121) .

RAIL14SP00034AA

RAIL13SP04771AA

SOIL17SP00475AA

Left-hand hydrostatic pump removal 1. Remove the gear pump (1). Please see Pump - Remove - Gear pump (35.104) .

2. Remove the oil inlet hose (1) for the gear pump from the oil reservoir. 3. Disconnect and remove the oil inlet hose (2) from the oil reservoir and the left hand hydrostatic pump.

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Hydrostatic drive - Pump and motor components

4. Disconnect the electrical connectors (1).

SOIL17SP00476AA

SOIL17SP00477AA

SOIL17SP00478AA

SOIL17SP00479AA

5. Disconnect the hose from the left-hand side of the lower manifold (1). 6. Disconnect the hose from the bottom of the pump (2).

7. Disconnect the three hoses (1) on the upper manifold block.

8. Disconnect the two hoses (1) at the top rear of the hydrostatic pump. 9. Disconnect the hose from the right-hand side of the lower manifold (2).

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Hydrostatic drive - Pump and motor components

10. Disconnect the hoses from the right-hand side of the pump (1).

SOIL17SP00480AA

SOIL17SP00481AA

SOIL17SP00482AA

11. Support the hydrostatic pump with a lifting strap and an overhead crane. 12. Remove the bolts (1) and the washers (2) on both sides of the pump.

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 pump from pump drive.

13. Remove O-ring (1).

Right-hand hydrostatic pump removal 1. Remove the variable pump (1). See Pump - Remove - Variable pump (35.106).

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Hydrostatic drive - Pump and motor components

2. Disconnect the two hoses from the upper manifold block (1). 3. Disconnect the hose from the lower manifold block (2).

SOIL17SP00486AA

SOIL17SP00487AA

SOIL17SP00488AA

SOIL17SP00489AA

4. Disconnect the hose from the right-hand block of the valve (1).

5. Support the hydrostatic pump with a lifting strap and an overhead crane. 6. Remove the bolts (1) and the washers (2) on both sides and remove the variable pump.

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

7. Remove O-ring (1).

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Hydrostatic drive - Pump and motor components

Pump - Install - Hydrostatic pump Right-hand hydrostatic pump installation NOTE: If replacing hardware must use the hardware noted in this Machine’s Parts Catalog. NOTE: New O-rings need to be installed on any fittings that are being installed. 1. Install a new O-ring on to the pump. NOTE: Lubricate O-ring with clean petroleum jelly.

RAIL13SP01483AA

SOIL17SP00488AA

2. Support the hydrostatic pump with a lifting strap and an overhead crane.

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

3. Lift the pump and position the pump in its housing. 4. Install the washers (1) and the mounting bolts (2). Torque. Torque the mounting bolts to 67.8 – 74.6 N·m (50 – 55 lb ft).

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Hydrostatic drive - Pump and motor components

5. Connect the hose of the right-hand valve block (1).

SOIL17SP00487AA

SOIL17SP00486AA

RAIL13SP04793AA

6. Connect the hose of the lower manifold block (1).

7. Install the two hoses on the upper manifold block (2).

8. Install the variable pump. Please see Pump - Install Variable pump (35.106) .

Left-hand hydrostatic pump installation NOTE: New O-rings need to be installed on any fittings that are being installed.

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Hydrostatic drive - Pump and motor components

1. Install a new O-ring (1) on the housing. NOTE: Lubricate O-ring with clean petroleum jelly.

SOIL17SP00482AA

SOIL17SP00481AA

SOIL17SP00480AA

2. Lift the hydrostatic pump with a lifting strap and an overhead hoist. Position the pump in its housing.

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

3. Install the bolts (1) and the washers (2) on both sides of the pump. Torque the mounting bolts to 67.8 – 74.6 N·m (50 – 55 lb ft).

4. Install the hoses of the right-hand side of the pump (1).

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Hydrostatic drive - Pump and motor components

5. Connect the two hoses (1) at the top rear of the hydrostatic pump. 6. Connect the hose of the right-hand side of the lower manifold (2).

SOIL17SP00479AA

7. Connect the three hoses (1) on the upper manifold block.

SOIL17SP00478AA

SOIL17SP00477AA

SOIL17SP00476AA

8. Connect the hose onto the bottom of the pump (1). 9. Connect the hose of the left-hand side of the lower manifold (2).

10. Connect electrical connectors (1).

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Hydrostatic drive - Pump and motor components

11. Connect the oil inlet hose (1) of the gear pump onto the oil reservoir. 12. Install the oil inlet hose (2) of the oil reservoir onto the left-hand hydrostatic pump.

SOIL17SP00475AA

RAIL13SP04771AA

RAIL13SP04768AA

SOIL17SP00403AA

13. Install the gear pump (1). Please see Pump - Install - Gear pump (35.104) .

14. Fill the hydraulic tank. Please see Oil reservoir Drain fluid (35.300) .

15. Connect the negative cable (1) to the batteries.

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Hydrostatic drive - Pump and motor components

16. Bleed the air and any impurities from the system by using the following procedure. 17. Install a new in-tank return filter on the auxiliary hydraulic circuit. 18. Start the engine and run at 1500 RPM with the vehicle in neutral for a minimum of 20 min to filter and warm the hydraulic oil prior to any operation. 19. Run the machine for at least 1 h under light load to complete the hydraulic oil filtration. 20. Shut down machine and check for leaks. NOTE: See the Initial start-up procedure Pump and motor components - Service instruction - Motor or pump replacement start-up (29.218). Next operation: Engine hood - Install (90.105)

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Motor - Test - Wheel motor case drain test WARNING Stay clear! The steering tires will move automatically during this procedure. ALWAYS make sure the work area is clear of bystanders and domestic animals before starting this procedure. Know the full area of movement of the machine. Do not permit anyone to enter the area of movement during this procedure. Failure to comply could result in death or serious injury. W0066A

NOTE: When testing full system pressure, a second person is required in the cab to apply service brakes and to turn the machine “OFF” if needed. 1. Install the flowmeter in the case drain line from the wheel motor to the hydraulic tank. NOTE: Make sure the direction of flow indicated on the meter matches true oil flow out of the motor.

RAIL13SP01398AA

RAIL13SP01385AA

2. Disconnect the parking brake quick disconnect and install brake bleed fitting. Please see Parking brake or parking lock - Overview - Quick disconnect (33.110) . NOTE: This allows the parking brake switch to be disengaged, which in turn, provides the 12 V signal to the power train control module. This procedure will allow the machine to think it can propel, or at least attempt to propel, as the parking brakes within the planetaries are still applied. 3. Properly anchor the machine with suitable chain to a immovable object, so it will not move unexpectedly. 4. Start the engine and raise the temperature of the hydraulic oil to 49 °C (120 °F). 5. With a second individual in the cab of the machine, raise the engine RPMs to high idle, release the parking brake, and slowly move the hydrostatic control lever forward. 6. Record the reading on the flowmeter. move the lever back in the neutral position. Apply the parking brake, reduce engine RPM and turn Off the ignition. The case drain flow rate for a new motor will range from 5.8 – 7.6 l/min (1.5 – 2.0 US gpm). Wheel motors should not be replaced until the leakage is high enough that the charge pump cannot keep up. Case drain pressure should not exceed 3 bar (44 psi) continuously, or 5 bar (72 psi) intermittently.

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Motor - Test - Verification of wheel motor shift WARNING Stay clear! The steering tires will move automatically during this procedure. ALWAYS make sure the work area is clear of bystanders and domestic animals before starting this procedure. Know the full area of movement of the machine. Do not permit anyone to enter the area of movement during this procedure. Failure to comply could result in death or serious injury. W0066A

Wheel motors are shifted with a hydraulic pilot pressure controlled by the Motor Control Valve (MCV). The wheel motors start in maximum displacement (low speed high torque) and stroke to minimum displacement (high speed low torque). This test is to determine at what input (signal) pressure the wheel motor starts shifting from maximum displacement towards minimum displacement. Install pressure gauges at the “X”, “M1” and “G” ports to monitor the shifting and working pressures of the motor. Test equipment needed: • One 10 bar or 100 bar ( 600 psi or 1000 psi) gauge • Two 1000 bar ( 10000 psi) gauge 1. NOTE: The port numbers are embossed in the casting. Remove the plug from the “X” port elbow or tee into port connection. Install the 10 bar or 100 bar ( 600 psi or 1000 psi) gauge into the “X” port. Remove the plug. Install a 100 bar ( 10000 psi) gauge in the “M1” port. Remove the plug. Install a 100 bar ( 10000 psi) gauge in the “G” port. Run all gauges to an area where they will visible from the cab. NOTE: The port threads for the “M1” port are not the same as the “G” port. The threads for “M1” port are M14 X 1.5, “G” port is 9/16-18UNF-2B. 2. The wheel motor starts to shift at approximately 5 bar (72 psi) of pilot pressure (“X” port pressure reading). Pilot pressure is used to shift the control spool, but the motor uses working pressure to shift the servo. Working pressure can be read at the “G” port gauge. “M1” gauge will read working pressure when the motor is fully shifted to minimum displacement. 3. Start the engine and warm the hydraulic oil to a minimum of 49 °C (120 °F). 4. Turn the speed control knob to the minimum. Drive the unit in a clear area. Set the hydrostatic lever at 3/4 of full travel. Start turning the speed pot and monitor when the “M1” gauge reads approximately half the pressure of the “G” port gauge. Record the value on gauge “X”. This is the motor shift pressure.

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RAIL13SP01398AA

Hydrostatic drive - Pump and motor components

Motor - Remove - Wheel motor Prior operation: The wheel motor tests can be found in Motor - Test - Wheel motor case drain test (29.218). Prior operation: Power wash machine around area to be worked on. 1.

Remove the pressure from the hydraulic tank by slowly loosening the breather cap until pressure is bled from the hydraulic tank. RAIL13SP01429AA

RAIL13SP01863AA

RAIL13SP01868AA

2. Remove hydraulic line (1) from lower rear of wheel motor. (Left hand front wheel motor shown). 3. Remove two split flange hoses (2) from top and bottom of wheel motor. 4. Remove hydraulic line (3) from top of wheel motor. NOTE: Clean all connections to be removed with an aerosol degreaser and brush before loosening. Repeat flush with aerosol degreaser with fitting backed out 2-3 turns NOTICE: Immediately cap or plug any connection opened with clean, threaded caps and plugs. 5. Remove the two hydraulic hose clamps (1) and plastic ties (2).

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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

Use a proper lifting device to support wheel motor. Remove two bolts and remove wheel motor.

RAIL13SP02003AA

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Motor - Install - Wheel motor Prior operation: New O-rings need to be installed on any fittings that are being installed. 1. After cleaning motor, apply petroleum jelly to O-ring and install on to motor.

RAIL13SP02004AA

RAIL13SP02003AA

RAIL13SP01863AA

RAIL13SP01868AA

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

Use a proper lifting device to support wheel motor. Install the wheel motor and secure with two bolts. Tighten the bolts to 118 – 132 N·m (87 – 97 lb ft).

3. Remove the caps and plugs. Install the hydraulic line (1) onto the lower rear side of the wheel motor. (Left-hand front wheel motor shown). Install two split flange hoses (2) on top and bottom of wheel motor. Install the hydraulic line (3) onto the top of the wheel motor.

4. Install two hydraulic hose clamps and secure with nuts. Secure the hoses together with plastic ties.

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5. Close the hydraulic reservoir breather (1) 6.

Bleed the air and any impurities from the system by using the following procedure. 7. Install a new in-tank return filter on the auxiliary hydraulic circuit. 8. Start the engine and run at 1500 RPM with the vehicle in neutral for a minimum of 20 min to filter and warm the hydraulic oil prior to any operation. 9. Run the machine for at least 1 h under light load to complete the hydraulic oil filtration. 10. Shut down the machine and check for leaks.

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RAIL15SP00386AA

Hydrostatic drive - Pump and motor components

Motor valves - Remove - Motor control valve Prior operation: If replacing hardware must use the hardware noted in this machineâ&#x20AC;&#x2122;s parts manual. Prior operation: The motor control valve (1) is on underside of machine, in front of rear cross member. Prior operation: Power wash entire machine, especially around area to be worked on. 1.

Depressurize the hydraulic tank. Slowly loosen breather until pressure has been bled from the hydraulic tank. Tighten breather.

RAIL13SP01357AA

RAIL17SP01346AA

The motor control valve is on underside of machine, in front of rear cross member. Disconnect the wire harness (1) and hydraulic lines (2). Remove the mounting bolts and remove motor control valve from unit. NOTE: Mark the hydraulic lines for proper installation. NOTE: Clean all connections to be removed with an aerosol degreaser and brush before loosening. Repeat flush with aerosol degreaser with fitting backed out 2-3 turns. NOTICE: Immediately cap or plug any connection that is opened with clean, threaded caps and plugs.

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Motor valves - Install - Motor control valve NOTE: If any of the fittings were removed the O-rings must be replaced. 1. Install the motor control valve with the original mounting hardware. Connect the hydraulic lines (2) and wire harness (1).

RAIL17SP01346AA

RAIL13SP01357AA

3. Install a new in-tank return filter on the auxiliary hydraulic circuit. 4. Start the engine and run in neutral at a minimum of 1500 RPM. 5. Allow the engine to run at 1500 RPM with the vehicle in neutral for a minimum of 20 min to filter and warm the hydraulic oil prior to any operation. 6. Run the machine for at least 1 h under light load to complete the hydraulic oil filtration. 7. Shut down the machine and check for leaks.

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Pump valves - Disassemble - Neutral bypass valve 1. Place the valve body (1) in a vice and remove the solenoid coil nut (2).

RAIL13SP01537AA

RAIL13SP01538AA

RAIL13SP01539AA

2. Remove the coil (1) from the solenoid (2).

3. Remove the solenoid (1) from the valve body (2). 4. Inspect the solenoid and valve body for any damage or excessive wear. Replace as required.

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Pump valves - Assemble - Neutral bypass valve 1. Apply petroleum jelly on the O-rings (1). Install new O-rings (1) on the solenoid (2).

RAIL13SP01539AA

RAIL13SP01540AA

RAIL13SP01537AA

2. Install the solenoid (1) into the valve body (2) and torque to 35 – 40 N·m (26 – 30 lb ft).

3. Install coil (1) and coil nut (2). Torque coil nut to 4 – 6 N·m (3 – 4 lb ft).

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Pump valves - Remove - Neutral bypass valve WARNING Escaping fluid! The hydraulic tank is a pressurized system. Vent tank slowly by loosening the breather before performing work on the hydraulic system. Failure to comply could result in death or serious injury. W1047A

Power wash entire machine, especially around area to be worked on. 1. Depressurize the hydraulic tank. Slowly loosen the breather until pressure has been bled from the hydraulic tank. Tighten the breather.

RAIL14SP00274AA

RCPH11BEN228BAU

2. The shunt valve is located on top of the left-hand hydraulic pump and on the bottom of the right-hand hydraulic pump. Disconnect the wire harness (1), hydraulic line (2) and remove valve (3). NOTE: Clean all connections to be removed with an aerosol degreaser and brush before loosening. Repeat flush with aerosol degreaser with fitting backed out 2-3 turns. NOTE: Immediately cap or plug any connection opened with clean, threaded caps and plugs.

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Pump valves - Install - Neutral bypass valve DANGER Unexpected machine movement! Air in the hydraulic system could cause unexpected machine movement. Purge the air from the hydraulic system after any hydraulic system maintenance or repair. Failure to comply will result in death or serious injury. D0054A

NOTE: If any of the fittings were removed, the O-rings must be replaced. 1. Install the valve (1). Connect the hydraulic line (2) and the wire harness (3).

RCPH11BEN228BAU

RAIL14SP00274AA

2. Install a new in-tank return filter on the auxiliary hydraulic circuit. 3. Start the engine and allow it to run at 1500 RPM with the vehicle in neutral for a minimum of 20 min to filter and warm the hydraulic oil prior to any operation. 4. Run the machine for at least 1 h under light load to complete the hydraulic oil filtration. 5. Shut down the machine and check for leaks.

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Index Hydrostatic drive - 29 Pump and motor components - 218 Hydrostatic system feed pump - General specification - Hydrostatic pump with control module . . .

Hydrostatic system feed pump - General specification - Hydrostatic pump without control module

Hydrostatic system feed pump - Overview - Hydrostatic pump with control module . . . . . . . . . . . . . .

Hydrostatic system feed pump - Overview - Hydrostatic pump without control module . . . . . . . . . . .

Motor - General specification - Wheel motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor - Install - Wheel motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor - Overview - Wheel motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor - Remove - Wheel motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor - Test - Verification of wheel motor shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor - Test - Wheel motor case drain test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor valves - Install - Motor control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor valves - Remove - Motor control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump valves - Remove - Neutral bypass valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump - Install - Hydrostatic pump - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump - Remove - Hydrostatic pump - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump and motor components - Dynamic description - Drive circuit . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump and motor components - Overview - Drive circuit troubleshooting . . . . . . . . . . . . . . . . . . . . . . .

Pump and motor components - Service instruction - Motor or pump replacement start-up . . . . . . . .

Pump and motor components - Service instruction - Start-up procedure after replacement . . . . . . .

Pump valves - Assemble - Neutral bypass valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump valves - Disassemble - Neutral bypass valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump valves - Dynamic description - Neutral bypass valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump valves - Install - Neutral bypass valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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CNH Industrial Latin America LTDA, Av. Jerome Case, 1801, Aparecidinha - Socoraba (SP) - Brasil, CEP:18087-220

SERVICE - Technical Publications & Tools

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SERVICE MANUAL Brakes and controls SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Brakes and controls - 33

[33.202] Hydraulic service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1 [33.110] Parking brake or parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.2

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Brakes and controls - 33 Hydraulic service brakes - 202

SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Brakes and controls - 33 Hydraulic service brakes - 202

FUNCTIONAL DATA Hydraulic service brakes Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Brake pedals Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Brake pedal control valve Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Brake caliper Service instruction - Brake bleeding procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Replace - Brake pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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Brakes and controls - Hydraulic service brakes

Hydraulic service brakes - Overview The service brake serves two functions on this machine. The first function is to stop or slow the machine in an emergency situation, and the second is to deactivate the drive system. The service brake circuit is connected to the pressure compensation pump. The pressure and flow required to engage the brake calipers on the two front wheels is supplied by the pressure compensation pump. The service brake valve is mounted to the front of the cab near the steering orbit motor. When the service brake valve (1) is actuated, the hydraulic fluid is ported to the calipers. As the service brake valve pedal is released and the spring shifts the valve, the hydraulic fluid is vented or dumped into the suction line of the gear pump (product pump) circuit. The return line of the service brake valve is plumbed into the gear pump suction to eliminate any back pressure and will keep the service brakes disengaged. The pressure in this line should be about -6.9 â&#x20AC;&#x201C; 0.0 kPa (-1.0 â&#x20AC;&#x201C; 0.0 psi) . If the return was plumbed to an actual tank line, there would be enough back pressure from the return manifolds, coolers, filters, and the pressurized hydraulic tank, to hold the brakes on slightly. This would cause the brake pads to wear out prematurely.

RAIL13SP01424AA

RAIL13SP01425AA

The hydrostatic drive system is deactivated when the momentary service brake switch (2) is released and the power train control module sees a 12 V input at pin 48 ( Rexroth controller). This switch is located under the center console, and is released when the brake pedal is pushed down.

NOTE: When the service brake has been activated, the hydrostatic control lever will need to be placed back to the neutral position to release the service brake. This will allow the hydraulic system to be reactivated.

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General Information

RAIL13SPO5033HA

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

Description Wheel hub parking brake – left rear Wheel hub parking brake– left front Service brake calipers – left front Service brake valve assembly Pressure compensation pump supply Suction side of the gear pump Return to hydraulic tank Service brake calipers – right front Wheel hub parking brake – right front Wheel hub parking brake – right rear Charge pump supply Parking brake valve Motor control valve

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Brakes and controls - Hydraulic service brakes

The main components of the brake system are the brake pedal, the service brake valve, the parking brake valve, the brake calipers, the brake rotor, and the torque hub (parking) brake. While in the â&#x20AC;&#x153;OFFâ&#x20AC;? position, the parking brake switch (on the right hand console) energizes the parking brake valve, which applies pressure to the torque hub (parking) brake. This hydraulic pressure overcomes the spring pressure in the torque hub and releases the brake inside the torque hub, allowing wheel rotation. When the brake pedal is pressed, the service brake valve applies pressure to the brake calipers. Brake calipers are only on the front wheels.

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Brake pedals - Remove WARNING Pressurized system! Before attempting any service procedure, it is your responsibility to know the number of accumulators on the machine, and the correct procedure for releasing the pressure of each accumulator. Failure to comply could result in death or serious injury. W0136A

WARNING Escaping fluid! If a hydraulic hose, line, or pipe shows signs of wear or damage, replace the component IMMEDIATELY. Failure to comply could result in death or serious injury. W0297A

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: Front shield - Remove (90.105) 1. Remove the pin with lock (1) from the rod. 2. Remove the pin with lock (1) to release the pedal (2).

SOIL16SP00313AA

SOIL16SP00314AA

3. Remove cap screws (1).

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Brakes and controls - Hydraulic service brakes

4. With the hoses still connected, push the control valve (1) out of the housing of the cab. NOTE: The figure to the left does not show the fuel tank,so as to provide a better view of the valve (1). 5. Disconnect the following hoses: • Hose (2) of the oil return port of the valve. • Supply hose (3) that comes from the gear pump. • Pressure hose (4) for application of the brakes. NOTICE: Cover the connection points to avoid the entry of dirt. SOIL16SP00315AA

6. Remove the control valve (1).

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Brake pedals - Install WARNING Pressurized system! Before attempting any service procedure, it is your responsibility to know the number of accumulators on the machine, and the correct procedure for releasing the pressure of each accumulator. Failure to comply could result in death or serious injury. W0136A

WARNING Escaping fluid! If a hydraulic hose, line, or pipe shows signs of wear or damage, replace the component IMMEDIATELY. Failure to comply could result in death or serious injury. W0297A

1. Position the control valve (1) on the front of the cab. NOTE: The figure to the left does not show the fuel tank,so as to provide a better view of the valve (1). 2. Connect the following hoses: • Hose (2) of the oil return port of the valve. • Supply hose (3) that comes from the gear pump. • Pressure hose (4) for application of the brakes. 3. Push the control valve (1) completely into the housing of the cab. SOIL16SP00315AA

SOIL16SP00314AA

4. Secure the control valve to the console with the bolts (1).

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5. Install the pin with lock (1) to connect the terminal of the valve to the pedal (2). 6. Fit the pin with lock (1) in the valve stem.

SOIL16SP00313AA

Next operation: Front shield - Install (90.105)

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Brake pedal control valve - Remove WARNING Pressurized system! Before attempting any service procedure, it is your responsibility to know the number of accumulators on the machine, and the correct procedure for releasing the pressure of each accumulator. Failure to comply could result in death or serious injury. W0136A

WARNING Escaping fluid! If a hydraulic hose, line, or pipe shows signs of wear or damage, replace the component IMMEDIATELY. Failure to comply could result in death or serious injury. W0297A

Prior operation: Front shield - Remove - Front hood (90.105) 1. Remove the pin with lock (1) from the rod. 2. Remove the pin with lock (1) to release the pedal (2).

SOIL16SP00313AA

SOIL16SP00314AA

3. Remove cap screws (1).

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Brakes and controls - Hydraulic service brakes

6. Remove the control valve (1).

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Brake pedal control valve - Install WARNING Pressurized system! Before attempting any service procedure, it is your responsibility to know the number of accumulators on the machine, and the correct procedure for releasing the pressure of each accumulator. Failure to comply could result in death or serious injury. W0136A

WARNING Escaping fluid! If a hydraulic hose, line, or pipe shows signs of wear or damage, replace the component IMMEDIATELY. Failure to comply could result in death or serious injury. W0297A

SOIL16SP00314AA

4. Secure the control valve to the console with the bolts (1).

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5. Install the pin with lock (1) to connect the terminal of the valve to the pedal (2). 6. Fit the pin with lock (1) in the valve stem.

SOIL16SP00313AA

Next operation: Front shield - Install - Front hood (90.105)

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Brake caliper - Service instruction - Brake bleeding procedure 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

Place a clear hose onto the brake bleed valves to catch fluid in a suitable container. 2.

WARNING Unexpected machine movement! Before starting the engine, move all operating controls to neutral or park lock position. This prevents accidental movement of the machine or start up of power-driven equipment. Failure to comply could result in death or serious injury. W0302A

With the aid of a helper, start the machine and apply and hold the brake pedal down. 3. Open a bleed valve and allow fluid to flow until the pedal bottoms out and then close the valve. Have the helper pump the pedal and then hold down again. Continue to open a bleed valve and allow fluid to flow until no air bubbles are seen in the hose. Close the bleed valve and remove the hose. Repeat on opposite the opposite bleed valve. NOTE: Bleed both the front and rear bleed valves on each caliper assembly.

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RAIL17SP01377AA

Brakes and controls - Hydraulic service brakes

Brake caliper - Replace - Brake pads 1. Remove the wheel. NOTE: With the wheel removed, thread a lug nut onto a wheel stud to secure rotor to hub. NOTE: Depending on tire size it may be possible to replace the brake pads without removing the wheel.

RAIL13SP01904AA

RAIL13SP01850AA

RAIL17SP01381AA

RAIL17SP01378AA

Insert a lever between the brake pads to push the brake caliper pistons fully open. This will allow the caliper to accept the new thicker pads.

3. Remove the rear rue clips (1) from the stator pins.

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Brakes and controls - Hydraulic service brakes

4. Remove the stator pins (2) and then remove the old brake pads (3). 5. Insert new brake pads (3) into the caliper and reinsert the stator pins (2) to retain the brake pads.

RAIL17SP01379AA

RAIL17SP01378AA

RAIL13SP01904AA

6. Install the rear rue clips (1) on the stator pins.

7. Install the wheel if removed. 8. Repeat steps 1 through 7 to replace the brake pads on the opposite side. 9. Start unit and check brakes for proper operation.

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Brakes and controls - Hydraulic service brakes

Brake caliper - Remove NOTE: If you replace hardware, use the hardware noted in this Machineâ&#x20AC;&#x2122;s Parts Manual. 1. Remove the wheel. NOTE: With the wheel removed, thread a lug nut onto a wheel stud to secure rotor to hub.

RAIL13SP01904AA

RAIL13SP01850AA

RAIL17SP01381AA

Remove the hydraulic brake line from caliper. NOTE: Visually check brake lines for damage. Replace as required. NOTE: A small amount of fluid may leak from line. Cap and plug ports upon removal of line. NOTICE: To avoid system contamination, clean area around hydraulic line connection with degreaser before disconnecting line.

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Brakes and controls - Hydraulic service brakes

3. Remove the two bolts (1) and the fastening nuts (2). 4. Remove the caliper and the spacer (3) from the mounting bracket. NOTE: Check the condition of the piston. Replace if damaged or worn excessively.

RAIL17SP01382AA

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Brakes and controls - Hydraulic service brakes

Brake caliper - Disassemble 1. Remove the rue clips (1), remove the stator pins (2) and then remove the brake pads (3).

RAIL17SP01350AA

RAIL17SP01351AA

RAIL17SP01352AA

RAIL17SP01353AA

2. Press the end cap (1) and then remove the C-ring (2).

3. Remove the bolt (1) from the end cap.

4. Screw a slide hammer into the end cap and remove the end cap (1).

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Brakes and controls - Hydraulic service brakes

5. Push the outer piston (1) out the back of the piston bore. 6. Remove the piston boot (2) from the piston.

RAIL17SP01355AA

RAIL17SP01354AA

RAIL17SP01356AA

RAIL17SP01357AA

7. Remove the flattened rings (1) from the outer piston bore.

8. Insert a slide hammer through the outer piston bore, and screw into the inner piston (1). Remove the inner piston. 9. Remove the piston boot (2) from the piston.

10. Remove the flattened rings (1) from the inner piston bore. 11. Inspect the piston bores. They must be clean and rust free. If rust is present, use emery cloth to remove. If the bore is badly scored, replace the caliper. 12. Inspect the pistons, if badly scored, replace the pistons.

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Brakes and controls - Hydraulic service brakes

Brake caliper - Assemble 1. Lubricate the piston bores, the pistons, the flattened rings (1), and the O-rings with clean hydraulic oil. 2. Install new square rings in the inner piston bore.

RAIL17SP01357AA

RAIL17SP01356AA

RAIL17SP01354AA

RAIL17SP01355AA

3. Install a new O-ring on the piston (1). 4. Install a new piston boot (2) on the piston. Make sure that the small opening of the boot is seated in the groove on the front side of the piston. Pull the boot over the full length of the piston and extend the boot beyond the end of the piston approximately 6.35 mm (0.25 in). 5. Start the boot lip into the piston bore. Use a vice or shop press to slowly move the piston into the bore until the piston bottoms out. Make sure the boot has properly seated in the piston bore.

6. Install new flattened rings (1) in the outer piston bore.

7. Install a new O-ring on the piston (1). 8. Install a new piston boot (2) on the piston. Make sure that the small opening of the boot is seated in the groove on the front side of the piston. Pull the boot over the full length of the piston and extend the boot beyond the end of the piston approximately 6.35 mm (0.25 in). 9. Press the piston boot inside the outer hole. Insert the piston in the hole. Push through the square rings until the shim is seated in the groove on the front side of the piston. Take care not to push the piston boot out of its bore.

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Brakes and controls - Hydraulic service brakes

10. Install a new O-ring and backup ring on the end cap (1). Then push into the rear hole beyond the C-ring groove. Secure the end cap with the C-ring (2).

RAIL17SP01351AA

RAIL17SP01350AA

11. Install the brake pads (3). Insert the stator pins (2) and install the rue clips (1).

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Brakes and controls - Hydraulic service brakes

Brake caliper - Install 1. Separate the brake pads on the caliper and position the caliper on the rotor (1). Make sure the spacer is between the caliper and the mounting bracket. 2. Secure the caliper with the two bolts (2) and nuts (3). Torque the bolts to 169 – 183 N·m (125 – 135 lb ft).

RAIL17SP01382AA

RAIL17SP01381AA

2. Install brake line onto caliper and tighten fitting.

3. Install the wheel. 4. Brake bleeding procedure. Please see Brake caliper - Service instruction - Brake bleeding procedure (33.202) .

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Index Brakes and controls - 33 Hydraulic service brakes - 202 Brake caliper - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake caliper - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake caliper - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake caliper - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake caliper - Replace - Brake pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake caliper - Service instruction - Brake bleeding procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake pedal control valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake pedal control valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake pedals - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake pedals - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic service brakes - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Brakes and controls - 33 Parking brake or parking lock - 110

SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Brakes and controls - 33 Parking brake or parking lock - 110

TECHNICAL DATA Parking brake or parking lock Special tools - Park brake release for towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Parking brake or parking lock Overview - Quick disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Overview - Solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Parking brake or parking lock Test - Release test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Service instruction - Parking brake release for towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Parking brake control valve or manifold Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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Brakes and controls - Parking brake or parking lock

Parking brake or parking lock - Special tools - Park brake release for towing Kit, hand pump â&#x20AC;&#x201C; Assembled Install the tee fitting into port 1 on the hand pump. Install two hoses onto the tee. Install 0 â&#x20AC;&#x201C; 50 bar ( 0 â&#x20AC;&#x201C; 600 psi) gauge (1) onto hose and install female coupler (2) onto other hose. Install straight adaptor fitting into port 2 on the hand pump. Install hose onto the fitting in port 2 and install the male coupler (3) onto the hose.

RAIL13SP01149AA

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Brakes and controls - Parking brake or parking lock

Parking brake or parking lock - Overview - Quick disconnect NOTE: Always disconnect the park brake quick disconnect with engine â&#x20AC;&#x153;OFFâ&#x20AC;?. This component is located near center of machine, just in front of rear cross frame. It is used primarily as a troubleshooting aid when testing certain hydraulic components. By disconnecting the coupler (1), no oil is supplied to the planetary drive hubs allowing the internal parking brakes to remain applied. The parking brake quick disconnect is also used for towing purposes. Please see Parking brake or parking lock Overview - Quick disconnect (33.110) .

RAIL13SP01385AA

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Brakes and controls - Parking brake or parking lock

Parking brake or parking lock - Overview - Solenoid valve The parking brake is actuated by a switch located on the right-hand console. This switch activates the park brake solenoid valve (1) located near center of machine, just in front of rear cross frame. As the park brake is engaged or disengaged, the cartridge is actuated to either supply oil to the parking brakes in the hubs or to prohibit the oil from reaching the hub. The parking brakes within the drive hubs are spring applied and hydraulically released. Through the park brake valve (park brake OFF), charge pressure oil is supplied to the brake assembly overcoming the spring tension and the brakes are released. The supply to park brakes within the drive hubs is port #1 on top of the valve, port #3 is return to tank and port #2 is charge pressure supply to brake solenoid valve.

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RAIL13SP01157AA

Brakes and controls - Parking brake or parking lock

Parking brake or parking lock - Test - Release test 1. Engine shutdown, disconnect the parking brake quick disconnect. Install a length of hose with a female quick disconnect to the open male coupler. Have a helper hold the hose into a collection container. 2. Start the engine and disengage the park brake switch. If oil flow is present, the valve is operating properly.

RAIL13SP01157AA

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Brakes and controls - Parking brake or parking lock

Parking brake or parking lock - Service instruction - Parking brake release for towing Preparing the machine for towing WARNING Loss of control! Only tow at safe speeds. Use caution when making corners or meeting traffic. Failure to comply could result in death or serious injury. W0126A

NOTICE: The maximum towing speed is 4.8 – 6.4 km/h (3 – 4 mph). NOTICE: If the engine or the hydrostatic are not functional, the parking brake switch will not release the parking brake. Use the following procedure to release the parking brake. NOTICE: If replacing parts or components, use the parts listed in this Machine’s Parts Manual.

Prepare hydrostatic pump for towing Release the parking brake 1. Block wheels as necessary to prevent machine from rolling when brakes are released. 2.

Disconnect the parking brake quick coupler (1) (located on the inner left side frame rail near the rear of the machine). RAIL13SP01157AA

RAIL13SP01153AA

3. Connect the line from the hand pump (1) with 0 – 50 bar ( 0 – 600 psi) gauge installed to the steel line adapter (2) on the parking brake line. Connect the other line from the hand pump to the hose coupler (3) from the parking brake valve.

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Brakes and controls - Parking brake or parking lock

4. Turn the ignition switch (1) to the “ON” position and release the parking brake switch (2).

SOIL16SC00354AA

RAIL13SP01153AA

RAIL13SP01154AA

5. Using the hand pump, pressurize the circuit to 27.6 bar (400 psi).

Activate bypass function of the pumps The engine should be shut down when opening or closing the bypass valves. The bypass function is performed by the multi-function valve cartridges. Both bypass actuators on both multi-function valve cartridges on each hydrostatic pump must be opened to engage the bypass function. 6. The bypass function is performed by the multi-function valve cartridges (1) located at the rear of the machine. Loosen lock nut (2). Turn the bypass screw (3) six turns. Tighten the lock nut (2). Once the machine has been moved, block the wheels as necessary to prevent the machine from moving. When the machine is ready to return to service, see “Returning to service after towing” below.

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Brakes and controls - Parking brake or parking lock

Returning to service after towing Engage the parking brake 1. Slowly bleed off pressure in the brake line (by loosening the hose fitting from the parking brake steel line) until the pressure gauge reads 0 kPa (0 psi).

RAIL13SP01156AA

RAIL13SP01157AA

RAIL13SP01155AA

2. Disconnect the two hydraulic lines and remove the hand pump. Reconnect the coupler to the parking brake steel line.

Closing each bypass valve 3. (Valve is shown removed from machine for clarity - Do not remove the valve from the machine.) Loosen lock nut (2). Turn the bypass screw (3) until it stops. Tighten the lock nut (2).

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Brakes and controls - Parking brake or parking lock

Parking brake control valve or manifold - Remove Prior operation: If replacing hardware, must use the hardware noted in this Machineâ&#x20AC;&#x2122;s Parts Manual. Prior operation: The park brake valve is on underside of machine, in front of rear cross member. Prior operation: Power wash entire machine, especially around area to be worked on. 1.

Depressurize the hydraulic tank. Slowly loosen breather until pressure has been bled from the hydraulic tank. Tighten breather.

RAIL13SP01357AA

RAIL13SP01157AA

The park brake valve (1) is on underside of machine, in front of rear cross member. The park brake valve (1) and the motor control valve (2) share a common supply and tank port plumbing. Disconnect wire harness and hydraulic lines. Remove mounting bolts and remove motor control valve (1). NOTE: Mark hydraulic lines for proper installation. NOTE: Clean all connections to be removed with an aerosol degreaser and brush before loosening. Repeat flush with aerosol degreaser with fitting backed out 2-3 turns. NOTICE: Immediately cap or plug any connection opened with clean, threaded caps and plugs.

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Brakes and controls - Parking brake or parking lock

Parking brake control valve or manifold - Disassemble 1. Remove nut and coil from solenoid valve. NOTE: Note the position of coil electrical connections for proper installation.

RAIL13SP01542AA

RAIL13SP01543AA

2. Remove solenoid valve from park brake valve. 3. Inspect solenoid valve for any damage. Replace if necessary. 4. Replace all O-rings (1).

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Parking brake control valve or manifold - Assemble 1. Apply petroleum jelly on the O-rings (1). Install the solenoid valve (2). Torque solenoid valve to 29.8 NÂˇm (22 lb ft).

RAIL13SP01543AA

RAIL13SP01544AA

2. Install the coil (1) and the nut (2) onto the solenoid valve. Torque the nut to 4 NÂˇm (3 lb ft) .

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Brakes and controls - Parking brake or parking lock

Parking brake control valve or manifold - Install NOTE: f any of the fittings were removed the O-rings must be replaced. 1. Install park brake valve. Connect hydraulic lines and wire harness.

RAIL13SP01157AA

RAIL13SP01357AA

3. Start the engine and run in neutral at a minimum of 1500 RPM. 4. Allow the engine to run at 1500 RPM with the vehicle in neutral for a minimum of 20 min to filter and warm the hydraulic oil prior to any operation. 5. Run the machine for at least 1 h under light load to complete the hydraulic oil filtration. 6. Shut down machine and check for leaks.

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Index Brakes and controls - 33 Parking brake or parking lock - 110 Parking brake control valve or manifold - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parking brake control valve or manifold - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parking brake control valve or manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parking brake control valve or manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parking brake or parking lock - Overview - Quick disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parking brake or parking lock - Overview - Solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parking brake or parking lock - Service instruction - Parking brake release for towing . . . . . . . . . . .

Parking brake or parking lock - Special tools - Park brake release for towing . . . . . . . . . . . . . . . . . . .

Parking brake or parking lock - Test - Release test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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CNH Industrial Latin America LTDA, Av. Jerome Case, 1801, Aparecidinha - Socoraba (SP) - Brasil, CEP:18087-220

SERVICE - Technical Publications & Tools

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SERVICE MANUAL Hydraulic systems SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Hydraulic systems - 35

[35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 [35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2 [35.104] Fixed displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3 [35.106] Variable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4 [35.105] Charge pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5 [35.703] Stabilizer hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.6 [35.735] Track frame widening system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.7 [35.911] Sprayer hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.8

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Hydraulic systems - 35 Hydraulic systems - 000

SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Hydraulic systems - 35 Hydraulic systems - 000

TECHNICAL DATA Hydraulic systems Calibration - Pressure tapping points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Hydraulic systems Hydraulic symbol - Schematic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Hydraulic symbol - Table of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - Hydraulic symbol - Pressure control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Hydraulic symbol - Directional control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Hydraulic symbol - Composite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Hydraulic symbol - Flow control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Overview - Cylinder circuit troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Overview - Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Hydraulic schema - Transmission, steering, and spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Hydraulic schema - Self-leveling booms and automatic steering system . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Hydraulic schema - Flow Divider 4x4 (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

SERVICE Hydraulic systems Overhaul - Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

DIAGNOSTIC Hydraulic systems Troubleshooting - Fault analysis and possible causes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Calibration - Pressure tapping points Pressure tapping points on the wheel motor NOTE THAT P1, P2 AND P3, AND P4 REFER TO EACH SPECIFIC WHEEL MOTOR

SOIL17SP00490AA

IDENTIFICA- DESCRIPTION TION P1 INPUT “M1” PRESSURE CONTROL MEASUREMENT POINT ON THE RIGHT FRONT WHEEL MOTOR P2 INPUT “M1” PRESSURE CONTROL MEASUREMENT POINT ON THE LEFT REAR WHEEL MOTOR P3 INPUT “M1” PRESSURE CONTROL MEASUREMENT POINT ON THE LEFT FRONT WHEEL MOTOR P4 INPUT “M1” PRESSURE CONTROL MEASUREMENT POINT ON THE RIGHT REAR WHEEL MOTOR

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MAXIMUM PRESSURE (BAR) 420 BAR 420 BAR 420 BAR 420 BAR

Hydraulic systems - Hydraulic systems

Pressure tapping points on the hydraulic pumps To measure the pressure, install the diagnostic nipple P/N 307993

SOIL17SP00491AA

Identification

Description

Input “MA” Pressure control measurement point on the right hydraulic pump Input “MB” Pressure control measurement point on the right hydraulic pump Input “MA” Pressure control measurement point on the left hydraulic pump Input “MB” Pressure control measurement point on the left hydraulic pump Input “FA” Pressure control measurement point on the charge pump.

P6 P7 P8 P9

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Maximum Pressure (bar) 450 bar 450 bar 450 bar 450 bar 25 bar

Hydraulic systems - Hydraulic systems

Pressure tapping points on the oil radiator

SOIL17SP00494AA

Identification

Description

P10 P11

Pressure control measurement point on the radiator Pressure control measurement point on the radiator

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Maximum Pressure (bar) 3 bar 3 bar

Hydraulic systems - Hydraulic systems

Brake pressure tapping points

SOIL17SP00492AA

SOIL17SP00493AA

Identification

Description

P12

Pressure control measurement point of the parking brake 48149953 12/06/2018

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Maximum Pressure (bar) 29 bar

Hydraulic systems - Hydraulic systems

P13

Pressure control measurement point of the emergency brake

186 bar

Pressure tapping points on the product pump

SOIL17SP00495AA

Identification

Description

P14 P15 P16

Input “P,” Pressure control measurement point on the valve Input “M1,” Pressure control measurement point on the valve Input “M2,” Pressure control measurement point on the valve

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Maximum Pressure (bar) 145 bar 145 bar 5 bar

Hydraulic systems - Hydraulic systems

Pressure tapping points on the hydraulic block

SOIL17SP00496AA

Identification

Description

P17

Input â&#x20AC;&#x153;P,â&#x20AC;? Pressure control measurement point on the valve

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Maximum Pressure (bar) 5 bar

Hydraulic systems - Hydraulic systems

SOIL17SP00497AA

Identification

Description

P18

Input “P,” Pressure control measurement point on the hydraulic cylinder block input Input “A1A,” Pressure control measurement point at the rear of the rear cylinder of the left-hand inner boom Input “A1B,” Pressure control measurement point at the rear of the outer cylinder of the left-hand inner boom Input “B1A,” Pressure control measurement point at the front of the inner cylinder of the left-hand inner boom Input “B1B,” Pressure control measurement point at the front of the outer cylinder of the left-hand inner boom Input “A2,” Pressure control measurement point at the rear of the cylinder of the left-hand idler bar with damper Input “A2,” Pressure control measurement point at the front of the cylinder of the left-hand idler bar with damper Input “A3,” Pressure control measurement point on the rear port of the cylinder Input “B3,” Pressure control measurement point Input “A4,” Pressure control measurement point Input “B4,” Pressure control measurement point Input “A5,” Pressure control measurement point at the rear of the cylinder of the right-hand idler bar with damper Input “B5,” Pressure control measurement point at the front of the cylinder of the right-hand idler bar with damper Input “A6A,” Pressure control measurement point Input “A6B,” Pressure control measurement point Input “B6A,” Pressure control measurement point Input “B6B,” Pressure control measurement point on the valve

P19 P20 P21 P22 P23 P24 P25 P26 P27 P28 P29 P30 P31 P32 P33 P34

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Maximum Pressure (bar) 190 bar 207 bar 207 bar 104 bar 104 bar 190 bar 190 bar 190 bar 190 bar 190 bar 190 bar 190 bar 190 bar 207 bar 207 bar 104 bar 104 bar

Hydraulic systems - Hydraulic systems

Hydraulic systems - Hydraulic symbol - Schematic components Accurate diagrams of hydraulic circuits are essential to the technician who must repair them. The diagram shows how the components interact. The diagram shows how the system works, what each component should be doing and where the oil should be going so the technician can diagnose and repair the system. There are two types of circuit diagrams: • Cutaway circuit diagrams show the internal construction of the components as well as the flow paths. Using colors, shades or various patterns in the lines and passages, they show many different conditions of flow and pressure. Cutaway diagrams take considerably longer to produce because of their complexity. • Schematic circuit diagrams, the “shorthand” system of the industry, are usually preferred for troubleshooting. A schematic diagram is made up of simple geometric symbols for the components and their controls and connections. There are several systems of symbols used when making schematic diagrams: • ISO – International Standards Organization • ANSI – American National Standards Institute • ASA – American Standards Association • JIC – Joint Industry Conference A combination of symbols from these systems are shown. There are differences between the symbol systems. There is enough similarity, however, so if you understand the symbols shown, you will be able to interpret other symbols as well.

Reservoirs A rectangle with the top removed represents a vented reservoir (A). A rectangle with the top in place represents a pressurized reservoir (B).

RCIL07CCH025AAA

RCIL07CCH027AAA

RCIL07CCH030AAA

RCIL07CCH032AAA

There are other schematic diagrams that show a slightly different version of a pressurized reservoir, but the symbols are similar and easily recognized. An oval with a short line on top or a rectangle with curved sides represents a reservoir that is pressurized.

Lines connected to the reservoir usually are drawn from the top, regardless of where the actual connection is. This symbol shows a line which returns fluid above the level in the reservoir.

If the hydraulic line returns fluid below the level in the reservoir, it is drawn all the way to the bottom of the symbol.

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Hydraulic systems - Hydraulic systems

A hydraulic line connected to the bottom of the reservoir may be drawn from the bottom of the symbol if the bottom connection is essential to the systems operation.

RCIL07CCH033AAA

RCIL07CCH124AAA

RCIL07CCH034AAA

RCIL07CCH035AAA

RCIL07CCH036AAA

If the pump inlet (B) must be charged or flooded with fluid above the inlet port, the reservoir symbol (A) appears above the pump symbol, and the suction line is drawn out of the bottom of the reservoir symbol. Every system reservoir has at least two hydraulic lines connected to it, and some may have many more. Often the components that are connected to the reservoir are spread all over the schematic. Rather than multiplying lines all over the schematic, individual reservoir symbols are drawn close to the components. The reservoir is usually the only component symbol pictured more than once on a diagram.

Lines, tubes and hoses A hydraulic line, tube, hose or any conductor that carries the fluid between components is shown as a line. A working line, such as an inlet pressure or return, is shown as a solid line.

Working lines with arrows show direction of flow. In the first example (A), fluid flows in one direction only; in the second example (B), fluid can flow in both directions.

Pilot or control lines (A) are broken into long dashes. Drain lines (B) for leakage oil are broken into short dashes.

A flexible line is shown as an arc between two dots and is always represented by a solid line.

RCIL07CCH026AAA

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Hydraulic systems - Hydraulic systems

An enclosure outline indicates that there are several symbols that make up a component assembly such as a valve or a valve stack. The enclosure outline is rectangular and is broken with dashes on all sides.

RCIL07CCH028AAA

RCIL07CCH038AAA

RCIL07CCH047AAA

RCIL07CCH048AAA

RCIL07CCH040AAA

RCIL07CCH041AAA

Lines between components are drawn differently when they are crossing or connected. There are lines that cross other lines but are not connected. There are several ways to show crossing lines which are not connected.

Lines that are connected are shown with a dot that represents the connection or shown as a tee connection. The dot connection is the most commonly used when drawing schematic diagrams.

Pumps There are many basic pump designs. A simple fixed displacement pump (A) is shown as a circle with a solid arrow that pointing outward. The arrow points in the direction that the fluid flows. If the pump is reversible (B) or designed to pump in either direction, the symbol has two arrows which point in opposite directions. The pump normally has a pressure port and line (1) from which pressurized fluid is discharged and a suction port and line (2) into which fluid is drawn from the reservoir.

A variable displacement pump (A) is shown by an arrow drawn through the pump symbol at a 45 degree angle. A variable displacement, pressure compensated pump (B) is shown by a small box with an arrow, added to the side of the pump symbol.

If the pump is controlled by a lever (A) or a pedal (B), the appropriate symbol is added to the side of the pump.

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Hydraulic systems - Hydraulic systems

A drive shaft is shown as two short parallel lines extending from the side of the pump. A curved arrow, if present, on the drive shaft indicates the direction of rotation.

RCIL07CCH049AAA

RCIL07CCH051AAA

RCIL07CCH046AAA

RCIL07CCH055AAA

Motors Motor symbols are circles with solid black arrows, which point in the opposite direction of a pumpâ&#x20AC;&#x2122;s arrow, to show the motor as a receiver of fluid. One arrow is used for non-reversible motors (A); and two arrows are used for reversible motors (B).

A simple schematic diagram is shown of a hydraulic motor (A) connected to a hydraulic pump (B).

Cylinders A cylinder is a simple rectangle (A) representing the barrel. The piston and rod are represented by a tee (B), inserted into the rectangle. The symbol can be drawn in any position.

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Hydraulic systems - Hydraulic systems

If the cylinder is single-acting (A), there is only one port shown on the end of the cylinder that receives pressurized fluid. The opposite end of the cylinder is left open. Both ends are closed on a double-acting cylinder (B), and two ports are shown.

RCIL07CCH054AAA

RCIL07CCH057AAA

RCIL07CCH126AAA

RCIL07CCH080AAA

A double rod end cylinder has a rod extending from each end of the rectangle.

Some cylinders have cushions built into them. The cushion slows the movement of the piston as it nears the end of its stroke. Cylinder cushions are shown as a smaller rectangle (A) on the piston. If the cushion has an adjustable orifice, a slanted arrow is drawn at 45 degrees (B) across the symbol.

Accessories Filters, strainers and heat exchangers are represented as squares that are turned 45 degrees and have the port connections at the corners. A dotted line perpendicular to the flow line represent a filter, strainer or screen.

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Hydraulic systems - Hydraulic systems

A solid line perpendicular to the flow with solid arrows pointing outward represents a cooler.

RCIL07CCH081AAA

RCIL07CCH118AAA

RCIL07CCH119AAA

RCIL07CCH130AAA

The symbol for a heater is like the symbol for a cooler, except the solid arrows point inward.

Two sets of arrows pointing inward and outward represents a temperature control unit The solid arrows point in the direction that heat is dissipated. Or in the case of the control unit, they show that heat can be regulated.

An oval with details inside represents an accumulator. The details explain what type of accumulator it is: spring loaded (A), gas charged (B), or other features. The divider line indicates there is a separator between the charge and the fluid. A hollow arrow indicates gas. A spring indicates that the accumulator is spring-loaded.

Reference:

Hydraulic systems - Hydraulic symbol - Pressure control (35.000) Hydraulic systems - Hydraulic symbol - Directional control (35.000) Hydraulic systems - Hydraulic symbol - Composite (35.000) Hydraulic systems - Hydraulic symbol - Flow control (35.000) Hydraulic systems - Hydraulic symbol - Table of symbols (35.000)

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Hydraulic symbol - Table of symbols Line and line functions Solid line - main line

Dotted line - exhaust or drain line

Dashed line - pilot line

Enclosure outline

Lines crossing

Lines joining

Lines crossing

Liquid direction of flow

Gaseous direction of flow

Flexible line

Mechanical devices Connections (two parallel lines) for shafts, levers, etc.

Variable component (arrow intersects symbol at 45Â°)

Spring

Pumps and motors Pump, fixed displacement

Pump, variable displacement

Pressure compensated, variable displacement pump

Fixed displacement pump (bidirectional flow)

Motor, fixed displacement

Motor, variable displacement

Oscillator

Reservoirs

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Reservoir, open to atmosphere

Pressurized reservoir

Return line to reservoir below fluid level

Return line to reservoir above fluid level

Cylinders Single acting

Double acting, single rod end

Double acting. double rod end

Single rod end, fixed cushion both ends

Single rod end, adjustable cushion, rod end only

Differential cylinder

Valves Check valve

Pilot-operated check valve

On/Off manual shut off valve

Regulating or selector valves

2 position, 2 way valve

2 position, 3 way valve

2 position, 4 way valve

3 position, 4 way valve

2 position, 4 way open center, crossover valve

Valve capable of infinite positioning (indicated by horizontal lines parallel to the envelope)

Pressure relief valve

Pressure reducing valve

Non-adjustable restrictor valve

Adjustable restrictor valve

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Hydraulic systems - Hydraulic systems

Adjustable restrictor, pressure compensated

Adjustable restrictor, temperature and pressure compensated

Valve actuators Solenoid

Detent

Spring

Manual

Push button

Lever

Pedal

Mechanical

Pressure compensated

Pilot pressure, remote supply

Liquid supply

Accessories Filter

Cooler

Heater

Temperature controller

Accumulator (hydropneumatic

Reversing motor

Station or test point

Pressure indicator

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Hydraulic systems - Hydraulic systems

Temperature indicator

Pressure switch

Quick disconnect (disconnected)

Quick disconnect (connected)

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Hydraulic symbol - Pressure control The basic valve symbol is a square (which is called an envelope) with external port connections and an arrow inside to show the fluid passage and direction of flow. The valve usually operates by balancing fluid pressure against a spring, so a spring is shown on one side of the symbol and a pilot pressure line on the other side.

Normally closed valve A normally closed valve, such as a relief or sequence valve, is shown with an arrow offset from the ports [inlet (A), outlet (B)] toward the pilot pressure line (C) side of the square. The spring (D) holds the valve closed until the pilot line pressure is greater than the spring pressure. Mentally visualize a build up of pressure in the pilot line and the envelope moving over, compressing the spring. Fluid can now flow through the valve. RCIL07CCH059AAA

RCIL07CCH060AAA

RCIL07CCH061AAA

Normally open valve A normally open valve is shown with the arrow connecting the inlet and outlet ports. It closes when pressure overcomes spring force. Mentally visualize a build up of pressure in the pilot line and the envelope moving over, compressing the spring. Fluid flow through the valve is now blocked.

Relief valve A relief valve is shown as a normally closed symbol connected between the pressure line (A) and the reservoir (B). The flow direction arrow points away from the pressure line port and toward the reservoir. This graphically represents how a relief valve operates. When pressure in the system overcomes the valve spring (C), flow is from the pressure line through the relief valve to the reservoir.

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Hydraulic systems - Hydraulic systems

Pressure reducing valve A pressure reducing valve is shown as a normally open symbol in a pressure line. This valve works opposite of a relief valve, since it senses outlet pressure (A) versus inlet pressure (B). As the outlet pressure builds, it works against a predetermined spring force. As the spring force is overcome, flow through the valve is reduced or shut off.

RCIL07CCH063AAA

RCIL07CCH062AAA

Sequence valve The normally closed symbol is also used for a sequence valve (A). The inlet port is connected to a primary cylinder (B) and the outlet port to the secondary cylinder line (C). When the piston in the primary cylinder reaches the end of its stroke, the pressure in the supply line increases. The sequence valve is also connected to the supply line and also feels the increase in pressure. As pressure increases, the envelope and directional flow arrow move over, connecting the inlet and outlet ports allowing fluid to flow to the secondary cylinder.

Reference:

Hydraulic systems - Hydraulic symbol - Directional control (35.000) Hydraulic systems - Hydraulic symbol - Composite (35.000) Hydraulic systems - Hydraulic symbol - Flow control (35.000) Hydraulic systems - Hydraulic symbol - Table of symbols (35.000)

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Hydraulic symbol - Directional control One way valve A simple ball check valve is shown. When fluid pressure is exerted on the left side of the ball, the ball is forced into the “V” and no fluid can flow though the valve. When fluid pressure is applied to the right side of the ball, the ball moves away from the “V” and fluid can flow through the valve.

RCIL07CCH066AAA

RCIL07CCH067AAA

Bypass valve A bypass valve is shown as a one-way valve with a spring on the ball end of the symbol. Pressurized flow is necessary to overcome the spring force and allow flow around the ball.

Reference:

Hydraulic systems - Hydraulic symbol - Composite (35.000) Hydraulic systems - Hydraulic symbol - Flow control (35.000) Hydraulic systems - Hydraulic symbol - Table of symbols (35.000)

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Hydraulic symbol - Composite One way valve A more complex one-way valve is shown. This directional control symbol uses multiple envelopes with a separate envelope for each valve position. Within each envelope, arrows show the flow paths when the valve is shifted to that position. NOTE: All port connections are made to the envelope which shows the neutral condition of the valve. The left symbol (A) a one-way valve in the closed position. Mentally visualize a build up of pressure on the right side of the valve symbol (B) to enable free flow through the valve. RCIL07CCH072AAA

RCIL07CCH073AAA

RCIL07CCH074AAA

Two position valve Two envelopes (representing the spool) indicate a two position valve. Each envelopes shows the flow conditions for its position. This simple schematic shows fluid supplied to the rod end of the cylinder (A) from the control valve (B). Return flow is from the piston end of the cylinder through the control valve to tank.

Mentally visualize the directional control valve shifted to the other position. Pressurized fluid is supplied to the piston end of the cylinder (A) from the control valve (B), and return fluid flows from the rod end of the cylinder through the control valve to tank.

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Hydraulic systems - Hydraulic systems

Three position valve Three position valves have a centered (neutral) position. The centered position can be either open or closed to flow. The open center (A) is usually used with a fixed displacement pump, while the closed center (B) is usually used with a variable displacement pump.

RCIL07CCH068AAA

RCIL07CCH069AAA

RCIL07CCH017BAA

Actuating controls Valve spools are controlled by pedals (A), levers (B), pilot fluid (C), electric solenoids (D), etc., which are called actuating controls. These actuating controls are shown by symbols placed on the ends of the envelopes. This symbol (E) is used when a solenoid is controlled with internal pilot assist pressure.

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Hydraulic systems - Hydraulic systems

To show that a valve is spring-centered, a spring symbol is placed at each end of the envelope. This symbol shows that a solenoid and pilot pressure assist are required to overcome spring force to move the valve spool.

RCIL07CCH070AAA

Reference:

Hydraulic systems - Hydraulic symbol - Flow control (35.000) Hydraulic systems - Hydraulic symbol - Table of symbols (35.000)

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Hydraulic symbol - Flow control Restrictors The basic flow control symbol is a restrictor. If the restrictor is adjustable, a slanted arrow is drawn across the symbol. The restrictor could be a special fitting with a small hole in it or a small drilled passageway within a valve. An adjustable restrictor acts like a faucet: adjusting the restriction regulates flow. Restrictors are used to meter and bleed circuits.

RCIL07CCH075AAA

RCIL07CCH078AAA

Adjustable restrictors can be pressure-compensated: the size of the opening in the restrictor changes with increases and decreases in pressure. A perpendicular arrow indicates pressure compensation. If the restrictor has both pressure and temperature compensation, the symbol for a thermometer is added.

Reference:

Hydraulic systems - Hydraulic symbol - Table of symbols (35.000)

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Overview - Cylinder circuit troubleshooting Symptom Steering, Axle slide, Boom cylinders and/or Service brake not operating properly

Possible cause Hydraulic oil level low Hydraulic fluid too cold Hydraulic tank breather plugged Hydraulic hose collapsed Cylinder not working properly

Suction strainer clogged Pressure compensator not working properly Pressure compensated pump worn or damaged Steering does not work properly, hard Hydraulic oil level low steering, slow or no response Steering cylinder not operating properly Suction strainer clogged Pressure compensator not working properly Pressure compensated pump worn or damaged Boom height and/or axle slides do not Hydraulic oil level low work properly, slow or no response Two section valve bank faulty

Boom movement does not work properly, slow or no response

Auto booms do not operate properly

Corrective action Fill hydraulic tank to proper level Warm fluid to the operating temperature 49 Â°C (120 Â°F) Clean or replace breather Replace collapsed hydraulic hose Test steering cylinder. Repair or replace cylinder Clean or replace suction strainer Adjust compensator on pump Replace pump Fill hydraulic tank to proper level Test steering cylinder. Repair or replace cylinder. Replace steering cylinder Clean or replace suction strainer Adjust compensator on pump Replace pump

Fill hydraulic tank to proper level Test valve bank. Repair/Replace two Section valve bank Cylinder faulty Test cylinder. Replace faulty cylinder Hydraulic hose collapsed Replace collapsed hydraulic hose Hydraulic oil level low Fill hydraulic tank to proper level Test valve bank. Repair or replace six Six or eight section valve bank faulty or eight Section valve bank Cylinder faulty Test cylinder. Replace faulty cylinder Hydraulic hose collapsed Replace collapsed hydraulic hose Hydraulic oil level low Fill hydraulic tank to proper level Test valve bank. Repair or replace six Six or eight section valve bank faulty or eight Section valve bank Cylinder faulty Test cylinder. Replace faulty cylinder Hydraulic hose collapsed Replace collapsed hydraulic hose Auto-center switch out of adjustment Test auto-center switch or faulty

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Overview - Manifold The manifold is beneficial for diagnostic purposes. Several capped ports ( G, P2, P5, and P6) are available to install pressure gauges for testing of the pressure compensated pump circuit. 1. A 500 bar ( 5000 psi) gauge may be installed in any of the ( G, P2, P5, and P6) ports. 2. Start the engine and warm the hydraulic oil to 49 Â°C (120 Â°F).

RAIL13SP01409AA

RAIL17SP01376AA

3. As long as no functions are activated, 190 bar (2750 psi) is the reading on the gauge. If the reading on the gauge is not 190 bar (2750 psi), the compensator on the PC pump must be adjusted to bring the pressure to the correct setting: 1. Loosen the locknut, turn the adjustment screw in to increase the pressure and out to lower the pressure. 2. Adjust screw and repeat test until the correct pressure is reached. 3. After desired pressure is obtained, hold the adjustment screw stationary, tighten the locknut.

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Hydraulic schema - Transmission, steering, and spraying NOTE: In this hydraulic diagram, the layout that represents the sprayer boom drive system (reference â&#x20AC;&#x201C; item (20)), is applicable for machines with bar 27 m and 30 m booms. Item (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (29) (30) (31) (32) (33) (34) (35) (36) (37) (38) (39) (40) (41) (42) (43) (44) (47) (49)

Description Hydraulic oil reservoir Hydrostatic pump with control module Pump hydrostatic Multiplier gear box Charge pump filter Brake calipers Brake control valve Rear wheel hubs Front wheel hubs Drain valve Gear pump Hydraulic wheel motors Ladder drive cylinder Active suspension cylinders Control valve Product pump with hydraulic motor Product flow control PWM valve Valve manifold Variable pump with compensator Boom cylinder control/6-section valve Inner boom fold cylinders (right-hand and left-hand) Axle width adjustment cylinders Pressure accumulators Equalizing valves Boom height adjustment cylinders (right-hand and left-hand) Boom leveling cylinders (right-hand and left-hand) Boom height and axle track control valve/2-section valve Steering Cylinders Steering Control Unit Retention valve Hydraulic Return Filter Oil radiator Suction Filters Hydraulic return manifold Outer boom fold cylinders (right-hand and left-hand) Pressure switch Level and temperature sensor Shunt valve Vent Sight glass and temperature gauge Restriction orifice Valve Brake disk Pressure sensor hydraulic valve Pressure sensor

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T1 A1

CCW

A4 B4

1.40:1

.92 GPM

.052

.92 GPM

200

S Fs

B6A

1500 PSI

A6B B6B

3000

A6A

MB L

T1 T2 T3

33 T4

100 PSI

SAE-12

2500 PSI

40 T3

17 41

32 1.16 CIR 2750 PSI

29 PSI

30 18 19

3 PSI

34 51441319_SHT_1

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P4 P7 P2 P3

P 3 PSI

MA R

P1 P6

T G

.041

R T1 T2 a

T G

.042

.047

1.4 CIR

.059

a b

.071

CCW

a b

.059

a b

.052

3 a

.059

a b

.059

.071

B1A A2

a b

1500 PSI

200

A1B B1B

.041

3000

Fs MB

A1A

.92 GPM

.042

23 .047

.92 GPM

a b

.045

MA A

22 A2

27 ab

5 R T1

12 3

.042 DIA.

Hydraulic systems - Hydraulic systems

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Hydraulic systems - Hydraulic schema - Self-leveling booms and automatic steering system 36 m sprayer boom drive system Item (28) (36) (42) (46) (51) (52) (54) (55)

Description Retention valve Outer boom fold cylinders (right-hand and left-hand) Restriction orifice Boom cylinder control/8-section valve Inner boom fold cylinders (right-hand and left-hand) Intermediate boom fold cylinders (right-hand and left-hand) Boom leveling cylinders (right-hand and left-hand) Pressure accumulators

IntelliHeight (optional) â&#x20AC;&#x201C; For machines with 27 m and 30 m booms Item (20) (21) (26) (36) (50)

Description Boom cylinder control/6-section valve Inner boom fold cylinders (right-hand and left-hand) Boom leveling cylinders (right-hand and left-hand) Outer boom fold cylinders (right-hand and left-hand) Boom self-leveling stack valve

IntelliHeight (optional) â&#x20AC;&#x201C; For machines with 36 m booms Item (28) (42) (46) (50) (51) (52) (53) (54) (55)

Description Retention valve Restriction orifice Boom cylinder control/8-section valve Boom self-leveling stack valve Inner boom fold cylinders (right-hand and left-hand) Intermediate boom fold cylinders (right-hand and left-hand) Outer boom fold cylinders (right-hand and left-hand) Boom leveling cylinders (right-hand and left-hand) Pressure accumulators

Automatic steering (optional) Item (30) (47) (48) (59)

Description Steering Control Unit Pressure sensor hydraulic valve Control valve Press sensor (hyd.

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.042

B5 A6

.042

B7 .059

.039

3000

1500 .041 .041

A8A A8B B8B

.047

B8A

1 23

RLT

.042

3000

A2 B2 A3 .059

3000

B8A

.041 .041

1500

A1B B1B B1A

.039

3000

b a

A8A A8B B8B

LV LF

.047 .071

1500 .041 .041

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a b

3000

.047 .039

b a

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b a

.042

B6 .059

.071

LF LV LF

3000

b a

RLT

b a

1 23

b a

3000

1500 PSI

.041

3000

b a

3000

.042

b a

.047

A5 B5 A6A A6B B6B B6A .059

a b

.071

.042

3000

A4 B4 .052

.071

a b

b a

A2 B2 A3 .059

.071

.059

a b

1 51441319_SHT_2

b a

A1B B1B B1A

1500 .041 .041

a b

A3 B3 .052

a b

A1A

3000

.047 .039

1500 PSI

.059

a b

28 LF

b a

3000

.059

A1A A1B B1B B1A A2 B2

.041

.071

RT P T

54 55 51 RV RC

51 P T

51 51 P

21 RV RC

46 RT P

48 B A

a b R L

P P T

.042

a b

42 7 7

200

52 200

55 53 42 5

42 200

52 6 5

42 5

53 4

36 4

55 3 3

26 4

52 36 52

42 200

54 P T

P4 P7 P2 P3 P6

.047

a b

200

54 1 1

26 1

2 2

54 200

P T

51 51 51 51 21 21

P T

28 23

Hydraulic systems - Hydraulic systems

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Hydraulic systems - Hydraulic schema - Flow Divider 4x4 (optional) Item (45)

Description Flow Divider control valve

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LR A

Fa PS

R T1 T2

3 2

B X

X G

T M1

2 B 3

Fs MA

3 GPM

45 G1 G2 A

P 0.6

G2 A

P B

0.6

3 GPM X1

S Fs

3 B 2

1.4 CIR

R T1 T2 a

PS Fa

3 GPM

2 A 3

RR 51441319_SHT_3

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Hydraulic systems - Overhaul - Cylinders NOTICE: If replacing hardware must use the hardware noted in this Machineâ&#x20AC;&#x2122;s Parts Manual.

Cylinder disassembly 1. Clamp the cylinder into a vise in a vertical position with the rod end up. Using the proper sized spanner wrench, remove the head gland (1) from the cylinder tube (2). NOTE: Have a drain pan available to catch any oil coming out of the cylinder parts when the piston rod assembly is removed.

RAIL13SP01585AA

RAIL13SP01586AA

RAIL13SP01587AA

2. Slide the rod (1) out of the cylinder tube (2).

3. Clamp the rod end into vise and remove locknut (1). Then slide piston (2) and gland nut (3) off of the cylinder rod. NOTICE: Do not clamp the polished surface of the rod in a vise. This can damage the surface of the rod.

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4. Inspect piston (1), gland nut (2), cylinder tube (3) and cylinder rod (4) for any damage. NOTICE: Pay close attention for any scoring on the polished end of the rod (4) and cylinder tube (3).

RAIL13SP01588AA

RAIL13SP01589AA

RAIL13SP01587AA

Cylinder assembly 1. Replace all the O-rings, wear bands, deep Z-seal and canned wipers that are provided with the correct seal kit. NOTICE: Make sure all parts are installed in the correct direction. Improper installation of parts can cause leaks. 2. Place rod end in a vise. Slide gland head (1) and piston (2) onto the rod.

3. Apply LOCTITE® 271™ to threads of the piston rod. Install locknut onto rod and torque. NOTE: Use information below for required torque of the cylinder rod nut for the cylinder being assembled.

Torque 288 N·m (212 lb ft) 481 N·m (355 lb ft) 287 N·m (212 lb ft) 481 N·m (355 lb ft) 14 N·m (10 lb ft) 406.75 N·m (300 lb ft) 203 N·m (150 lb ft) 287 N·m (212 lb ft) 288 N·m (212 lb ft)

Rod nut Axle adjust Boom level Inner boom fold 60 ft, 90 ft and 100 ft boom Inner boom fold 120 ft boom Ladder Mid boom fold 120 ft boom Outer boom fold 60 ft, 90 ft and 100 ft boom Parallel link Steering

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4. Liberally apply hydraulic oil to the piston and gland head. 5. Slide the cylinder rod assembly into the cylinder tube. Using the proper sized spanner wrench torque the gland head (1). NOTE: The mid boom fold cylinder on the 120 ft boom uses four tie rod shaft assemblies in place of the gland nut. NOTE: Use information below for required torque of the head gland for the cylinder being assembled.

RAIL13SP01590AA

Torque 305 N·m (225 lb ft) 373 N·m (275 lb ft) 373 N·m (275 lb ft) 305 N·m (225 lb ft) 373 N·m (275 lb ft) 14 N·m (10 lb ft) 217 N·m (160 lb ft) 203 N·m (150 lb ft) 305 N·m (225 lb ft) 305 N·m (225 lb ft)

Gland nut Axle adjust Boom level 60 ft, 90 ft and 100 ft boom Boom level 120 ft boom Inner boom fold 60 ft, 90 ft and 100 ft boom Inner boom fold 120 ft boom Ladder Mid boom fold 120 ft boom Outer boom fold 60 ft, 90 ft and 100 ft boom Parallel link Steering

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Hydraulic systems - Troubleshooting - Fault analysis and possible causes Problem Machine vibrates when leaving

Possible Cause Low diesel engine speed

Correction Check that the working speed of of the diesel engine is 1800 to 2200 rpm Machine operating in “hare” (second gear) Move to “tortoise” (first gear) Drive pumps with pressure issue or differ- Install the pressure gauges on the MB ports of the front and rear pumps. Check in rectient pressures linear movement if the pressures are close (plus or minus 10%). If there is a significant difference, check the orifices of ports X1 and X2, starting with the pump with the lower pressure. If they are normal, check the centering of the pumps. (as per procedure). Machine seems to lose Loss of pressure from the charge pump (G) Check the pressure of G. If the pressure is power and does not reach not correct, adjust G as per procedure. maximum speed Isolate port G of both pumps and check whether the loss of pressure persists. If so, check the setting of the charge pressure limiter valves. Adjust (as per procedure). If adjustment is not possible, remove the valves and clean the valves. If this does not resolve the issue, the pump must be replaced. Isolate the hoses connected to Ps and Loss of command pressure Ps check the pressure of Ps. If the Ps value does not reach a value close to the pressure of the charge pump (G) at maximum speed, the machine will not reach maximum speed. Adjust Ps (as per procedure). If adjustment is not possible, replace valve DA. Connect a pressure gauge to Ps. If the pressure is different from the charge pressure, check the orifice of Ps, which may be clogged and causing the loss of Ps. Drive pumps with pressure issue. Machine seems to lose Check pressures (as per procedures). power, cannot overcome slight obstacles, and does not reach maximum speed. Measure internal pressure, put at maxiPump with oil leak from High internal pressure mum rpm, and install a low-scale pressure the shaft retainer gauge on port R. The pressure should be = < 3 bar. OBS. If > Check whether the drain line is blocked (filter, hoses, etc.) Faulty retainer Replace retainer.

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Problem Machine does not move from “hare” mode to “tortoise” mode.

Possible Cause Loss of transmission performance.

Correction Monitor the MB pressures of the front and rear pump by placing a 600 bar scale pressure gauge on each of the pumps. Check whether an increase in pressure on both lines occurs during a shift in gear. The pressure should approximately double in value. If this happens normally on either pump, check the pumps and motors (as per procedures). If the pressure increase does not happen on either of the pumps, the issue is in the pilot circuit or internal valve of the motors (see below). Electrical system faulty. Test system operation. Note: In “hare,” the solenoid should receive 12 volts. In “tortoise,” the solenoid will not receive any voltage. Remove the solenoid valve. Remove the Spool valve stuck. spool valve. Examine and replace the faulty valve. Gear shift block faulty. Test block: In “hare,” the four pilot hoses of the hydraulic motors should receive a pressure of approximately 30 bar (charge pump pressure). In “tortoise,” this pressure should be at zero. If not, replace the gear shift block. Second speed valves on the hydraulic mo- Test engine: 1st – Disconnect the pilot hose from the motor. Note that when the mators. chine is running in “tortoise/hare” mode and vice-versa, there should be little oil flowing out of the motor. Otherwise, replace the motor or take it to an authorized Rexroth dealer.

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Index Hydraulic systems - 35 Hydraulic systems - 000 Hydraulic systems - Hydraulic symbol - Pressure control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic systems - Calibration - Pressure tapping points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic systems - Hydraulic schema - Flow Divider 4x4 (optional) . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic systems - Hydraulic schema - Self-leveling booms and automatic steering system . . . . .

Hydraulic systems - Hydraulic schema - Transmission, steering, and spraying . . . . . . . . . . . . . . . . .

Hydraulic systems - Hydraulic symbol - Composite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic systems - Hydraulic symbol - Directional control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic systems - Hydraulic symbol - Flow control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic systems - Hydraulic symbol - Schematic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic systems - Hydraulic symbol - Table of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic systems - Overhaul - Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic systems - Overview - Cylinder circuit troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic systems - Overview - Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic systems - Troubleshooting - Fault analysis and possible causes . . . . . . . . . . . . . . . . . . . . .

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

SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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

SERVICE Oil reservoir Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Oil filters Replace - Charge filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Oil return filter Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Oil cooler/Heat exchanger Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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Oil reservoir - Drain fluid NOTICE: New oil purchased either in bulk or in sealed containers does not meet the cleanliness standards required to insure satisfactory operation and prolonged life of hydrostatic components. Therefore, it is recommended that new oil be pumped into the tank through the return filter, center fitting. NOTICE: All hydraulic fluid is dirty. Anytime the hydraulic system is opened up for repairs and/or anytime fluid is changed or added, it must be assumed that contaminants are being introduced to the system. Cleanliness cannot be overemphasized. Changing the oil filter and oil at the proper intervals is necessary to maintain quality and a reliable system. NOTICE: It is very important when working on any hydraulic system to keep the components and surrounding area being serviced as clean as possible. Pressure wash all mud, grease, oil, and dirt off the area to be opened up and serviced. Before loosening and removing hydraulic fittings and hoses, spray the immediate area around the fittings with a pressure washer. Aerosol degreaser such as brake cleaner or carburetor cleaner are flammable fluids, If used, do not smoke and use only in a well ventilated area. Have threaded plugs and/or caps of the proper size in hand to install immediately. Do not leave hoses or hydraulic components exposed.

Hydraulic tank draining 1. Clean the tank top and filter areas before proceeding. 2.

Slowly loosen the breather to release the pressure from the hydraulic tank (1).

RAIL15SP00386AA

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3. Position a collection container with an appropriate volume below the drain hose (1). NOTE: The hydraulic tank capacity is 109.8 l (29 US gal).

SOIL18SP00164AA

SOIL18SP00161AA

4. Open the drain valve (1) and then drain the hydraulic tank. 5. Once drained, close drain valve (1) on the bottom of the hydraulic tank. Tighten breather at top of tank.

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Oil reservoir - Remove WARNING Escaping fluid! If a hydraulic hose, line, or pipe shows signs of wear or damage, replace the component IMMEDIATELY. Failure to comply could result in death or serious injury. W0297A

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

1. Disconnect the connector (1) of the oil temperature/ level sensor wiring harness. 2. Disconnect the connector (2) of the return filter restriction sensor wiring harness.

SOIL17SP00041AA

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3. Disconnect the following oil return hoses: • Return (1) from the power solenoid valves of the wheel motors. • Return (2) from the smaller variable displacement pump. • Return (3) from the tandem pump (front pump). • Return (4) from the tandem pump (rear pump). • Return (5) from the product pump motor and from the wheel motors. • Return (6) from the oil radiator. NOTE: Label all of the hoses that will be disconnected for the proper connection port. This precaution is essential for correct connection when you reinstall the oil reservoir.

SOIL17SP00042AA

SOIL18SP00162AA

SOIL18SP00163AA

NOTICE: Install clean plugs on all connections and on the disconnected hoses to prevent contamination of the hydraulic system. 4. Disconnect the following oil hoses: • gear pump oil hose (1). • hydrostatic pump oil hose (2). • hydrostatic pump oil hose (3). • variable pump oil hose (4).

5. Disconnect the hoses (1), (2), and (3). Move the hoses you have just disconnected through the opening (4), backwards from the reservoir.

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6. Disconnect the hoses (1), (2), (3), (4), (5), and (6). Move the hoses through the opening (7) on the righthand side of the hydraulic reservoir, backwards from the reservoir.

SOIL18SP00165AA

SOIL17SP00048AA

RAIL13SP04946AA

7. On both sides of the hydraulic reservoir, remove the bolts (1). Remove the hoist eyes (2).

8. Support the hydraulic reservoir with a lifting device. Secure the handles and the lift straps at the proper points.

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9. Remove the bolts (1) at the base of the hydraulic reservoir, on both sides. 10. Remove the hydraulic reservoir from the machine.

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SOIL18SP00166AA

SOIL18SP00167AA

Hydraulic systems - Reservoir, cooler, and filters

Oil reservoir - 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

Connect a suitable lifting device onto the tank. Position the tank in its housing.

RAIL13SP04946AA

SOIL18SP00167AA

SOIL18SP00166AA

SOIL17SP00048AA

2. Install the bolts (1) at the base of the hydraulic reservoir, on both sides. Torque.

3. Install the hoist eyes in the cradle (1). Install the bolts (2) on both sides of the hydraulic reservoir. Torque the bolts.

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4. Remove the lifting straps, clevises, and eyelets of the reservoir from the overhead crane.

RAIL13SP04946AA

RAIL13SP04945AA

SOIL18SP00165AA

SOIL18SP00163AA

5. Connect the oil return tube at the filter housing.

6. Route the hoses through the opening (1) on the righthand side of the hydraulic reservoir. Install the hose (2) at the top of the left-hand side of the right-hand upper block manifold. Install the hose (3) on the left-hand side of the variable pump. Install the hose (4) on the left-hand side of the left-hand upper block. Install the hose (5) on the left-hand side of the gear pump. Install the hose (6) on the side of the left-hand lower block. Install the hose (7) on the side of the left-hand upper block. 7. Route the hoses through the opening (1) on the lefthand side of the hydraulic reservoir Install the hose (2) at the top of the right-hand side of the right-hand upper block manifold. Install the hose (3) on the left-hand side of the righthand lower block manifold. Install the hose (4) on the left-hand side of the left-hand upper block manifold.

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8. Install the following oil hoses: • gear pump oil hose (1). • hydrostatic pump oil hose (2). • hydrostatic pump oil hose (3). • variable pump oil hose (4).

SOIL18SP00162AA

9. Route the pump drive vent hose up to the left hand side rail and secure with the strap clamp.

RAIL13SP04933AA

RAIL13SP04932AA

10. Connect the hydraulic return lines as labeled during disassembly.

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11. Route the harness and connect hydraulic level/temperature harness lead to the sensor (1) and the filter restriction harness lead to the sensor (2).

RAIL13SP04931AA

RAIL13SP04768AA

12. Refill the hydraulic tank. See . Oil reservoir - Drain fluid (35.300) 13. Start the engine and run in neutral at a minimum of 1500 RPM. 14. Allow the engine to run at 1500 RPM with the vehicle in neutral for a minimum of 20 min to filter and warm the hydraulic oil prior to any operation. 15. Run the machine for at least 1 h under light load to complete the hydraulic oil filtration. 16. Shut down machine and check for leaks.

Hydraulic tank strainer servicing WARNING Chemical hazard! Always wear protective clothing and goggles when cleaning with solvents, acids, or alkaline chemical agents. Always follow the chemical manufacturer's instructions. Failure to comply could result in death or serious injury. W0180A

WARNING Flying debris! Compressed air can propel dirt, rust, etc. into the air. Wear eye and face protection when using compressed air. Failure to comply could result in death or serious injury. W0307A

1. Pressure wash the outside and top of the hydraulic tank. Do this before starting the following procedure. 2. Drain hydraulic tank. See Oil reservoir - Drain fluid (35.300).

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3. Remove all four hydraulic suction strainers. 4. Clean strainers using solvent. Dry them off completely with compressed air. 5. Inspect hydraulic suction strainers for damage. Replace as required. 6. Apply sealant to threads and install the strainers. 7. Fill the hydraulic tank. See Oil reservoir - Drain fluid (35.300). 8. Start the engine and run in neutral at a minimum of 1500 RPM. 9. Allow the engine to run at 1500 RPM with the vehicle in neutral for a minimum of 20 min to filter and warm the hydraulic oil prior to any operation. 10. Run the machine for at least 1 h under light load to complete the hydraulic oil filtration. 11. Shut down machine and check for leaks.

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RAIL13SP01436AA

Hydraulic systems - Reservoir, cooler, and filters

Oil reservoir - Filling 1. Check whether the drain valve (1) under the hydraulic reservoir is closed.

SOIL18SP00161AA

SOIL16SP00073AA

SOIL17SP00028AA

SOIL16SP00073AA

2. Open the latch (1). 3. Tip the parts (2) and (3) of the engine hood.

4. Remove the filling plug (1) from the return filter housing (2). 5. Fill the reservoir with NEW HOLLAND AMBRA HI TECH 68 oil. Monitor the level through the sight glass (3). NOTE: The new oil, in bulk or in sealed containers, does not meet the cleanliness standards required to ensure a satisfactory operation and long service life of the hydrostatic components. Therefore, it is recommended that new oil be pumped into the tank through the plug hole (1). NOTE: There is a temperature gauge built into the level sight glass (3). 6. Close the parts (1) and (2) of the engine hood. 7. Apply the latch (3). 8. To warm up and filter the hydraulic oil, proceed as follows: â&#x20AC;˘ Run the engine at a speed of 1500 RPM, with the machine in neutral, for at least 20 min. â&#x20AC;˘ Run the machine under normal load conditions for at least 1 h to complete the oil filtering.

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Oil filters - Replace - Charge filter WARNING Escaping fluid! The hydraulic tank is a pressurized system. Vent tank slowly by loosening the breather before performing work on the hydraulic system. Failure to comply could result in death or serious injury. W1047A

WARNING Crushing hazard! Before performing service under the machine, park the machine on a level surface, engage the parking brake, and stop the engine. Put blocks at the front and rear of the tires. Failure to comply could result in death or serious injury. W0350A

CAUTION Burn hazard! Exhaust surfaces are hot! Always wear protective gloves when cleaning or working on or near the muffler, catalytic converter, or exhaust stack. Failure to comply could result in minor or moderate injury. C0142A

1. Clean the tank top and filter areas. Vent hydraulic tank by slowly loosening the breather (1).

RAIL13SP04670AA

SOIL17SP00484AA

2. Install the new hydraulic charge filters (2) on the dual hydrostatic pumps. Use a strap-type wrench or filter wrench to rotate the filters counter-clockwise as viewed from the bottom. 3. Lubricate the gasket on the new filters with clean hydraulic oil. Install the hydraulic charge filter (2). Rotate the filter clockwise on the threads of the adapter until the gasket makes contact. Tighten the filter 1/2 to 3/4 turn after the gasket makes contact with the adapter. Do not tighten too much. Do not use a filter wrench to tighten the filter.

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4. Fill the hydraulic oil tank with hydraulic oil through the plug (1) in the top of in-tank return filter and pump oil into tank through this port. Do not drop foreign material in the tank. Reinstall the plug. Check the level (2). 5. Allow the engine to run at 1500 RPM with the vehicle in neutral for a minimum of 20 minutes to filter and warm the hydraulic oil prior to any operation and then recheck the fluid level. 6. Run the machine for at least 1 hour under load to complete the hydraulic oil filtration. NOTICE: There must be oil in the tank when the engine is running. If the pumps do not receive oil, severe pump damage is possible within 10 seconds. RAIL13SP04110AA

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Oil return filter - Replace WARNING Escaping fluid! The hydraulic tank is a pressurized system. Vent tank slowly by loosening the breather before performing work on the hydraulic system. Failure to comply could result in death or serious injury. W1047A

1. Clean the tank top and filter areas. Vent hydraulic tank by slowly loosening the breather (1).

RAIL13SP04670AA

2. Remove the four bolts (3) on the top cover of the return filter housing.

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3. Pull the cover up and remove filter element (4) from cover. Install new filter element and reinstall filter cover with four bolts.

RCPH11BEN206BAM

RAIL13SP04110AA

4. Fill the hydraulic oil tank with hydraulic oil through the plug (5) in the top of in-tank return filter and pump oil into tank through this port. Do not drop foreign material in the tank. Reinstall the plug. Check the level with the level gauge (6). 5. Allow the engine to run at 1500 RPM with the vehicle in neutral for a minimum of 20 minutes to filter and warm the hydraulic oil prior to any operation and then recheck the fluid level. 6. Run the machine for at least 1 hour under load to complete the hydraulic oil filtration. NOTICE: There must be oil in the tank when the engine is running. If the pumps do not receive oil, severe pump damage is possible within 10 seconds.

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Oil cooler/Heat exchanger - Test The purpose of an oil cooler is to take heat out of the hydraulic system. 1. Use a temperature gun to determine the difference between the inlet (1) and outlet (2) temperatures on the cooler itself. NOTE: The left hand oil cooler is shown. The inlet is to the front of the machine. The right hand cooler also has the inlet to the front of the machine. 2. If there is not a difference between the temperatures, the cooler is not functioning properly. See cooler fin cleaning. 3. Use heat gun again and determine if the cleaning corrected the problem between the inlet (1) and outlet (2) temperatures on the cooler itself. If the cooler is still not functioning the cooler needs to be replaced. See hydraulic oil cooler. RAIL13SP05070AA

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Oil cooler/Heat exchanger - Remove Prior operation: If replacing hardware, must use the hardware noted in this Machineâ&#x20AC;&#x2122;s Parts Manual. Prior operation: Power wash area around radiator assembly. Prior operation: Remove the engine cowling. Engine hood - Remove (90.105) Prior operation: Remove the aftercooler. See Aftercooler - Remove (10.310).

Hydraulic oil cooler removal WARNING Escaping fluid! The hydraulic tank is a pressurized system. Vent tank slowly by loosening the breather before performing work on the hydraulic system. Failure to comply could result in death or serious injury. W1047A

1. Slowly loosen the breather cap (1) until the pressure is bled from the hydraulic tank to remove the pressure from the hydraulic tank.

RAIL13SP01405AA

RAIL13SP05069AA

Right hand cooler. 2. Disconnect the outlet (1) and inlet (2) hoses from the right hand oil cooler. NOTE: Clean all connections to be removed with an aerosol degreaser and brush before loosening. Repeat flush with aerosol degreaser with fitting backed out 2-3 turns. NOTE: Immediately cap or plug any connection opened with clean, threaded caps and plugs.

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5. Remove the clean out panel.

RAIL13SP05071AA

RAIL13SP05073AA

RAIL13SP05070AA

6. Remove the bolts securing the right hand cooler to the cooling package frame.

7. Slide the cooler out the right hand side of the cooling package.

Left hand cooler 8. Remove the right hand oil cooler. 9. Disconnect the inlet (1) and outlet (2) hoses from the left hand oil cooler. NOTE: Clean all connections to be removed with an aerosol degreaser and brush before loosening. Repeat flush with aerosol degreaser with fitting backed out 2-3 turns. NOTE: Immediately cap or plug any connection opened with clean, threaded caps and plugs.

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10. Remove the clean out panel.

RAIL13SP05072AA

RAIL13SP05075AA

11. Remove the bolts securing the left hand oil cooler to the cooling package frame and slide the cooler to the right hand of the machine.

12. Slide the cooler out the right hand side of the cooling package.

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Oil cooler/Heat exchanger - Install Left hand cooler 1. Install and slide the left-hand oil cooler to the left-hand side of the cooling assemble frame. Secure with the original bolts. 2. Tighten screws to 27 – 31 N·m (20 – 23 lb ft) .

RAIL13SP05075AA

RAIL13SP05072AA

RAIL13SP05070AA

3. Assemble the clean out panel to the cooling package frame. 4. Tighten screws to 14 – 16 N·m (10 – 12 lb ft) .

5. Connect the inlet (1) and outlet (2) hoses to the left hand oil cooler. NOTE: Uncap or unplug any connection that has been capped or plugged during disassembly.

Right hand cooler 6. Install and slide the right-hand cooler into the cooling assembly frame on the right-hand side of the machine.

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7. Assemble the bolts securing the right hand cooler to the cooling package frame. 8. Tighten screws to 27 – 31 N·m (20 – 23 lb ft) .

RAIL13SP05073AA

RAIL13SP05071AA

RAIL13SP05069AA

5. Assemble the clean out panel. 6. Tighten screws to 14 – 16 N·m (10 – 12 lb ft) .

7. Connect the outlet (1) and inlet (2) hoses to the right hand oil cooler. NOTE: Uncap or unplug any connection that has been capped or plugged during disassembly.

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8. A. Install a new in-tank return filter on the auxiliary hydraulic circuit. B. Start the engine and run in neutral at a minimum of 1500 RPM. C. Allow the engine to run at 1500 RPM with the vehicle in neutral for a minimum of 20 min to filter and warm the hydraulic oil prior to any operation. D. Run the machine for at least one hour under light load to complete the hydraulic oil filtration. E. Shut down machine and check for leaks. 9. Top up the hydraulic tank through the fitting on the top of the filter housing (1). 10. Install the aftercooler. (10.310).

See Aftercooler - Install

11. Install the engine cowling, refer to Engine hood - Install (90.105).

RAIL13SP01405AA

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Index Hydraulic systems - 35 Reservoir, cooler, and filters - 300 Oil cooler/Heat exchanger - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil cooler/Heat exchanger - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil cooler/Heat exchanger - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil filters - Replace - Charge filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil reservoir - Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil reservoir - Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil reservoir - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil reservoir - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil return filter - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Hydraulic systems - 35 Fixed displacement pump - 104

SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Hydraulic systems - 35 Fixed displacement pump - 104

TECHNICAL DATA Pump General specification - Gear pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Pump - Overview - Gear pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Pump Flow test - Gear pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Remove - Gear pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Install - Gear pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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Pump - General specification - Gear pump General specifications

SOIL17SP00571AA

Brand Location

axle

Offset (Vg) Maximum pressure Rpm range Mounting flange Ports

Rexroth Mounted at the rear of the left-hand hydrostatic pump (1) Type Outer spline 11 # of tines Pitch 16 / 32 Pressure angle 30° Base diameter 15,1229 mm Primitive diameter 17,4625 mm 17,8994 mm – 17,9705 mm Outer diameter 2,4562 mm (maximum) Circular thickness of tooth 2,3901 mm (minimum) Turning direction Counter-clockwise 1 cm³/rev@ 200 cm³/rev 300 bar 500 RPM - 10000 RPM 2 screws 1 inlet port (pressure) 1 outlet port (suction)

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Sectional view

SOIL18SP00180FA

Item 1 2 3 4 5 6 7 8

Details Axial seal Rear cover Front flange Pressure side Suction side Axial pressure field Axial pressure field seal Housing seal

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Pump - Overview - Gear pump

RAIL13SP01383AA

The hydraulic gear pump (1) is mounted on the rear of the left-hand hydrostatic pump. This pump supplies oil to the PWM (Pulse Width Modulated) product control valve which in turn supplies the product pump hydraulic motor. The gear pump has a displacement of 1.4 CIR, which results in a maximum hydraulic oil flow output of 70.7 l/min (18.7 US gpm).

Fluid conditioning Any time this machine is running, the gear pump is constantly filtering and cooling the hydraulic oil. The hydraulic oil flows from the gear pump to the PWM product control valve. The PWM product control valve is located in front of the product tank. If the product system is not running, the oil will flow through the PWM product control valve and exit through the “T” port and flow through the return manifold, hydraulic cooler, return filter and into system reservoir. If the product system is running, the required oil to achieve the desired application rate will leave the PWM product control valve through the “M1” port and go to the product pump motor. The return oil from the product pump motor enters the PWM valve through “M2” port and combines with the oil flow that was not used to run the product system. The oil then flows through the return manifold, hydraulic cooler, return filter and into system reservoir.

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RAIL13SP01400FA

1. 2. 3. 4.

PWM product control valve “M1” port motor supply “M2” port motor return “T” port return to tank

5. 6. 7. 8.

“P” port supply from gear pump Product pump motor Motor return to tank Motor inlet/supply

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SOIL18SP00179FA

Item 1 2 3 4

Details Outer spline shaft Inlet port (pressure) Mounting flange Outlet port (suction)

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Pump - Flow test - Gear pump NOTE: A 0 – 100 l/min (0 – 26.4 US gpm) flowmeter is necessary for this test. NOTICE: Before opening any hydraulic connections, the area must be thoroughly cleaned of any possible contaminant. Use great care not to introduce contaminants into the hydraulic system. 1. Disconnect the “P” port supply hose (1) at the PWM product pump control valve (2). Connect this supply hose to the flowmeter inlet port. Connect the flowmeter outlet port hose back to the open “P” port on PWM product pump control valve. Make sure the load valve on flowmeter is fully open. NOTICE: Be sure the pump flow is connected to flowmeter inlet. Reverse flow through a flowmeter can cause severe damage. 2. Engage the park brake and start the engine. Allow the hydraulic system to warm up to 49 °C (120 °F). RAIL13SP01401AA

PIIL18SP00006AA

RAIL13SP01403AA

3. At the pumping station controls place the liquid pump switch (1) into the manual position. Once the system is warmed up hold the engine RPM switch (2) up to increase the engine RPM to 2200 RPM. 4. The flowmeter reading should be approximately 63 – 70 l/min (16.6 – 18.5 US gpm). Record the flow value. 5. While watching the flowmeter, slowly increase the pressure by adjusting the load valve on flowmeter. Adjust the pressure to approximately 100 bar (1450 psi). As the pressure is increased the out flow reading should remain close to the value recorded in previous step. If the flow rate drops below 57 l/min (15.0 US gpm) the pump is losing efficiency. If the performance of the sprayer system is poor, replace pump. 6. Return engine to low idle. Shutoff engine. Remove flowmeter from circuit and connect supply back to “P” port. NOTE: Anytime the hydraulic system(s) is opened up for repairs, tests and/or anytime fluid is changed or added, it must be assumed that contaminates are being introduced to the system. Cleanliness cannot be overemphasized. Changing the oil filter and oil at the proper intervals is necessary to maintain a reliable hydraulic system. NOTE: If a system component failed. The hydraulic system in-tank return filter must be replaced. Please see Oil return filter - Replace (35.300) .

8. Start the engine and run in neutral at a minimum of 1500 RPM.

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9. Allow the engine to run at 1500 RPM with the vehicle in neutral for a minimum of 20 min to filter and warm the hydraulic oil prior to any operation. 10. Run the machine for at least 1 h under light load to complete the hydraulic oil filtration. 11. Shut down machine and check for leaks.

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Hydraulic systems - Fixed displacement pump

Pump - Remove - Gear pump NOTE: If replacing hardware must use the hardware noted in this Machineâ&#x20AC;&#x2122;s Parts Catalog. NOTE: The gear pump tests can be found in Pump - Flow test - Gear pump (35.104).

Gear pump removal NOTE: Clean all connections to be removed with an aerosol degreaser and brush before loosening. Repeat flush with aerosol degreaser with fitting backed out 2-3 turns. NOTE: Cap or plug any connection that is opened with clean caps and plugs. NOTE: Some oil may still be in hoses, drain into proper container. NOTE: Tag and label all hoses prior to removal. 1. Disconnect the negative cables (1) from the batteries. 2. Power wash area around hydraulic pumps. 3.

Drain hydraulic tank. Please see Oil reservoir - Drain fluid (35.300) .

SOIL17SP00403AA

RAIL13SP01445AA

4. Disconnect the hose from the T fitting as shown. Drain the oil into a suitable container. NOTE: Clean all connections to be removed with an aerosol degreaser and brush before loosening. Repeat flush with aerosol degreaser with fitting backed out 2-3 turns.

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5. Disconnect the hose from the T fitting as shown.

RAIL13SP01446AA

RAIL13SP01447AA

RAIL13SP01448AA

RAIL13SP01449AA

6. Disconnect the hose from the left-hand 90-degree fitting.

7. Disconnect hose from the right-hand 90-degree fitting.

8. Loosen jam nut on the left-hand 90-degree fitting and remove fitting from the gear pump.

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9. Loosen jam nut on the right-hand 90-degree fitting and remove fitting from the gear pump.

RAIL13SP01450AA

RAIL13SP01451AA

RAIL13SP01452AA

10. Remove two mounting bolts and washers.

11. Remove the gear pump.

12. Remove O-ring.

RAIL13SP01453AA

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Pump - Install - Gear pump NOTE: New O-rings need to be installed on any fittings that are being installed. 1. Install a new O-ring on to the pump. NOTE: Lubricate O-ring with clean petroleum jelly.

RAIL13SP01454AA

RAIL13SP01452AA

RAIL13SP01451AA

RAIL13SP01450AA

2. Install the gear pump.

3. Secure the pump with two mounting bolts and washers.

4. Install 90-degree fitting on right-hand side of pump and tighten jam nut in position shown.

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5. Install 90° fitting on left-hand side of pump and tighten jam nut in position shown.

RAIL13SP01449AA

RAIL13SP01448AA

RAIL13SP01447AA

RAIL13SP01446AA

6. Connect the hose to the right-hand 90° fitting.

7. Connect the hose to the left-hand 90° fitting.

8. Connect the hose to T fitting as shown.

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9. Connect the hose to T fitting as shown.

RAIL13SP01445AA

10. Connect the negative cables (1) on the batteries. 11. Fill the hydraulic tank. Please see Oil reservoir Drain fluid (35.300) . 12. Bleed the air and any impurities from the system by using the following procedure. 13. Install a new in-tank return filter on the auxiliary hydraulic circuit. 14. Start the engine and run at 1500 RPM with the vehicle in neutral for a minimum of 20 min to filter and warm the hydraulic oil prior to any operation. 15. Run the machine for at least 1 h under light load to complete the hydraulic oil filtration. 16. Shut down machine and check for leaks.

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SOIL17SP00403AA

Index Hydraulic systems - 35 Fixed displacement pump - 104 Pump - Overview - Gear pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump - Flow test - Gear pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump - General specification - Gear pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump - Install - Gear pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump - Remove - Gear pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Hydraulic systems - 35 Variable displacement pump - 106

SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Hydraulic systems - 35 Variable displacement pump - 106

TECHNICAL DATA Variable displacement pump General specification - Variable pump with compensator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Variable displacement pump Overview - Variable pump with . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Pump Overview - Pressure compensated pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SERVICE Pump Remove - Variable pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install - Variable pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Variable displacement pump - General specification - Variable pump with compensator General specifications

SOIL17SP00501FA

Brand Type Location Axle type # of tines Pitch Pressure angle Turning direction Offset (Vg) Maximum pressure Maximum flow rate Mounting flange

Rexroth Variable pump with compensator Mounted at the rear of the right-hand hydrostatic pump (1) Outer spline 13 16 / 32 30Â° Counter-clockwise 20,3 cmÂł/rev 190 bar 60,6 L/min 2 screws

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Ports

SOIL18SP00184FA

Item B S L L1

Details Inlet port (pressure) Outlet port (suction) Drain port Drain port

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Variable displacement pump - Overview - Variable pump with

SOIL18SP00183FA

Item 1 2 3

Details Outer spline shaft Mounting flange Balancer

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Pump - Overview - Pressure compensated pump The pressure compensated pump supplies oil for a variety of functions. As the oil leaves the pump, it flows to the pressure compensated manifold. From there it flows out to the boom height/axle adjust block, the steering circuit and the service brake, and finally to the six section valve. All the functions listed above are supplied oil by a variable displacement, pressure compensated pump. The pressure compensated pump is mounted on the rear of the right-hand hydrostatic pump. This pump has a maximum displacement of 1.16 CIR with a stand-by (maximum) pressure setting of 190 bar (2750 psi). Maximum hydraulic oil flow capability of this pump is 58.6 l/min (15.5 US gpm). (1.16 CIR x 2200 RPM x 1.4) / 231 = 15.47. NOTE: This is a variable displacement pump, only the amount of oil required to perform the task/work will be generated. With no functions in this circuit activated, there is no flow. The stand-by pressure reading can be accomplished by installing a 500 bar ( 5000 psi) pressure gauge in one of the unused ports located on the manifold valve which is located underneath the machine just in front of rear cross member. Please see Hydraulic systems - Overview Manifold (35.000) .

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RAIL17SP01376AA

Hydraulic systems - Variable displacement pump

Pump - Remove - Variable pump Prior operation: If you replace hardware, use the hardware specified in the Parts Catalog of this machine. Prior operation: Power wash the area around the hydraulic pumps. 1.

Drain the hydraulic tank. See Pump-drive assembly Drain fluid (19.121) . NOTE: Clean all connections to be removed with an aerosol degreaser and brush before loosening. Repeat flush with aerosol degreaser with fitting backed out 2-3 turns. 2. Loosen all four clamp bolts (1). Remove the half of the clamp (2). Disconnect the inlet hose from the pump (3). NOTE: Plug and cap all disconnected hoses, fittings and ports. 3. Disconnect the hose from the left-hand side of the variable pump (4)

SOIL17SP00483AA

SOIL17SP00484AA

4. Loosen all four clamp bolts (1). Remove the half of the clamp (2). Disconnect the outlet hose from the pump (3). 5. Disconnect the hose from the right-hand side of the variable pump (4)

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6. Remove the bolts (1) and the washers (2) on both sides. Remove the variable pump.

SOIL17SP00485AA

RAIL13SP04781AA

7. Remove the O-ring.

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Pump - Install - Variable pump NOTE: New O-rings need to be installed on any fittings that are being installed. 1. Install a new O-ring on the pressure compensated pump. NOTE: Lubricate the O-ring with clean petroleum jelly.

RAIL13SP04781AA

SOIL17SP00485AA

SOIL17SP00484AA

2. Install the variable pump in its housing. Install the two washers (1) and mounting bolts (2) on both sides. Torque.

3. Connect the hose of the right-hand side of the variable pump (1). 4. Make sure that the O-ring is in place. Position the outlet hose (2) in place under the half of the clamp (3). Install the other half of the clamp with the bolts (4). Torque.

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5. Make sure that the O-ring is in place. Position the inlet hose (1) in place under the half of the clamp (2). Install the other half of the clamp with the washers (3) and the bolts (4). Torque. 6. Install the hose of the left-hand side of the variable pump (5). 7. Fill the hydraulic tank. See Oil reservoir - Drain fluid (35.300) . 8. Bleed the air and any impurities from the system by using the following procedure. 9. Install a new in-tank return filter on the auxiliary hydraulic circuit. 10. Start the engine and run at 1500 RPM with the vehicle in neutral for a minimum of 20 min to filter and warm the hydraulic oil prior to any operation. 11. Run the machine for at least 1 h under light load to complete the hydraulic oil filtration. 12. Shut down machine and check for leaks.

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SOIL17SP00483AA

Index Hydraulic systems - 35 Variable displacement pump - 106 Pump - Install - Variable pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump - Overview - Pressure compensated pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump - Remove - Variable pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Variable displacement pump - General specification - Variable pump with compensator . . . . . . . . .

Variable displacement pump - Overview - Variable pump with . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Hydraulic systems - 35 Charge pump - 105

SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Hydraulic systems - 35 Charge pump - 105

SERVICE Charge pump Pressure setting Checking and adjusting the charge pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Pressure setting Checking and adjusting neutral position (if the machine moves in neutral) . . . . . . . . . . 4 Pressure setting Checking and adjusting neutral position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Pressure setting - Checking and adjusting the pump Ps (adjustment through the DA valve) . . . . . . . . . . 6 Pressure setting - Checking and adjusting the cut-off pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Pressure setting - Checking and adjusting the relief pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Hydraulic systems - Charge pump

Charge pump - Pressure setting Checking and adjusting the charge pump 1. Install the pressure gauge (1) with a 0 a 70 bargraduated scale on port G (2) of the charge pump. 2. With the diesel engine in any speed range, the pressure found should be approximately 30 bar. (pressure can vary approx. 2 bar according to the speed).

SOIL17SP00498AA

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Charge pump - Pressure setting Checking and adjusting neutral position (if the machine moves in neutral) 1. First, install two pressure gauges (1) with a 0 รก 600 bar graduated scale on ports MA (2) and MB (3) of the pump. 2. Connect lines X1 (4) and X2 (5). With the diesel engine at working speed and in neutral gear (it is recommended that you release the HW lever), 3. the pressure found on both gauges should be equal. Replace with pressure gauges with a 0 รก 70 bar scale. 4. Any differences should be corrected in the mechanical adjustment of the cylinder (6). SOIL17SP00499AA

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Hydraulic systems - Charge pump

Charge pump - Pressure setting Checking and adjusting neutral position 1. Install two pressure gauges (1) with a 0 รก 70 bar graduated scale on ports X1 (2) and X2 (3) of the pump. 2. With the diesel engine at working speed and in neutral gear (it is recommended that you release the HW lever), 3. the pressure found on both pressure gauges should be equal. 4. Any differences should be corrected in the return adjustment (4).

PIIL18SP00001AA

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Hydraulic systems - Charge pump

Charge pump - Pressure setting - Checking and adjusting the pump Ps (adjustment through the DA valve) 1. Install the pressure gauge (1) with a 0 รก 70 bargraduated scale on port G (2) of the drive pump 2. Run the engine at idle speed. Release the parking brake. Check the pressure, which should be low, and equal to or less than approximately 07 bar. Move the joystick forward and make sure that the machine does not move. 3. Check the change in pressure due to the increase in speed (neutral gear). 4. Adjust the machine start-up to 1250 rpm. PIIL18SP00002AA

A = Start of check

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Hydraulic systems - Charge pump

Charge pump - Pressure setting - Checking and adjusting the cut-off pressure 1. On a flat surface free of obstacles, chock the machine so that the machine cannot move. 2. Install a pressure gauge (1) with a graduated scale up to 600 bar on each pump. (Port MB (2) machine moving forward, port MA (3) machine moving in reverse). 3. With the machine in â&#x20AC;&#x153;hareâ&#x20AC;? mode (second gear), the engine at 2300 RPM, and the brakes released, move the joystick forward. Note that the pressures on both pressure gauges should be the same at 410 bar. The difference between the two pressure values should not exceed 10%.

PIIL18SP00003AA

NOTICE: If this difference is exceeded, adjust the pumps so that the values stay within this established range

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Hydraulic systems - Charge pump

Charge pump - Pressure setting - Checking and adjusting the relief pressures 1. After you check the cut-off pressure, check the measurement of the cut-off pressure screw. Fully close the cut-off valve adjustment screw. 2. With the machine in â&#x20AC;&#x153;hareâ&#x20AC;? mode (second gear), the engine at 2300 rpm, and the brakes released, move the joystick forward. Note that the pressures on both pressure gauges should be the same at 410 bar. The difference between the two pressure values should be approximately 10% greater than the cut-off adjustment. 3. Return the cut-off valve to its original adjustment

PIIL18SP00004AA

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Index Hydraulic systems - 35 Charge pump - 105 Charge pump - Pressure setting - Checking and adjusting the cut-off pressure . . . . . . . . . . . . . . . . .

Charge pump - Pressure setting - Checking and adjusting the pump Ps (adjustment through the DA valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Charge pump - Pressure setting - Checking and adjusting the relief pressures . . . . . . . . . . . . . . . . .

Charge pump - Pressure setting Checking and adjusting the charge pump . . . . . . . . . . . . . . . . . . . .

Charge pump - Pressure setting Checking and adjusting neutral position . . . . . . . . . . . . . . . . . . . . . .

Charge pump - Pressure setting Checking and adjusting neutral position (if the machine moves in neutral) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Hydraulic systems - 35 Stabilizer hydraulic system - 703

SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Hydraulic systems - 35 Stabilizer hydraulic system - 703

SERVICE Stabilizer cylinder Remove - Active suspension, shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install - Active suspension, shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Hydraulic systems - Stabilizer hydraulic system

Stabilizer cylinder - Remove - Active suspension, shock absorber WARNING Escaping fluid! The hydraulic tank is a pressurized system. Vent tank slowly by loosening the breather before performing work on the hydraulic system. Failure to comply could result in death or serious injury. W1047A

NOTE: It is not necessary to remove the suspension spring to remove shock absorber/suspension cylinder. 1. Power wash entire machine, especially around area to be worked on. 2. Remove the pressure from the hydraulic tank by slowly loosening the breather cap until pressure is bled from the hydraulic tank. Tighten breather. NOTE: This is only required if working on the front suspension cylinders.

RAIL14SP00274AA

RCPH11BEN046BAU

3. Disconnect hydraulic lines (1) and remove bolts (2) from the lower area of the shock absorber. NOTE: The hydraulic lines are only on the front suspension cylinders. NOTE: Clean all connections to be removed with an aerosol degreaser and brush before loosening. Repeat flush with aerosol degreaser with fitting backed out 2-3 turns. Immediately cap or plug any connection that is opened with clean, threaded caps and plugs.

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4. Remove the nuts from the upper shock absorber/suspension cylinder mount and remove the cylinder through the lower mount area. NOTE: There is no overhaul for the rear shock absorber.

RCPH11BEN047BAU

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Hydraulic systems - Stabilizer hydraulic system

Stabilizer cylinder - Install - Active suspension, shock absorber WARNING Unexpected movement! When cylinders are connected to the machine hydraulic system, cycle the hydraulic circuits several times to remove air from the cylinder and hose. Air in the system can cause erratic operation or can cause equipment to drop unexpectedly. Failure to comply could result in death or serious injury. W1083A

1. Install the shock through the lower shock mount area and apply anti-seize to the threads. Install the nuts on the upper mount and tighten to compress rubber and urethane to achieve the correct dimension. Install and tighten jam nut. Front suspension cylinder compress the urethane bushing 3 mm (0.1 in) (A). Rear shock absorber- 4 mm (0.2 in) (B).

RCPH11BEN047BAU

RCPH11BEN046BAU

2. Install bolts (1) and hydraulic lines (2).

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Hydraulic systems - Stabilizer hydraulic system

3. Install a new in-tank return filter on the auxiliary hydraulic circuit. NOTE: This step is only required if installing a front suspension cylinder. 4. Start the engine and run in neutral at a minimum of 1500 RPM. 5. While driving the machine depress the traction assist pedal to cycle the cylinder five times to move any air and debris to the tank. 6. Allow the engine to run at 1500 RPM with the vehicle in neutral for a minimum of 20 min to filter and warm the hydraulic oil prior to any operation. 7. Run the machine for at least one hour under light load to complete the hydraulic oil filtration. 8. Shut down the machine and check for leaks.

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RAIL14SP00274AA

Hydraulic systems - Stabilizer hydraulic system

Stabilizer cylinder - Disassemble 1. Clamp the cylinder into a vise in a vertical position with the rod end up. Using the proper sized spanner wrench, remove the head gland (1) from the cylinder tube (2). NOTE: Have a drain pan available to catch any oil coming out of the cylinder parts when the piston rod assembly is removed.

RCPH11BEN167BAU

RCPH11BEN081BAU

RCPH11BEN070BAU

2. Slide the rod (1) out of the cylinder tube (2).

3. Clamp the rod end into vise and remove locknut (1). NOTE: Do not clamp the polished surface of the rod in a vise. This can damage the surface of the rod. 4. With a spanner wrench that has 3.96 mm (0.156 in) pins, unscrew the piston (2) from the rod. 5. Slide the gland (3) off of the cylinder rod.

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Hydraulic systems - Stabilizer hydraulic system

6. Inspect piston (1), gland nut (2) cylinder tube (3) and cylinder rod (4) for any damage. NOTE: Pay close attention for any scoring on the polished end of the rod (4) and cylinder tube (3).

RCPH11BEN083BAU

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Hydraulic systems - Stabilizer hydraulic system

Stabilizer cylinder - Assemble 1. Replace all the O-rings, wear bands, deep Z-seal and canned wipers that are provided with the correct seal kit. NOTE: Make sure all parts are installed in the correct direction. Improper installation of parts can cause leaks. 2. Place rod end in a vise. NOTE: Do not clamp the polished surface of the rod in a vise. This can damage the surface of the rod. 3. Slide gland (1) onto the rod. 4. Apply LOCTITE® 271™ to threads of the piston rod. 5. With a spanner wrench that has 3.96 mm (0.156 in) pins, screw the piston onto the piston rod. Torque the piston to 68 – 88 N·m (50 – 65 lb ft).

RCPH11BEN070BAU

RCPH11BEN300BAM

6. Install the piston rod nut and torque to 61 – 75 N·m (45 – 55 lb ft). 7. Liberally apply hydraulic oil to the piston and gland. 8. Slide the cylinder rod assembly into the cylinder tube. 9. With the proper sized spanner wrench, torque the gland (1) to 102 N·m (75 lb ft).

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Index Hydraulic systems - 35 Stabilizer hydraulic system - 703 Stabilizer cylinder - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stabilizer cylinder - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stabilizer cylinder - Install - Active suspension, shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stabilizer cylinder - Remove - Active suspension, shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Hydraulic systems - 35 Track frame widening system - 735

SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Hydraulic systems - 35 Track frame widening system - 735

SERVICE Track widening cylinder Remove - Axle adjust cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install - Axle adjust cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Hydraulic systems - Track frame widening system

Track widening cylinder - Remove - Axle adjust cylinder Prior operation: If replacing hardware, must use the hardware noted in this Machineâ&#x20AC;&#x2122;s Parts Manual. Prior operation: Power wash entire machine, especially around area to be worked on. 1.

Remove the pressure from the hydraulic tank by slowly loosening the breather cap until pressure is bled from the hydraulic tank. Tighten breather. RAIL13SP01405AA

RAIL13SP01566AA

RAIL13SP01567AA

2. NOTE: Clean all connections to be removed with an aerosol degreaser and brush before loosening. Repeat flush with aerosol degreaser with fitting backed out 2-3 turns. NOTE: Label hoses prior to removal. NOTICE: Immediately cap or plug any connection opened with clean, threaded caps and plugs. Disconnect hydraulic lines.

3. Remove bolts holding axle slide bar. (Outer end of bar shown). NOTE: Lower slide bar straight down to remove from tube.

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Hydraulic systems - Track frame widening system

4. Move slide bar (1) away from axle adjusting cylinder to allow room to remove cylinder pin (2). Place a proper supporting device under slide bar assembly. Remove cotter pin and washer then remove pin. NOTE: Steering cylinder does not need to be removed from slide bar.

RAIL13SP01568AA

RAIL13SP01569AA

5. Remove bolt holding rod end of cylinder to axle and remove cylinder.

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Hydraulic systems - Track frame widening system

Track widening cylinder - Install - Axle adjust cylinder 1. Install bolt holding cylinder rod to axle.

RAIL13SP01569AA

RAIL13SP01568AA

RAIL13SP01567AA

RAIL13SP01566AA

2. Install cylinder pin (1), washer (2), and cotter pin (3).

3. Move slide bar into position and install mounting bolts (outer end shown).

4. Install hoses to cylinder.

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Hydraulic systems - Track frame widening system

6. Install a new in-tank return filter on the auxiliary hydraulic circuit. 7. Start the engine and run in neutral at a minimum of 1500 RPM.

RAIL13SP01405AA

RAIL13SP01554AA

8. Properly jack and support the axle. 9. Remove the axle stop bolt (1). 10. Cycle the cylinder five times through complete stroke to move any air and debris to the tank. 11. Install bolt into the position it was removed from. 12. Lower the machine off the support. 13. Allow the engine to run at 1500 RPM with the vehicle in neutral for a minimum of 20 min to filter and warm the hydraulic oil prior to any operation. 14. Run the machine for at least 1 h under light load to complete the hydraulic oil filtration. 15. Shut down the machine and check for leaks.

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Index Hydraulic systems - 35 Track frame widening system - 735 Track widening cylinder - Install - Axle adjust cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Track widening cylinder - Remove - Axle adjust cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Hydraulic systems - 35 Sprayer hydraulic system - 911

SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Hydraulic systems - 35 Sprayer hydraulic system - 911

TECHNICAL DATA Product pump hydraulic motor - General specification Product Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Sprayer hydraulic system Sprayer hydraulic system - Overview - Boom cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Control valves Overview - Two section valve bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Overview - Six or eight section valve bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 External view - Six or eight section valve bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Product pump hydraulic motor Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

SERVICE Sprayer hydraulic system Test - Boom cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Remove - Boom height cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Install - Boom height cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Boom fold cylinders Remove - Inner boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Install - Inner boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Remove - Outer boom (27, 30 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Install - Outer boom (27 and 30 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Remove - Outer and mid boom (120 foot) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Install - Outer and mid boom (120 foot) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Boom level cylinder Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Ladder cylinder Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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Remove - Two section valve bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Disassemble - Two section valve bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Assemble - Two section valve bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Install - Two section valve bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Test - Two section valve bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Service instruction - Eight section valve bank, bleeding procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Remove - Six or eight section valve bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Install - Six or eight section valve bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Test - Six or eight section valve bank, solenoid test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Test - Six or eight section valve bank, solenoid function test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 - Test - Six or eight section valve bank, function check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Test - Six or eight section valve bank, relief valve test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Adjust - Six or eight section valve bank, relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Product pump hydraulic motor Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Flow test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

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Hydraulic systems - Sprayer hydraulic system

Product pump hydraulic motor - General specification Product Pump

PIIL18SP00014AA

Pump Specifications Type of pump Inlet port Outlet port Flow Intermediate pressure Assembly approximate weight Engine type Volumetric displacement Flow Inlet pressure Output Pressure Oil Temp.

Centrifugal 1.5 in NPT 1.25 in NPT 473.2 L/min (125.0 US gpm) 11.7 bar (170.0 psi) 6 kg Hydraulic motor specifications Gerotor 0.6 cm³/rev 60.6 L/min (16.0 US gpm) 165.5 bar (2400.0 psi)– Continuous 206.9 bar (3000.0 psi)– Intermediate 10.3 bar (150.0 psi)– Continuous 20.7 bar (300.0 psi)– Intermediate 82.2 °C (180.0 °F)– Maximum 4.4 °C (40.0 °F)– Minimum

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Hydraulic systems - Sprayer hydraulic system

Sprayer hydraulic system - Overview - Boom cylinders Boom cylinders 27 m and 30 m boom

SOIL18SP00154FA

Inner boom fold cylinder Once the switch has been activated to command a boom movement, the hydraulic cartridge changes positions to allow oil to travel to either the rod or blind end of the cylinder. The schematics show that pilot operated check valves are present on both the pressure and tank lines. These check valves provide the mechanism that keeps the cylinders in place when the cartridge is in its normal or centered state. • There are orifices on each of the lines going to the cylinders, both rod and blind end. These orifices control the speed at which the cylinders extend or retract. • There are also two relief valves on this circuit. These relief valves provide circuit protection in a boom breakaway circumstance. The relief valve for the blind end is set to 200 bar (2900 psi), while the relief valve for the rod end is set to 100 bar (1450 psi).

Outer boom fold cylinder The outer boom cylinder operates with dual pilot operated check valves and an orifice in the rod end side of the circuit. The check valves provide the “locking” mechanism to keep the booms where they were set, and the orifice provides a “flow control” which limits the speed at which the cylinder stroke will travel.

Boom level cylinders Once the boom level cylinder is commanded to raise or retract, the pilot operated check valve is opened by the pressure needed to retract the cylinder. NOTE: This allows the displaced oil from the rod end side of the cylinder to dump to the tank line in the manifold. There is a relief valve on the blind end or extend portion of the manifold. The relief valve is set to 14 bar (203 psi) and is responsible for providing protection on the extend function of the circuit, such as cradling the boom. 48149953 12/06/2018

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Boom cylinders 36 m boom

SOIL18SP00155FA

Middle and outer boom fold cylinders The middle and outer boom cylinders operate with check valves and a 200 bar (2900 psi) counter-balance valve on both rod and blind cylinder ports. The check valves provide the “locking” mechanism to keep the booms where they were set, and the counter-balance valves provides a “flow control” which limits the speed at which the cylinder stroke will travel.

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Control valves - Overview - Two section valve bank The valve block for the axle adjust and boom height is a two section valve bank and is located on the underside, just in front of the rear cross frame member. This valve bank receives its hydraulic fluid from the pressure manifold. The two cartridges are not the same. The float center cartridge is for the axle adjust function (1) and the closed center cartridge is for the boom height function (2). The hydraulic cartridges are NOT interchangeable. The solenoid coils are interchangeable. If problems are experienced with either of the two above mentioned functions, some simple testing can be done to rule out the valve block. If the valve block is faulty it will need to be repaired or replaced.

RAIL13SP01410AA

RAIL13SP01411AA

RAIL13SP01412AA

RAIL13SP01413AA

Axle adjust The axles are commanded to move by activating the momentary toggle switch inside the right hand armrest of the cab. The hydraulic valve changes its position and ports oil to either the blind end of the cylinders to extend the axles or the rod end of the cylinders to retract the axles. Once the switch is returned to the center position, the hydraulic valve centers and the pilot operated check valves hold the axle cylinders in their set position.

Boom height adjustment The boom height function is operated by a momentary rocker switch. To raise the center section height, oil is ported out the “A1” port and travels to the counter-balance valves, which are located on the cylinder barrels. The oil pilots open the counter-balance valve on the rod side and oil passes through the check valve and into the blind side of the cylinder, which extends the cylinder and raises the center section. To lower the center section height, oil is ported out the “B1” port and travels to the counter-balance valves. Pilots open the valve on the blind side and oil passes through the check valve on the rod side. This retracts the cylinder and lowers the center section. Once the center section is at its desired height, release the rocker switch and the counter-balance valves (1) will hold the boom height position. The counter-balance valves act as a check valve, keeping the center section at the desired height and provide circuit/cylinder protection. NOTE: The counter-balance valve setting on this component is set to 152 bar (2200 psi). NOTE: If a center section seems to settle and the seals in the cylinders test satisfactorily, it is possible for the oil to be leaking past the check valve portion of the counterbalance valve.

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Control valves - Overview - Six or eight section valve bank NOTICE: If replacing hardware, must use the hardware noted in this Machineâ&#x20AC;&#x2122;s Parts Manual. All the boom functions except for the boom height are controlled by the boom valve bank. This valve bank is located on the top center of the mast center section.

27 m and 30 m booms: The 27 m and 30 m boom models use a six-function valve bank. These functions include: Left inner boom fold, Left boom level, Left outer boom fold, Right outer boom fold, Right boom level, and Right inner boom fold. RAIL13SP01415AA

36 m boom: The 36 m boom models use an eight-function valve bank. These functions include: Left inner boom fold, Left boom level, Left middle boom fold, Left outer boom fold, Right outer boom fold, Right middle boom fold, Right boom level, and Right inner boom fold. NOTE: Hydraulic oil is supplied to this manifold from the pressure compensated pump at a stand-by pressure of 190 bar (2750 psi). As long as no function has been activated, there is no flow and a hydraulic pressure of 190 bar (2750 psi).

Six function valve bank: The six function valve bank solenoids are all 12 V solenoids, when a solenoid is energized it is full ON and when de-energized full OFF.

Eight function valve bank: Only two of the eight function valve bank solenoids are 12 V, ON or OFF type solenoids, the left and right boom level solenoids. The remaining six are 12 V Pulse Width Modulated (PWM) solenoids. The PWM solenoids are variable flow and are controlled by a controller.

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Control valves - External view - Six or eight section valve bank Six function valve bank solenoid identification

RAIL13SP01416FA

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

Left inner boom fold Left boom level Left outer boom fold Right outer boom fold Right boom level Right inner boom fold

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

Left inner boom fold 1500 psi rod end relief valve Left inner boom fold 3000 psi blind end relief valve Left boom level 200 psi blind end relief valve Right boom level 200 psi blind end relief valve Right inner boom fold 1500 psi rod end relief valve Right inner boom fold 3000 psi blind end relief valve

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Eight function valve bank solenoid identification

RAIL13SP01417FA

1. 2. 3. 4. 5. 6. 7.

Left inner boom fold Left boom level (non PWM) Left middle boom fold Left outer boom fold Right outer boom fold Right middle boom fold Right boom level (non PWM)

8. 9. 10. 11. 12. 13. 14.

Right inner boom fold Left inner boom fold 1500 psi rod end relief valve Left inner boom fold 3000 psi blind end relief valve Left boom level 200 psi blind end relief valve Right boom level 200 psi blind end relief valve Right inner boom fold 1500 psi rod end relief valve Right inner boom fold 3000 psi blind end relief valve

NOTE: When disassembling components from the valve block, make sure the area is clean of debris and new seals are always utilized.

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Product pump hydraulic motor - Overview The product pump hydraulic motor (1) is a gear style with a displacement of 0.7 CIR. The motor has a maximum pressure rating of 172.36 bar (2500 psi). Product pump motor testing can be found in Product pump hydraulic motor - Flow test (35.911).

PIIL18SP00014AA

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Sprayer hydraulic system - Test - Boom 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. Start engine and warm the hydraulic oil to a minimum of 49 Â°C (120 Â°F). 2. Fully extend or retract the cylinder in question. 3. Disconnect the hydraulic line from the end of the cylinder with the least amount of available volume. NOTE: Disconnect the rod end if the cylinder is fully extended, or disconnect blind end if the cylinder is fully retracted. 4. Place the disconnected hose in a collection container. 5. Activate the function so as to attempt to extend a fully extended or retract a fully retracted cylinder. NOTE: If no oil is collected, or only drops per minute, the seal is ok. If leakage is substantial the cylinder will have to be repaired or replaced. 6.

Install a new in-tank return filter on the auxiliary hydraulic circuit. RAIL13SP01403AA

7. Start the engine and run in neutral at a minimum of 1500 RPM. 8. Cycle the cylinder five times through complete stroke to move any air and debris to the tank. 9. Allow the engine to run at 1500 RPM with the vehicle in neutral for a minimum of 20 min to filter and warm the hydraulic oil prior to any operation. 10. Run the machine for at least 1 h under light load to complete the hydraulic oil filtration. 11. Shut down the machine and check for leaks.

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Sprayer hydraulic system - Remove - Boom height cylinder Prior operation: If replacing hardware, must use the hardware noted in this Machine’s Parts Manual. Prior operation: Power wash entire machine, especially around area to be worked on. 1. Position center section so the cylinder pin is visible through the opening. NOTE: This hole is located on the parallel link mounting frame. 2.

RAIL13SP01405AA

RAIL13SP01575AA

Support the center section with proper lifting device. 3.

Remove the pressure from the hydraulic tank by slowly loosening the breather cap until pressure is bled from the hydraulic tank. Tighten breather.

4. NOTE: Mark the hydraulic lines for proper installation. NOTE: Clean all connections to be removed with an aerosol degreaser and brush before loosening. Repeat flush with aerosol degreaser with fitting backed out 2-3 turns. NOTICE: Immediately cap or plug any connection opened with clean, threaded caps and plugs. NOTE: Slowly loosen “B” port cylinder hose, allowing pressure to bleed off the rod side of the cylinder. Disconnect hydraulic lines on the cylinder.

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5. Remove roll pin from cylinder mount pin.

RAIL13SP01576AA

RAIL13SP01574AA

RAIL13SP01577AA

6. Remove cylinder pin through opening in mount.

7. Remove cylinder pin from rod end of cylinder. Remove the cylinder.

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Sprayer hydraulic system - Install - Boom height cylinder 1. Position cylinder in place, install rod end of cylinder and install pin (1). Install nut and bolt (2). Torque to 44 – 61 N·m (32 – 45 lb ft).

RAIL13SP01577AA

RAIL13SP01574AA

RAIL13SP01575AA

2. Install cylinder pin through opening in mount into base end of cylinder and install new roll pin.

3. Connect hydraulic lines.

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WARNING Unexpected movement! When cylinders are connected to the machine hydraulic system, cycle the machine remote lever several times to remove air from the cylinder and hose. Air in the system can cause erratic operation or can cause equipment to drop unexpectedly. Failure to comply could result in death or serious injury. W0347A

5. Install a new in-tank return filter on the auxiliary hydraulic circuit. 6. Start the engine and run in neutral at a minimum of 1500 RPM. 7. Cycle the cylinder five times through complete stroke to move any air and debris to the tank. 8. Allow the engine to run at 1500 RPM with the vehicle in neutral for a minimum of 20 min to filter and warm the hydraulic oil prior to any operation. 9. Run the machine for at least 1 h under light load to complete the hydraulic oil filtration. 10. Shut down the machine and check for leaks.

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RAIL13SP01405AA

Hydraulic systems - Sprayer hydraulic system

Boom fold cylinders - Remove - Inner boom Prior operation: If replacing hardware, must use the hardware noted in this Machineâ&#x20AC;&#x2122;s Parts Manual. Prior operation: Power wash entire machine, especially around area to be worked on. 1.

Remove the pressure from the hydraulic tank by slowly loosening the breather cap until pressure is bled from the hydraulic tank. Tighten breather. RAIL13SP01405AA

RAIL13SP01570AA

2. NOTE: Clean all connections to be removed with an aerosol degreaser and brush before loosening. Repeat flush with aerosol degreaser with fitting backed out 2-3 turns NOTICE: Immediately cap or plug any connection opened with clean, threaded caps and plugs. Disconnect hydraulic lines (1), remove bolts (2) and remove cylinder.

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Boom fold cylinders - Install - Inner boom 1. Install cylinder, install pins (1) connect the hydraulic lines (2). Lube grease zerks with lithium 2 grease. NOTE: When installing cylinder have all grease zerks facing the rear of the machine and hydraulic ports away from the center section.

RAIL13SP01570AA

RAIL13SP01405AA

3. Install a new in-tank return filter on the auxiliary hydraulic circuit. 4. Start the engine and run in neutral at a minimum of 1500 RPM. 5. Cycle the cylinder five times through complete stroke to move any air and debris to the tank. 6. Allow the engine to run at 1500 RPM with the vehicle in neutral for a minimum of 20 min to filter and warm the hydraulic oil prior to any operation. 7. Run the machine for at least 1 h under light load to complete the hydraulic oil filtration. 8. Shut down the machine and check for leaks.

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Boom fold cylinders - Remove - Outer boom (27, 30 ft) Prior operation: If replacing hardware, must use the hardware noted in this Machineâ&#x20AC;&#x2122;s Parts Manual. Prior operation: Cylinder can be removed and installed with boom folded or unfolded. Prior operation: Power wash entire machine, especially around area to be worked on. 1.

Remove the pressure from the hydraulic tank by slowly loosening the breather cap until pressure is bled from the hydraulic tank. Tighten breather. RAIL13SP01405AA

RAIL13SP01571AA

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Boom fold cylinders - Install - Outer boom (27 and 30 ft) 1. Install cylinder, install pins (1) and connect hydraulic lines (2).

RAIL13SP01571AA

RAIL13SP01405AA

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Boom fold cylinders - Remove - Outer and mid boom (120 foot) Prior operation: If replacing hardware, must use the hardware noted in this Machineâ&#x20AC;&#x2122;s Parts Manual. Prior operation: Outer boom fold cylinder removal and installation shown. Procedure is the same for the mid boom cylinder. Prior operation: Unfold the booms. See Operator Manual. Prior operation: Power wash entire machine, especially around area to be worked on. 1.

Remove the pressure from the hydraulic tank by slowly loosening the breather cap until pressure is bled from the hydraulic tank. Tighten breather. RAIL13SP01405AA

RAIL13SP01572AA

2. Disconnect hydraulic lines (1), remove mounting bolt (2) and pin (3). Remove the cylinder. NOTE: Clean all connections to be removed with an aerosol degreaser and brush before loosening. Repeat flush with aerosol degreaser with fitting backed out 2-3 turns. NOTICE: Immediately cap or plug any connection opened with clean, threaded caps and plugs. NOTE: There is no overhaul procedure for these cylinders.

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Boom fold cylinders - Install - Outer and mid boom (120 foot) 1. Install the cylinder. Install the pin (1) and mounting bolt (2). Connect the hydraulic lines (3). Install nut (4) and torque nut to 68 NÂˇm (50 lb ft). Install jam nut (5) and torque to 136 NÂˇm (100 lb ft).

RAIL13SP01573AA

RAIL13SP01405AA

WARNING Unexpected movement! When cylinders are connected to the machine hydraulic system, cycle the hydraulic circuits several times to remove air from the cylinder and hose. Air in the system can cause erratic operation or can cause equipment to drop unexpectedly. Failure to comply could result in death or serious injury. W1083A

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Boom level cylinder - Remove Prior operation: Boom should be in the cradle or supported properly to perform this task. Prior operation: If replacing hardware, must use the hardware noted in this Machineâ&#x20AC;&#x2122;s Parts Manual. Prior operation: 100 ft boom level cylinder removal and installation shown. Procedure is the same for all boom level cylinders. Prior operation: Power wash entire machine, especially around area to be worked on. 1.

Remove the pressure from the hydraulic tank by slowly loosening the breather cap until pressure is bled from the hydraulic tank. Tighten breather.

RAIL13SP01405AA

RAIL13SP01578AA

WARNING Crushing hazard! When assembling or adjusting the implement, block up raised sections. Be sure each section is stable before assembly. Never rely on a jack or hydraulic device to support a raised implement. Failure to comply could result in death or serious injury. W0118A

NOTE: Clean all connections to be removed with an aerosol degreaser and brush before loosening. Repeat flush with aerosol degreaser with fitting backed out 2-3 turns. NOTICE: Immediately cap or plug any connection opened with clean, threaded caps and plugs. NOTE: Slowly loosen the hydraulic hose fittings at the cylinder ports allowing the pressure to bleed off. Disconnect hydraulic lines (1), remove the cylinder pins (2) and remove the cylinder.

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Boom level cylinder - Install 1. Install the cylinder, cylinder pins (1), and the hydraulic lines (2). Apply lithium #2 grease to the grease zerks.

RAIL13SP01578AA

RAIL13SP01405AA

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Ladder cylinder - Remove Prior operation: . If replacing hardware, must use the hardware noted in this Machineâ&#x20AC;&#x2122;s Parts Manual. Prior operation: Power wash entire machine, especially around area to be worked on. 1.

Remove the pressure from the hydraulic tank by slowly loosening the breather cap until pressure is bled from the hydraulic tank. Tighten breather. RAIL13SP01405AA

RAIL13SP01579AA

2. NOTE: Clean all connections to be removed with an aerosol degreaser and brush before loosening. Repeat flush with aerosol degreaser with fitting backed out 2-3 turns. NOTICE: Immediately cap or plug any connection opened with clean, threaded caps and plugs. Disconnect hydraulic line (1), remove pins (2) and remove cylinder.

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Ladder cylinder - Install 1. Install the cylinder, install pins (1) and connect the hydraulic line (2).

RAIL13SP01579AA

RAIL13SP01405AA

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Control valves - Remove - Two section valve bank Prior operation: If replacing hardware, must use the hardware noted in this Machineâ&#x20AC;&#x2122;s Parts Manual. Prior operation: The two-section valve bank is located below the radiator. Prior operation: Two-section valve bank testing can be found in Control valves - Test - Two section valve bank (35.911). Prior operation: Power wash entire machine, especially around area to be worked on. 1.

Depressurize the hydraulic tank. Slowly loosen breather until pressure has been bled from the hydraulic tank. Tighten breather. RAIL13SP01357AA

RAIL13SP01545AA

2. Disconnect the wires (1) and six hydraulic lines (2). Remove the mounting bolts (3) and remove the valve. NOTE: Mark the wire harnesses and hydraulic lines for proper installation. NOTE: Clean all connections to be removed with an aerosol degreaser and brush before loosening. Repeat flush with aerosol degreaser with fitting backed out 2-3 turns. NOTICE: Immediately cap or plug any connection opened with clean, threaded caps and plugs.

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Control valves - Disassemble - Two section valve bank 1. Note the position of coil electrical connections for proper installation. Remove the two nuts on solenoid valves and the four coils. Check coils for damage or excessive wear. Replace if necessary.

RAIL13SP01546AA

RAIL13SP01547AA

RAIL13SP01548AA

RAIL13SP01549AA

2. Remove both solenoid valves. Check valve for damage. Replace if necessary.

3. Remove check valve from two-section valve. Check the valve for damage or excessive wear. Replace if necessary. NOTE: There are two check valves in the two section valve assembly. Removal, service, and installation procedures are the same for both

4. Remove pilot piston assembly. Check assembly for damage or excessive wear. Replace if necessary.

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Control valves - Assemble - Two section valve bank NOTE: Lubricate seals before installing the piston. 1. Replace seals on pilot piston and install piston into valve body.

RAIL13SP01549AA

RAIL13SP01550AA

RAIL13SP01547AA

RAIL13SP01551AA

2. Replace O-rings and backing rings on solenoid valve before installation.

3. Lubricate O-rings with hydraulic oil. Install both solenoid valves. Torque to 29.8 NÂˇm (22 lb ft).

4. Install the four coils and two nuts onto solenoid valve. Torque nut to 4 NÂˇm (3 lb ft).

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Control valves - Install - Two section valve bank NOTE: If any of the fittings were removed the O-rings must be replaced. 1. Install the valve. Install mounting bolts (1). Connect the hydraulic lines (2) and wire harnesses (3).

RAIL13SP01545AA

RAIL13SP01357AA

Install a new in-tank return filter on the auxiliary hydraulic circuit. 3. Start the engine and run in neutral at a minimum of 1500 RPM. 4. Allow the engine to run at 1500 RPM with the vehicle in neutral for a minimum of 20 min to filter and warm the hydraulic oil prior to any operation. 5. Fully extend both booms. See the Operatorâ&#x20AC;&#x2122;s Manual. 6. Fully raise and lower booms five times to remove any air from the boom height circuit. 7. Shut down the machine.

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Properly jack and support entire machine. NOTICE: Jack must be rated for minimum 10 t (22046 lb).

RAIL13SP01552AA

RAIL13SP01553AA

RAIL13SP01554AA

8. Remove all four axle adjusting bolts. 9. Start the engine and run in neutral at a minimum of 1500 RPM. 10. Fully extend and retract the axle cylinders five times to remove any air in the axle circuit. 11. Run the machine for at least 1 h under light load to complete the hydraulic oil filtration. 12. Shut down the machine and check for leaks. 13. Lower the entire machine off of jacks.

14. Install all four axle adjusting bolts.

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Control valves - Test - Two section valve bank 1. Check the electrical signal to the boom up/down solenoid (1) and to the axle in/out solenoid (2). Install the test probes and additional lengths of wire up and into the cab. Connect multimeter to wires. NOTE: When testing the solenoids there should be +12 V at the connector during appropriate function is used. Coils should measure 6 – 10 Ω at 20 °C (68 °F) 2. See the Operator Manual for the proper operation of the axle adjust feature and for boom height function. 3. Start the engine and warm the hydraulic oil to a minimum of 49 °C (120 °F). 4. Activate the desired function (axle adjust or boom height adjustment). If neither function is operational, first check other PFC piston pump functions such as steering and boom fold. If the other PFC functions are okay and the electrical checks in Step 1 were good the valve block is faulty it will need to be repaired or replaced. See Control valves - Remove - Two section valve bank (35.911). If only one function is operational (axle adjust or boom height adjustment) remove the faulty valve cartridge, it will need to be repaired or replaced. See Control valves - Remove - Two section valve bank (35.911).

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RAIL13SP01414AA

Hydraulic systems - Sprayer hydraulic system

Control valves - Service instruction - Eight section valve bank, bleeding procedure NOTE: Perform this procedure anytime the valve bank is repaired, replaced or hydraulic lines associated with valve bank are replaced. This procedure is only performed on eight-section bank valve systems ( 36 m boom). 1. Booms must be racked and boom locks in place. 2. Start the engine and run at idle to 1200 RPM. 3. Loosen lock nut and loosen bleed screws on the end of the six proportional valves. The bleed screws may be loosened 2 to 3 turns. 4. Oil should begin to trickle out from bleed screws. 5. Run the machine with bleed screws open for 10 – 20 min. 6. Tighten bleed screws ( 3 – 5 N·m (26.55 – 44.25 lb in)) and tighten lock nut. 7. Unfold the booms. Shut the engine off, wait for approximately 1 min. 8. Start engine and watch for movement on outer tip of booms. 9. If any outer tip movement is detected repeat the bleeding procedure.

RAIL13SP02005BA

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Control valves - Remove - Six or eight section valve bank Prior operation: Power wash entire machine, especially around area to be worked on. 1.

Depressurize the hydraulic tank. Loosen the breather cap. Tighten breather cap after tank pressure is released.

RAIL13SP01357AA

RAIL13SP01555AA

RAIL13SP01556AA

2. Disconnect all wires from the top of the valve. The six section valve bank has twelve wires and the eight section valve bank has sixteen wires. NOTICE: Mark all wire locations.

DANGER Pressurized system! Always remove all pressure before working on the hydraulic system. Follow the pressure BLEED program in the Configuration Mode to remove the pressure in the entire hydraulic system. Failure to comply will result in death or serious injury. D0035A

Disconnect all hydraulic lines. NOTE: Mark hydraulic lines for proper installation. NOTE: Clean all connections to be removed with an aerosol degreaser and brush before loosening. Repeat flush with aerosol degreaser with fitting backed out 2-3 turns. NOTICE: Immediately cap or plug any connection opened with clean, threaded caps and plugs.

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4. Remove the mounting nuts and remove the valve.

RAIL13SP01557AA

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Control valves - Install - Six or eight section valve bank NOTE: f any of the fittings were removed the O-rings must be replaced. 1. Install valve and install mounting bolts.

RAIL16SP00196AA

RAIL16SP00194AA

RAIL13SP01555AA

2. Connect all sixteen hydraulic lines. NOTE: Make sure the O-rings for the hydraulic lines are in place and not damaged.

3. Install all 12 wire connectors.

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DANGER

Unexpected machine movement! Air in the hydraulic system could cause unexpected machine movement. Purge the air from the hydraulic system after any hydraulic system maintenance or repair. Failure to comply will result in death or serious injury. D0054A

DANGER Crushing hazard! Stay clear of the implement when the wings are folded or unfolded. Hydraulic or mechanical failure may cause rapid uncontrolled falling of the wings. Failure to comply will result in death or serious injury. D0108A

5. Install a new in-tank return filter on the hydraulic circuit. 6. Start the engine and run in neutral at a minimum of 1500 RPM. 7. Allow the engine to run at 1500 RPM with the vehicle in neutral for a minimum of 20 min to filter and warm the hydraulic oil prior to any operation. 8. Operate all boom cylinders per the operators manual five times through complete cycles, to move any air and debris to the tank. A. Left boom raise and lower. B. Left boom extend and retract. C. Right boom raise and lower. D. Right boom extend and retract. E. Boom height. F.

Left outer tip extend and retract.

G. Right outer tip extend and retract. 9. Run the machine for at least 1 h under light load to complete the hydraulic oil filtration. 10. Turn off engine and check for leaks. NOTICE: For more testing and adjusting see valve bank testing in Control valves - Test - Two section valve bank (35.911) and Control valves - Adjust - Six or eight section valve bank, relief valve (35.911).

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RAIL13SP01357AA

Hydraulic systems - Sprayer hydraulic system

Control valves - Test - Six or eight section valve bank, solenoid test 1. Connect a wire from the “+” terminal of the solenoid to the positive terminal of a 12 V power source. NOTE: Solenoid electrical terminals are marked “+” and “-” for proper solenoid operation. Identifying marks are found on the end of terminal housing.

RAIL13SP01558AA

RAIL13SP01420AA

2. Connect a wire from the “-” terminal of the solenoid to the negative terminal of a 12 V power source. An audible click should be heard each time the solenoid is energized.

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Control valves - Test - Six or eight section valve bank, solenoid function test NOTE: Solenoid removed for clarity. It is not required to remove the solenoid to accomplish this test. 1. Connect a wire from the “+” terminal of the solenoid to the positive terminal of a 12 V power source. NOTE: Solenoid electrical terminals are marked “+” and “-” for proper solenoid operation. Identifying marks are found on the end of terminal housing.

RAIL13SP01419AB

RAIL13SP01420AA

2. Connect a wire from the “-” terminal of the solenoid to the negative terminal of a 12 V power source. An audible click should be heard each time the solenoid is energized. NOTE: If there is no audible click the solenoid needs to be replaced. Please see Control valves - Remove - Six or eight section valve bank (35.911) . .

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Control valves - Test - Six or eight section valve bank, function check Boom valve bank function check NOTICE: Follow all safety guidelines and procedures outlined in Operator’s Manual when operating boom functions. 1. Follow the Operator Manual procedure for boom operation. Unfold and fold the boom to identify the problem. If no boom functions are operative confirm hydrostatic control is in neutral and that the master power switch is ON. Follow the Operator Manual procedure for boom operation. If no boom functions are operative continue with Step 2. If one boom function is not functioning properly continue with Step 3. 2. Check other PFC piston pump functions such as steering, or axle width adjustment. If the other PFC functions are operating correctly the problem is likely to be electrical. If all the PFC piston pump circuits are inoperative, see Pump - Overview - Product pump circuit troubleshooting (63.100). Check all connectors and the harness between the boom valve bank, the bulkhead connector BH40 located on top of boom assembly just to left of boom valve bank. Follow the harness back to the bulkhead connector BH4 at lower rear of cab. Look for damaged, pinched or loose connections. 3. Locate the solenoid for the problem circuit at the boom bank valve. Use a multimeter to check the resistance of both coils for the problem circuit. For six function valve banks the coil resistance should read from 6 – 8 Ω at 20 °C (68 °F). For eight function valve banks the coil resistance should read from 6 – 8 Ω at 20 °C (68 °F) for non-PWM coils and from 4.5 – 6.5 Ω at 20 °C (68 °F) for PWM coils. If a coil is out of specification or indicates an open circuit (infinite resistance) replace the coil. If the coils are in specification, continue with Step 4. 4. Install test probes onto the solenoid connector with the issue. Add additional lengths of common gauged wire up and into cab. Connect multimeter to wires. Follow the Operator Manual procedure for boom operation. Unfold and fold the boom and monitor the voltage at the problem circuit. If the reading is approximately 12 V the problem is likely hydraulic. The problem solenoid cartridge valve must be removed from the valve bank and inspected. See Control valves - Remove - Six or eight section valve bank (35.911) for proper procedure.

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Control valves - Test - Six or eight section valve bank, relief valve test NOTE: Perform this test if the relief valves are suspected of leaking, or are misadjusted. Equipment needed: 2- 300 bar ( 3000 psi) gauges.

Six section valve bank relief valve setting table NOTE: Port identification is stamped in the valve body. Cylinder function and boom cylinder side (Blind or rod end) LH inner boom fold Blind side LH inner boom fold Rod end side LH boom level Blind side LH boom level Rod end side LH outer boom fold Blind side LH outer boom fold Rod end side RH outer boom fold Blind side RH outer boom fold Rod end side RH boom level Blind side RH boom level Rod end side RH inner boom fold Blind side RH inner boom fold Rod end side

Port identification

Relief pressure setting

A1A and A1B

200 bar (2900 psi)

B1A and B1B

100 bar (1450 psi)

14 bar (203 psi)

N/A

14 bar (203 psi)

N/A

A6A and A6B

200 bar (2900 psi)

B6A and B6B

100 bar (1450 psi)

NOTE: This is for the left-hand inner boom circuit, all other circuits are similar.

Valve bank (eight section) relief valve test NOTE: Perform this test if the relief valves are suspected of leaking, or are misadjusted. Equipment needed: 2- 300 bar ( 3000 psi) gauges.

Eight section valve bank relief valve setting table NOTE: Port identification is stamped in the valve body. Cylinder function and boom cylinder side (Blind or rod end) LH inner boom fold Blind side LH inner boom fold Rod end side LH boom level Blind side LH boom level Rod end side LH middle boom fold Rod end side

Port identification

Relief pressure setting

A1A and A1B

200 bar (2900 psi)

B1A and B1B

100 bar (1450 psi)

14 bar (203 psi)

N/A

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Cylinder function and boom cylinder side (Blind or rod end) LH middle boom fold Blind side LH outer boom fold Blind side LH outer boom fold Rod end side RH outer boom fold Blind side RH outer boom fold Rod end side LH middle boom fold Rod end side LH middle boom fold Blind side RH boom level Blind side RH boom level Rod end side RH inner boom fold Blind side RH inner boom fold Rod end side

Port identification

Relief pressure setting

N/A

14 bar (203 psi)

N/A

A8A and A8B

200 bar (2900 psi)

B8A and B8B

100 bar (1450 psi)

1. Install a 300 bar ( 3000 psi) gauge in the hydraulic line between the valve body (1) and the blind end side of the inner boom fold cylinder. Install a 300 bar ( 3000 psi) gauge in the hydraulic line between the valve body (2) and the rod end side of the inner boom fold cylinder. 2. Activate the function such as to take the boom fold to it's full extent of travel. Record the reading on the corresponding pressure gauge. NOTE: This is for the left-hand inner boom circuit, all other circuits are similar. NOTICE: If the reading does not match the specification on the table in this Section, adjustment is necessary. Please see Control valves - Adjust - Six or eight section valve bank, relief valve (35.911) . 3. Remove the pressure gauges.

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RAIL16SP00195AA

Hydraulic systems - Sprayer hydraulic system

Control valves - Adjust - Six or eight section valve bank, relief valve There are six relief valves: • Two 3.8 l/min (1 US gpm) at 13.8 bar (200 psi) relief valves (1). • Two 3.8 l/min (1 US gpm) at 103.4 bar (1500 psi) relief valves (2). • Two 3.8 l/min (1 US gpm) at 203.3 bar (2950 psi) relief valves (3). NOTE: This is for the left-hand inner boom circuit, all other circuits are similar. See tables in Control valves - Test Six or eight section valve bank, relief valve test (35.911) for port identification and pressure settings. RAIL13SP02006AA

RAIL13SP01418AA

1. Install a 300 bar ( 3000 psi) gauge in the hydraulic line between the valve body (1) and the blind end side of the inner boom fold cylinder. 2. Install a 300 bar ( 3000 psi) gauge in the hydraulic line between the valve body (2) and the rod end side of the inner boom fold cylinder. 3. Take the left-hand inner boom fold to it's full extent of travel. Record the reading on the corresponding pressure gauge. 4. Loosen the jam nut (1) and turn set screw (2) of the end of the relief valve that is out of adjustment. Tighten jam nut. Accomplish Step 3 again. 5. Remove the pressure gauges when the relief valve setting is correct.

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Product pump hydraulic motor - Remove See Pump - Remove - Product pump (63.100) to remove the product pump and motor assembly from the machine. Remove the four cap screws and remove the motor from the product pump.

RAIL13SP01485AA

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Product pump hydraulic motor - Disassemble Prior operation: The work area and hydraulic motor must be clean to prevent contamination of parts. 1. Remove the case drain elbow from the motor. Note the position of the fitting.

RAIL13SP01486AA

RAIL13SP01487AA

RAIL13SP01488AA

2. Remove the pressure and return fittings from the motor.

3. Remove the socket head cap screws from the motor end plate.

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4. Scribe a line on the motor casing (end plate, drive plate and housing) to aid in orientation during assembly.

RAIL13SP01489AA

RAIL13SP01490AA

RAIL13SP01491AA

RAIL13SP01492AA

5. Remove the end plate. NOTE: It may be necessary to tap the end plate with a soft faced hammer to loosen.

6. Remove the idler gear/shaft assembly.

7. Remove the gear housing.

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8. Remove the drive gear and drive gear dowel pin (1) from the shaft. NOTICE: Failure to remove the dowel pin from the shaft will result in damage to the shaft bushing.

RAIL13SP01493AA

RAIL13SP01494AA

9. Use a soft faced hammer and tap the drive shaft/bearing assembly and seal from the drive plate. 10. Remove and discard the O-rings and shaft seal.

Motor inspection 11. Wash all parts in clean solvent. Dry with compressed air.

WARNING Chemical hazard! Always wear protective clothing and goggles when cleaning with solvents, acids, or alkaline chemical agents. Always follow the chemical manufacturer's instructions. Failure to comply could result in death or serious injury. W0180A

• Inspect the motor end plate, drive plate and gear housing for heavy wear or damage. Check the shaft for wear or grooving in the seal area. • Check the gears and bearing for heavy wear or damage. • If any of the above parts have heavy wear or damage, the motor must be replaced.

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Product pump hydraulic motor - Assemble NOTE: Apply clean hydraulic oil to all rotating parts during assembly. 1. Position the drive shaft and bearing assembly (1) in the drive plate. Apply a thin film of clean hydraulic oil onto the seal installation bullet (2). Install the bullet and seal (3) over the shaft tang. Press the seal by hand over the bullet until the seal contacts the drive plate.

RAIL13SP01495AA

RAIL13SP01496AA

RAIL13SP01497AA

RAIL13SP01498AA

2. Position a .937 in deep well socket over the seal and press or tap into the seal cavity until fully seated. Remove the installation bullet. NOTE: Do not install the seal using the seal support spacer.

3. Apply petroleum jelly to the dowel pin and install the pin into the drive shaft.

4. Install the drive gear on the shaft.

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5. Apply petroleum jelly to a new O-ring. Install the O-ring onto the gear housing.

RAIL13SP01499AA

RAIL13SP01500AA

RAIL13SP01501AA

RAIL13SP01502AA

6. Align the scribe marks and install the gear housing onto the drive plate.

7. Install the idler gear/shaft assembly.

8. Apply petroleum jelly to a new O-ring. Install the O-ring onto the gear housing.

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9. Align the scribe marks and install the end plate onto the gear housing.

RAIL13SP01503AA

10. Install the four cap screws.

RAIL13SP01504AA

RAIL13SP01505AA

RAIL13SP01487AA

11. Tighten the four cap screws to a torque of 33 NÂˇm (24 lb ft).

12. Install and tighten the pressure and return fittings from the motor.

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13. Install the case drain. Position as noted during removal.

RAIL13SP01486AA

RAIL13SP01506AA

RAIL13SP01507AA

14. Install the seal support spacer (1) and fill the cavity halfway with coupling grease.

15. Fill the cavity on the product pump halfway with coupling grease.

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Product pump hydraulic motor - Install Align the motor shaft tang and the pump shaft slot and install the motor onto the pump. Rotate the motor to the proper orientation. Install and tighten the four cap screws. Install the motor and product pump assembly onto the machine. Please see Pump - Install - Product pump (63.100) .

RAIL13SP01485AA

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Product pump hydraulic motor - Flow test NOTICE: Do not run the product pump without liquid in the product tank. NOTE: Port identification is stamped in the valve body. 1. Perform the gear pump flow test. The flowmeter reading should be approximately 63 – 70 l/min (16.6 – 18.5 US gpm). If the gear pump is delivering adequate flow, continue with Step 2. 2. Perform the product pump control valve flow test. The flowmeter reading should be approximately 63 – 70 l/ min (16.6 – 18.5 US gpm) when the rate controller is set at maximum duty cycle. If the product pump control valve is delivering adequate flow, the hydraulic motor may have excessive internal leakage. 3. After performing the product pump control valve flow test. Use a temperature gun to determine the temperature difference between the inlet (1), outlet (2) and drain port (3) of the hydraulic motor. If there is excessive internal leakage the drain port temperature will be much higher than inlet and outlet ports, replace hydraulic motor. 4. If the hydraulic motor is okay, the product pump impeller maybe plugged or loose. See Pump - Disassemble - Product pump (63.100) and Pump - Assemble Product pump (63.100).

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PIIL18SP00009AA

Index Hydraulic systems - 35 Sprayer hydraulic system - 911 Boom fold cylinders - Install - Inner boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom fold cylinders - Install - Outer and mid boom (120 foot) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom fold cylinders - Install - Outer boom (27 and 30 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom fold cylinders - Remove - Inner boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom fold cylinders - Remove - Outer and mid boom (120 foot) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom fold cylinders - Remove - Outer boom (27, 30 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom level cylinder - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom level cylinder - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control valves - Test - Six or eight section valve bank, function check . . . . . . . . . . . . . . . . . . . . . . . . .

Control valves - Adjust - Six or eight section valve bank, relief valve . . . . . . . . . . . . . . . . . . . . . . . . . .

Control valves - Assemble - Two section valve bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control valves - Disassemble - Two section valve bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control valves - External view - Six or eight section valve bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control valves - Install - Six or eight section valve bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control valves - Install - Two section valve bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control valves - Overview - Six or eight section valve bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control valves - Overview - Two section valve bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control valves - Remove - Six or eight section valve bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control valves - Remove - Two section valve bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control valves - Service instruction - Eight section valve bank, bleeding procedure . . . . . . . . . . . . .

Control valves - Test - Six or eight section valve bank, relief valve test . . . . . . . . . . . . . . . . . . . . . . . .

Control valves - Test - Six or eight section valve bank, solenoid function test . . . . . . . . . . . . . . . . . . .

Control valves - Test - Six or eight section valve bank, solenoid test . . . . . . . . . . . . . . . . . . . . . . . . . .

Control valves - Test - Two section valve bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ladder cylinder - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ladder cylinder - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Product pump hydraulic motor - General specification Product Pump . . . . . . . . . . . . . . . . . . . . . . . . .

Product pump hydraulic motor - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Product pump hydraulic motor - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Product pump hydraulic motor - Flow test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Product pump hydraulic motor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Product pump hydraulic motor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Product pump hydraulic motor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sprayer hydraulic system - Install - Boom height cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Sprayer hydraulic system - Overview - Boom cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sprayer hydraulic system - Remove - Boom height cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sprayer hydraulic system - Test - Boom cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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CNH Industrial Latin America LTDA, Av. Jerome Case, 1801, Aparecidinha - Socoraba (SP) - Brasil, CEP:18087-220

SERVICE - Technical Publications & Tools

48149953 12/06/2018 EN

SERVICE MANUAL Frames and ballasting SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Frames and ballasting - 39

[39.130] Sprayer boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.1

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SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Frames and ballasting - 39 Sprayer boom - 130

SERVICE Sprayer boom Remove - 27, 30, and 36 meters, with cradle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install - 27, 30, and 36 meters, with cradle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Remove - Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Install - Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Remove - Boom pivot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Install - Boom pivot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Remove - Assembled center section and mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Install - Assembled center section and mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Center section Remove - Mid boom, 36 meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Install - Mid boom, 36 meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Remove - Center section, all . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Install - Center section, all . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Inner boom - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Outer boom Remove - 27-, 30-, and 36-meter boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Install - 60, 90, and 100 foot boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Remove - 120 foot boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Install - 120 foot boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Boom breakaway Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

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Frames and ballasting - Sprayer boom

Sprayer boom - Remove - 27, 30, and 36 meters, with cradle NOTE: If replacing hardware, must use the hardware noted in this Machineâ&#x20AC;&#x2122;s Parts Manual.

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

WARNING Hazard to bystanders! Always know the location of all workers in your area. Warn them before you start working on the machine. Always keep all unauthorized bystanders clear of the area. Failure to comply could result in death or serious injury. W0176A

1. Shut machine off and remove the key. 2. At the center section remove liquid foamer line (1) from solenoid valve and remove the black air line hose (2) from the tee.

RAIL13SP01948AA

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Frames and ballasting - Sprayer boom

3. At the center section, disconnect liquid plumbing hose from valve (1) and disconnect hose from spray bar tee (2). NOTE: Hoses may contain chemical, drain chemical into a container and dispose of properly.

RAIL13SP01949AA

RAIL13SP01357AA

RAIL13SP01957AA

RAIL13SP01951AA

Depressurize the hydraulic tank by slowly loosening the breather cap until pressure is bled from the hydraulic tank. Tighten breather.

5. Disconnect the hoses for outer boom fold cylinder at the six-bank valve (1) located on center section. NOTE: Clean all connections to be removed with an aerosol degreaser and brush before loosening. Repeat flush with aerosol degreaser with fitting backed out 2-3 turns. Immediately cap or plug any connection opened with clean, threaded caps and plugs. NOTE: Mark hoses before removal and take note of hose routing for proper installation.

6. Disconnect the electrical connections at the center section for harnesses to be removed with boom section. NOTE: Mark connectors before removal and take note of wire routing for proper installation. NOTE: This machine is equipped with Aim Command.

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Frames and ballasting - Sprayer boom

7. Pull all disconnected wiring and hoses back to the inner boom. Secure wiring and hoses to the inner boom frame. NOTE: Take note of wiring and hose routing before removal for proper installation.

RAIL13SP01958AA

RAIL13SP01959AA

RAIL13SP01960AA

RAIL13SP01578AA

8. Attach proper lifting device to the inner boom assembly.

9. Remove boom lock pin from the cradle.

10. Remove the nut and bolt (1) from the cylinder pin. While supporting the cylinder, remove the rod end cylinder mounting pin (2).

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11. Remove the nut and bolt (1) from the boom pivot pin (2) and remove the boom pivot pin. Remove the boom. NOTICE: When removing hardened pins such as a pivot pin, or a hardened shaft, use a soft head (brass or bronze) hammer or use a driver made from brass or bronze and a steel head hammer. Failure to comply may result in damage to the machine.

RAIL13SP01961AA

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Frames and ballasting - Sprayer boom

Sprayer boom - Install - 27, 30, and 36 meters, with cradle WARNING Hazard to bystanders! Always know the location of all workers in your area. Warn them before you start operating the machine. Always keep all unauthorized bystanders clear of the work area. Failure to comply could result in death or serious injury. W0206A

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

1. Attach a proper lifting device to the boom. 2. Place the boom into position, install the boom pivot pin (1) and secure with bolt and nut (2). NOTE: Grease the pin prior to installing with LITHIUM HEP251.

RAIL13SP01961AA

RAIL13SP01578AA

3. Attach the cylinder to boom with cylinder mounting pin (1). Install the bolt and lock nut (2) into the cylinder pin. NOTE: Grease the pin prior to installing with LITHIUM HEP251.

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4. Route the hoses and cables. Install the liquid foamer line (1) onto the solenoid valve. Install the black air hose (2) onto the tee.

RAIL13SP01948AA

RAIL13SP01949AA

RAIL13SP01951AA

RAIL13SP01955AA

5. Install liquid plumbing hose onto valve (1) and install hose onto spray bar tee (2).

6. Route the boom wiring harnesses along the center section, and connect to proper connector.

7. Install the two outer boom fold hydraulic lines onto the six-bank valve. NOTE: Secure any loose wires, hoses or lines with plastic ties.

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8. Install a new in-tank return filter on the auxiliary hydraulic circuit. 9. Start the engine and run in neutral at a minimum of 1500 RPM. 10. Cycle all the boom fold cylinders five times through complete stroke to move any air and debris to the tank. 11. Allow the engine to run at 1500 RPM with the vehicle in neutral for a minimum of 20 min to filter and warm the hydraulic oil prior to any operation. 12. Run the machine for at least 1 h under light load to complete the hydraulic oil filtration. 13. Shut down machine and check for leaks.

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Frames and ballasting - Sprayer boom

Sprayer boom - Remove - Mast NOTE: If replacing hardware must use the hardware noted in this Machineâ&#x20AC;&#x2122;s Parts Manual.

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

1. Remove breakaway tips. See Boom breakaway - Remove (39.130). 2. Remove the outer boom. For 60 ft, 90 ft, 100 ft boom, see Outer boom - Remove - 60, 90, and 100 foot boom (39.130). For 120 ft boom, see Outer boom Remove - 120 foot boom (39.130). 3. Remove inner booms. See Inner boom - Remove (39.130). 4. Remove center section. See Center section - Remove - Center section, all (39.130). 5. Attach proper lifting device to support the mast.

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6. Remove nuts and bolts (1) from upper mast mounts and remove pins (2). NOTICE: When removing hardened pins such as a pivot pin, or a hardened shaft, use a soft head (brass or bronze) hammer or use a driver made from brass or bronze and a steel head hammer. Failure to comply may result in damage to the machine.

RAIL13SP01969AA

RAIL13SP01970AA

7. Remove nuts and bolts (1) from the lower mast mounts and remove pins (2). Remove the mast.

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Sprayer boom - Install - Mast WARNING Hazard to bystanders! Always know the location of all workers in your area. Warn them before you start working on the machine. Always keep all unauthorized bystanders clear of the area. Failure to comply could result in death or serious injury. W0176A

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

1. Attach proper lifting device to the mast. 2. Install the mast to the upper parallel arms with pins (1). Install nuts and bolts (2). Torque nuts to 46 – 61 N·m (34 – 45 lb ft).

RAIL13SP01969AA

RAIL13SP01970AA

3. Install the mast to the lower parallel arms with pins (1). Install nuts and bolts (2). Torque nuts to 46 – 61 N·m (34 – 45 lb ft). 4. Install center section. See Center section - Install Center section, all (39.130). 5. Install inner boom sections. See Inner boom - Install (39.130). 6. Install the outer boom. For 60 ft, 90 ft or 100 ft boom, see Outer boom - Install - 60, 90, and 100 foot boom (39.130). For 120 ft boom, see Outer boom - Install 120 foot boom (39.130) . 7. Install breakaway tips. See Boom breakaway - Install (39.130).

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Install a new in-tank return filter on the auxiliary hydraulic circuit. 9. Start the engine and run in neutral at a minimum of 1500 RPM. 10. Cycle all the boom cylinders five times through complete stroke to move any air and debris to the tank. 11. Allow the engine to run at 1500 RPM with the machine in neutral for a minimum of 20 min to filter and warm the hydraulic oil prior to any operation. 12. Run the machine for at least 1 h under light load to complete the hydraulic oil filtration. 13. Shut down the machine and check for leaks.

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Sprayer boom - Remove - Boom pivot WARNING Hazard to bystanders! Always know the location of all workers in your area. Warn them before you start working on the machine. Always keep all unauthorized bystanders clear of the area. Failure to comply could result in death or serious injury. W0176A

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

1. Shut machine off and remove the key. 2. Leave the boom cradled with the travel locking pin installed. 3. Support booms securely with proper overhead lifting device before attempting any service work on the hinge pins. 4. Remove the lock nut and bolt (1) from the cylinder pin (2) on each end of the cylinder. Remove the cylinder pins and set cylinder aside. NOTE: Do not disconnect the hydraulic hoses on the cylinder.

RAIL13SP01971AA

RAIL13SP01972AA

5. Remove the nut and bolt (1) and boom pin (2). Slide boom away from pivot work area.

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6. Remove nut and slide the bolt (1) halfway out, while installing a hook device inside the inner pivot tube and out the bolt hole. Remove the bolt and pull out inner pivot tube (2) while supporting the upper pivot weldment (3). Remove the upper pivot weldment and two washers (4).

RAIL13SP01973AA

RAIL13SP01974AA

RAIL13SP01975AA

7. Remove the nut and bolt from the inner breakaway arm (1).

8. Attach a proper lifting device to the lower pivot weldment (3). Remove the nut and slide the bolt (1) out while securing the inner pivot tube (2) from falling, slowly slide the inner pivot tube down and remove. Remove the lower pivot weldment (3) and washers (4).

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Sprayer boom - Install - Boom pivot WARNING Hazard to bystanders! Always know the location of all workers in your area. Warn them before you start working on the machine. Always keep all unauthorized bystanders clear of the area. Failure to comply could result in death or serious injury. W0176A

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

1. Attach a proper lifting device to lower pivot weldment (1) for installation. Install the lower pivot weldment and washers (2). Install inner pivot tube (3). Align bolt hole and install the bolt (4) and secure with nut. NOTE: Grease inner pivot tube and washers with NLGI NO. 2 MULTI -PURPOSE LITHIUM EP GREASE prior to installation

RAIL13SP01975AA

RAIL13SP01974AA

2. Attach the inner breakaway arm (1) to the lower pivot weldment and secure with bolt (2) and nut.

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3. Attach the boom onto the boom pivot weldment and install the boom pin (1). Secure with nut and bolt (2).

RAIL13SP01972AA

RAIL13SP01973AA

RAIL13SP01971AA

4. Install the cylinder mounting bracket (1) and two washers (2). Install the inner pivot tube (3) and align the bolt hole. Install the bolt and nut (4). Torque bolt to 79 – 107 N·m (58 – 79 lb ft). NOTE: Grease inner pivot tube and washers with NLGI NO. 2 MULTI -PURPOSE LITHIUM EP GREASE prior to installation.

5. Install the cylinder and pins (1). Secure with bolts and lock nuts (2).

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Frames and ballasting - Sprayer boom

Sprayer boom - Remove - Assembled center section and mast NOTE: If replacing hardware must use the hardware noted in this machineâ&#x20AC;&#x2122;s parts manual.

Center section/Mast removal 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

1. Remove breakaway tip. See Boom breakaway - Remove (39.130). 2. Remove the outer boom. For 60 ft, 90 ft or 100 ft boom, see Outer boom - Remove - 60, 90, and 100 foot boom (39.130). For 120 ft, see Outer boom - Remove - 120 foot boom (39.130). 3. Remove inner booms from center section. See Inner boom - Remove (39.130). 4. Remove product hose clamps (1) from manifold located on center section and remove U-bolt (2) holding hose. Remove hose from manifold.

RAIL13SP01962AA

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Depressurize the hydraulic tank by slowly loosening the breather cap until pressure is bled from the hydraulic tank. Tighten breather. RAIL13SP01357AA

RAIL13SP01957AA

RAIL13SP01963AA

RAIL13SP01968AA

6. Disconnect the two hydraulic hoses on the right side of the six-bank valve. NOTE: Clean all connections to be removed with an aerosol degreaser and brush before loosening. Repeat flush with aerosol degreaser with fitting backed out 2-3 turns. Immediately cap or plug any connection that is opened with clean, threaded caps and plugs. NOTE: Mark hoses before removal for proper installation.

7. Disconnect the electrical connections at the center section. NOTE: Mark connectors for proper installation.

8. Disconnect air line hose (1) from tee and liquid foamer line (2) from solenoid valve.

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9. Attach a proper lifting device to support the center section and mast.

RAIL13SP01965AA

RAIL13SP01969AA

RAIL13SP01970AA

RAIL13SP01976AA

10. NOTICE: When removing hardened pins such as a pivot pin, or a hardened shaft, use a soft head (brass or bronze) hammer or use a driver made from brass or bronze and a steel head hammer. Failure to comply may result in damage to the machine. Remove nuts and bolts (1) from upper mast mounts and remove the pivot pins (2).

11. Remove nuts and bolts (1) from the lower mast mounts and remove the pivot pins (2).

12. Remove the center section/mast.

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Sprayer boom - Install - Assembled center section and mast WARNING Hazard to bystanders! Always know the location of all workers in your area. Warn them before you start working on the machine. Always keep all unauthorized bystanders clear of the area. Failure to comply could result in death or serious injury. W0176A

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

1. Attach proper lifting device to support the center section and mast. 2. Position center section and mast. Attach upper parallel link arms (1) to upper mast mounts, install pins (2). Secure with bolts and nuts (3).

RAIL13SP01969AA

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3. Attach the lower parallel link arms (1) to the lower mast mounts, install the pivot pins (2). Align bolt holes, install bolts and secure with nuts (3).

RAIL13SP01970AA

RAIL13SP01968AA

RAIL13SP01963AA

RAIL13SP01957AA

4. Connect air line hose (1) onto tee and the liquid foamer line (2) onto the solenoid valve.

5. Connect the electrical connections at the center section.

6. Connect the two hydraulic hoses on the right side of the six-bank valve.

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7. Install product hose on manifold located on center section. Install hose clamps (1) holding hose. Install U-bolt clamp (2) holding hose to center section. 8. Install inner booms. See Inner boom - Install (39.130). 9. Install the outer boom. For 60 ft, 90 ft or 100 ftboom, see Outer boom - Install - 60, 90, and 100 foot boom (39.130). For 120 ft boom, see Outer boom - Install 120 foot boom (39.130). 10. Install breakaway tips. See Boom breakaway - Install (39.130). 11. Secure all hoses and wiring with cable ties. RAIL13SP01962AA

12.

Install a new in-tank return filter on the auxiliary hydraulic circuit. 13. Start the engine and run in neutral at a minimum of 1500 RPM. 14. Cycle the cylinder five times through complete stroke to move any air and debris to the tank. 15. Allow the engine to run at 1500 RPM with the machine in neutral for a minimum of 20 min to filter and warm the hydraulic oil prior to any operation. 16. Run the machine for at least one hour under light load to complete the hydraulic oil filtration. 17. Shut down the machine and check for leaks.

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Frames and ballasting - Sprayer boom

Center section - Remove - Mid boom, 36 meters NOTE: If replacing hardware, must use the hardware noted in this Machineâ&#x20AC;&#x2122;s Parts Manual.

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

1. Remove breakaway tip. See Boom breakaway - Remove (39.130). 2. Remove the outer boom. See Outer boom - Remove - 120 foot boom (39.130). 3. Disconnect AIM Command wiring harness (if equipped) from nozzles on outer boom and lay harness aside.

RAIL13SP01940AA

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4. Remove product hose (1), foam hose (2), and fence row line (3) (if equipped). Pull hoses out of hose guide and lay off to the side. 5. Attach a proper lifting device to the inner boom extension.

RAIL13SP01941AA

RAIL13SP01945AA

RAIL13SP01946AA

RAIL13SP01947AA

6. Remove two nuts (1), bolt (2), and four washers (3) from boom cylinder linkage.

7. Remove nuts and bolt (1) and washer (2) from upper hinge.

8. Remove nuts and bolt (1) and washer (2) from lower hinge. Remove inner boom extension.

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Center section - Install - Mid boom, 36 meters WARNING Hazard to bystanders! Always know the location of all workers in your area. Warn them before you start operating the machine. Always keep all unauthorized bystanders clear of the work area. Failure to comply could result in death or serious injury. W0206A

CAUTION Chemical hazard! Wear protective clothing and a face shield when working with chemicals. Do not allow chemicals to contact skin or eyes. Always follow the chemical manufacturer's instructions. Failure to comply could result in minor or moderate injury. C0101A

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

1. Attach a proper lifting device onto boom extension and lift into place. 2. Install nut and bolt (1) and washer (2) into lower hinge.

RAIL13SP01947AA

RAIL13SP01946AA

3. Install nut and bolt (1) and washer (2) into upper hinge. Torque both bolts to 68 NÂˇm (50 lb ft).

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4. Install jam nut on both hinge bolts (upper hinge bolt shown). Torque to 136 N·m (100 lb ft) .

RAIL13SP01956AA

RAIL13SP01945AA

RAIL13SP01941AA

RAIL13SP01940AA

5. Install bolt (1), four washers (2), and nut (3) into boom cylinder linkage. Torque the nut to 68 N·m (50 lb ft) . Install jam nut (4) and torque to 136 N·m (100 lb ft).

6. Install product hose (1), foam hose (2), and fence row line (3) (if equipped).

7. Connect AIM command wiring harness (if equipped) to nozzles. 8. Install outer boom 120 ft. See Outer boom - Install 120 foot boom (39.130). 9. Install breakaway tip. See Boom breakaway - Install (39.130).

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Center section - Remove - Center section, all NOTE: If replacing hardware must use the hardware noted in this Machineâ&#x20AC;&#x2122;s Parts Manual.

WARNING Hazard to bystanders! Always know the location of all workers in your area. Warn them before you start operating the machine. Always keep all unauthorized bystanders clear of the work area. Failure to comply could result in death or serious injury. W0206A

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

1. Remove breakaway tips. See Boom breakaway - Remove (39.130). 2. Remove the outer boom. For 60 ft, 90 ft or 100 ft boom see Outer boom - Remove - 60, 90, and 100 foot boom (39.130). For 120 ft boom see Outer boom Remove - 120 foot boom (39.130). 3. Remove inner booms from the center section. See Inner boom - Remove (39.130). 4. Remove product hose clamps (1) from manifold located on center section and remove U-bolt (2) holding hose. Remove hose from manifold.

RAIL13SP01962AA

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5. Disconnect the air line hose (1) from the tee. Remove the foamer line (2) from the solenoid valve tee.

RAIL13SP01948AA

RAIL13SP01357AA

RAIL13SP01957AA

RAIL13SP01555AA

Depressurize the hydraulic tank by slowly loosening the breather cap until pressure is bled from the hydraulic tank. Tighten breather.

7. Disconnect the two hydraulic hoses on the right side of the six-bank valve. NOTE: Clean all connections to be removed with an aerosol degreaser and brush before loosening. Repeat flush with aerosol degreaser with fitting backed out 2-3 turns. Immediately cap or plug any connection that is opened with clean, threaded caps and plugs. NOTE: Mark hoses before removing for proper assembly.

8. Remove tie straps (1) and disconnect electrical harness (2) from six-bank valve on center section. NOTE: Mark hoses before removing for proper assembly.

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9. Disconnect the electrical connections at the center section for center section removal. NOTE: Mark hoses before removing for proper assembly.

RAIL13SP01963AA

RAIL13SP01964AA

RAIL13SP01965AA

10. Release spring tension from both ends of the shaft (1) by loosening the double nuts on ends of spacer tubes (2). Then loosen the two nuts (3) on the ends of shaft and remove the outer shaft nuts.

11. Slide the shaft to one side far enough to remove all of the nuts (1), washer (2), spacer (3), spring retainers (4) and spring (5). Slide the shaft to the other side and remove all nuts, washer, spacer, spring retainers and spring from the shaft. Remove the shaft.

12. Attach a proper lifting device to support the center section.

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13. NOTICE: When removing hardened pins such as a pivot pin, or a hardened shaft, use a soft head (brass or bronze) hammer or use a driver made from brass or bronze and a steel head hammer. Failure to comply may result in damage to the machine. Remove the nut and bolt (1), the pin weldment (2), washers (3) and spacer (4) on each side of the center section.

RAIL13SP01966AA

RAIL13SP01967AA

14. Lower the center section (1) until clearing upper and lower boom slide pad mounts (2). Remove the center section.

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Center section - Install - Center section, all WARNING Hazard to bystanders! Always know the location of all workers in your area. Warn them before you start working on the machine. Always keep all unauthorized bystanders clear of the area. Failure to comply could result in death or serious injury. W0176A

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

1. Install proper lifting device onto center section (1) and lift center section into the slide pad mounts (2).

RAIL13SP01967AA

RAIL13SP01966AA

2. Position the center section and install the four washers (1), spacer (2), and pin weldment (3) on each side. Install the bolt (4) into the hanger pin weldment and secure with nut.

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Frames and ballasting - Sprayer boom

3. Sliding the shaft through the center U-bracket (1) on the center section, install components in the following sequence: A. Spring retainer B. Compression spring C. Spring retainer D. Spacer E. Washer F. Nuts Slide shaft through far enough and install items in above sequence on the opposite end. Then install shaft into mounting bracket (2) on mast and secure with a nut on each end.

RAIL13SP01964AA

RAIL13SP01968AA

RAIL13SP01962AA

4. Center the shaft (1) between the two brackets (2) on the mast and tighten the nuts. Adjust the spring tension by tightening the inner nuts (3) until the springs (4) compress to 22.86 cm (9 in). Tighten the double nuts to secure the tension.

5. Connect the air line hose (1) to tee and liquid foamer line (2) to solenoid valve tee.

6. Install product hose on manifold located on center section. Install hose clamps (1) holding hose. Install U-bolt clamp (2) holding hose to center section.

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7. Route the boom wiring harnesses back through to the center section, and plug in the electrical connections. Secure harness wiring with tie straps.

RAIL13SP01963AA

RAIL13SP01957AA

RAIL13SP01555AA

8. Connect the two hydraulic hoses on the right side of the six-bank valve.

9. Install wiring harness (1) onto six-bank valve. Secure harness into position with tie straps (2). 10. Install inner booms. (39.130).

See Inner boom - Install

11. Install the outer boom. For 60 ft, 90 ft or 100 ft. boom, see Outer boom - Install - 60, 90, and 100 foot boom (39.130). For 120 ft boom, see Outer boom - Install - 120 foot boom (39.130). 12. Install breakaway tip. See Boom breakaway - Install (39.130). 13. Secure any loose wires, hoses or lines with plastic ties. 14.

15. Install a new in-tank return filter on the auxiliary hydraulic circuit. 16. Start the engine and run in neutral at a minimum of 1500 RPM. 17. Cycle all the boom fold cylinders five times through complete stroke to move any air and debris to the tank.

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Frames and ballasting - Sprayer boom

18. Allow the engine to run at 1500 RPM with the vehicle in neutral for a minimum of 20 min to filter and warm the hydraulic oil prior to any operation. 19. Run the machine for at least 1 h under light load to complete the hydraulic oil filtration. 20. Shut down the machine and check for leaks.

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Frames and ballasting - Sprayer boom

Inner boom - Remove NOTE: If replacing hardware must use the hardware noted in this Machineâ&#x20AC;&#x2122;s Parts Manual. NOTE: Procedures shown are for the 100 ft boom. All other inner booms are similar, but the procedure is the same.

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

1. Remove breakaway tip. See Boom breakaway - Remove (39.130). 2. Remove the outer boom. For 60 ft, 90 ft or 100 ft boom, see Outer boom - Remove - 60, 90, and 100 foot boom (39.130). For 120 ft boom, see Outer boom - Remove - 120 foot boom (39.130). 3. Properly support boom assembly on the opposite side of the machine being worked on.

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Frames and ballasting - Sprayer boom

4. At the center section, remove liquid foamer line (1) from solenoid valve and remove air hose (2) from tee. NOTE: Procedure shown is for removal of right side boom. Left boom removal procedure is similar.

RAIL13SP01948AA

RAIL13SP01949AA

RAIL13SP01357AA

RAIL13SP01950AA

5. At the center section, disconnect liquid plumbing hose from valve (1) and disconnect hose from spray bar tee (2). NOTE: Hoses may contain chemical. Drain chemical into a container and dispose of properly.

Depressurize the hydraulic tank by slowly loosening the breather cap until pressure is bled from the hydraulic tank. Tighten breather.

7. Disconnect the two outer boom fold cylinder hydraulic lines (1) from the six-bank valve (2) located on the center section. NOTE: Mark hoses before removal and take note of hose routing for proper installation. NOTE: Clean all connections to be removed with an aerosol degreaser and brush before loosening. Repeat flush with aerosol degreaser with fitting backed out 2-3 turns. Immediately cap or plug any connection that is opened with clean, threaded caps and plugs. NOTE: Procedure shown is for removal of right side boom. Left boom removal procedure is similar.

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8. Disconnect the electrical connections at the center section for harnesses to be removed with boom section. NOTE: Mark connectors before removal and take note of wire routing for proper installation.

RAIL13SP01951AA

RAIL13SP01952AA

RAIL13SP01953AA

RAIL13SP01954AA

9. Pull all disconnected wiring and hoses back to the inner boom. Secure wiring and hoses to the inner boom frame. NOTE: Take note of wiring and hose routing for proper installation.

10. Attach proper lifting device to the inner boom.

11. Remove the nut and bolt (1) from the cylinder pin on the rod end of the cylinder. While supporting the cylinder, remove the mounting pin (2). Set cylinder aside.

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Frames and ballasting - Sprayer boom

12. Remove the nut and bolt (1) from the boom pivot pin (2) and remove the boom pivot pin. Remove the boom. NOTICE: When removing hardened pins such as a pivot pin, or a hardened shaft, use a soft head (brass or bronze) hammer or use a driver made from brass or bronze and a steel head hammer. Failure to comply may result in damage to the machine.

RAIL13SP01952AA

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Inner boom - Install 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

1. Attach a proper lifting device to the boom and lift into position.

RAIL13SP01953AA

RAIL13SP01952AA

RAIL13SP01954AA

2. Install the boom pivot pin (1) and secure with bolt and nut (2). NOTE: Grease the pin prior to installing with NLGI NO. 2 MULTI -PURPOSE LITHIUM EP GREASE.

3. Attach the cylinder to boom with mounting pin (1). Install the bolt and lock nut (2) into the cylinder pin. NOTE: Grease the pin prior to installing with NLGI NO. 2 MULTI -PURPOSE LITHIUM EP GREASE.

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Frames and ballasting - Sprayer boom

4. Route the hoses and cables. Install the liquid foamer line (1) onto the solenoid valve. Install the hose (2) onto the tee.

RAIL13SP01948AA

RAIL13SP01949AA

RAIL13SP01951AA

RAIL13SP01955AA

5. Install liquid plumbing hose onto valve (1) and install hose onto spray bar tee (2).

6. Route the boom wiring harnesses along the center section, and connect to proper connectors.

7. Install the two outer boom fold hydraulic lines onto the six-bank valve. 8. Install outer boom. For 60 ft, 90 ft or 100 ft boom, see Outer boom - Install - 60, 90, and 100 foot boom (39.130). For 120 ft boom, see Outer boom - Install 120 foot boom (39.130). 9. Install breakaway tip. See Boom breakaway - Install (39.130). 10. Secure all hoses and wiring with cable ties.

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Frames and ballasting - Sprayer boom

11.

Install a new in-tank return filter on the auxiliary hydraulic circuit. 12. Start the engine and run in neutral at a minimum of 1500 RPM. 13. Cycle each cylinder on the boom five times through complete stroke to move any air and debris to the tank. 14. Allow the engine to run at 1500 RPM with the machine in neutral for a minimum of 20 min to filter and warm the hydraulic oil prior to any operation. 15. Run the machine for at least 1 h under light load to complete the hydraulic oil filtration. 16. Shut down the machine and check for leaks.

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Frames and ballasting - Sprayer boom

Outer boom - Remove - 27-, 30-, and 36-meter boom NOTE: If replacing hardware, must use the hardware noted in this Machineâ&#x20AC;&#x2122;s Parts Manual.

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

1. Remove breakaway tip. See Boom breakaway - Remove (39.130). 2. Disconnect AIM command wiring harness connectors (if equipped) from nozzles on outer boom and lay harness aside.

RAIL13SP01940AA

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Frames and ballasting - Sprayer boom

3. Remove product hose (1), foam hose (2), and fence row line (3) (if equipped). Pull hoses out of hose guide and lay off to the side.

RAIL13SP01941AA

RAIL13SP01942AA

RAIL13SP01943AA

4. Attach a proper lifting device to the outer boom.

5. Remove the two nuts and bolts (1) from the linkage pins (2). Remove pins and remove outer boom. NOTICE: When removing hardened pins such as a pivot pin, or a hardened shaft, use a soft head (brass or bronze) hammer or use a driver made from brass or bronze and a steel head hammer. Failure to comply may result in damage to the machine.

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Frames and ballasting - Sprayer boom

Outer boom - Install - 60, 90, and 100 foot boom 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

1. Attach proper lifting device to outer boom.

RAIL13SP01942AA

RAIL13SP01943AA

2. Position the outer boom section onto the inner boom. Install the boom hinge pin (1), connect the linkage bars (2) and install linkage pin (3). Install the bolts and nuts into the pins. Torque nuts to 57.8 NÂˇm (42.6 lb ft). NOTE: Grease pins at installation with NLGI NO. 2 MULTI PURPOSE LITHIUM EP GREASE.

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Frames and ballasting - Sprayer boom

3. Route hoses and AIM Command harness (if equipped) back through guides on boom section. Secure wiring and hoses with cable ties as required. (Outer end guide shown).

RAIL13SP01944AA

RAIL13SP01941AA

RAIL13SP01940AA

4. Connect product hose (1), foam hose (2), and fence row line (3) (if equipped).

5. Connect AIM Command wiring harness (if equipped) to nozzles on outer boom. Secure hoses and harnesses to boom with tie straps. 6. Install breakaway tip. See Boom breakaway - Install (39.130).

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Frames and ballasting - Sprayer boom

Outer boom - Remove - 120 foot boom NOTE: If replacing hardware must use the hardware noted in this machineâ&#x20AC;&#x2122;s parts manual.

Outer boom removal WARNING Hazard to bystanders! Always know the location of all workers in your area. Warn them before you start working on the machine. Always keep all unauthorized bystanders clear of the area. Failure to comply could result in death or serious injury. W0176A

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

1. Remove breakaway tip. See Boom breakaway - Remove (39.130). 2. Disconnect AIM Command wiring harness (if equipped) from nozzles on outer boom and lay harness aside.

RAIL13SP01940AA

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Frames and ballasting - Sprayer boom

3. Remove product hose (1), foam hose (2), and fence row line (3) (if equipped). Pull hoses out of hose guide and lay off to the side.

RAIL13SP01941AA

RAIL13SP01945AA

RAIL13SP01946AA

RAIL13SP01947AA

4. Remove two nuts (1), bolt (2), and four washers (3) from boom cylinder linkage.

5. Remove nuts and bolt (1) and washer (2) from upper hinge.

6. Remove nuts and bolt (1) and washer (2) from lower hinge. Remove inner boom extension.

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Frames and ballasting - Sprayer boom

Outer boom - Install - 120 foot boom 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

1. Attach a proper lifting device to outer boom and lift into place. 2. Install bolt (1) and washer (2) into outer boom lower hinge.

RAIL13SP01947AA

RAIL13SP01946AA

RAIL13SP01945AA

3. Install nuts and bolt (1) and washer (2) into upper hinge. Torque both bolts to 68 N·m (50 lb ft).

4. Install bolt (1), four washers (2), and nut (3) into boom cylinder linkage. Torque nut to 68 N·m (50 lb ft). Install jam nut (4) and torque to 136 N·m (100 lb ft).

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Frames and ballasting - Sprayer boom

5. Install product hose (1), foam hose (2), and fence row line (3) (if equipped).

RAIL13SP01941AA

RAIL13SP01940AA

6. Connect AIM command wiring harness (if equipped) to nozzles. 7. Install breakaway tip. See Boom breakaway - Install (39.130).

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Frames and ballasting - Sprayer boom

Boom breakaway - Remove NOTE: If replacing hardware must use the hardware noted in this machineâ&#x20AC;&#x2122;s parts manual. NOTE: Procedures shown are for the 100 ft. boom. All other breakaway tips are similar, but the procedure is the same.

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

Unfold and lower the booms, shutoff machine and remove key. See Operatorâ&#x20AC;&#x2122;s Manual for the procedure. 1. Close manual shutoff valve under product tank.

RAIL13SP01924AA

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Frames and ballasting - Sprayer boom

2. Close product tank sump valve (1). Remove the product fill cap (2). Open product tank fill valve (3) and drain product into a proper container.

RAIL13SP01925AA

RAIL13SP01926AA

RAIL13SP01927AA

RAIL13SP01928AA

3. Close valve on bottom of foam tank. 1.

Remove foam tank plumbing support (1).

Close shutoff valve (2).

4. Open drain valve on bottom of air tank to relieve air pressure from foam system. (Bottom view of tank shown.) Close valve after air pressure has been relieved. 5. Properly support boom assembly on the opposite side of the machine being worked on.

6. Remove foam hose (1) from the foam drop assembly. Disconnect fence row line (2) (if equipped) from fence row nozzle.

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7. Remove the product hose (1) from the spray bar. Disconnect the aim command wire harness (2) (if equipped) from the nozzle valves. Remove hoses and electrical harness from boom breakaway tip.

RAIL13SP01929AA

RAIL13SP01930AA

RAIL13SP01931AA

RAIL13SP01932AA

8. Remove the cable ties that secure the two cable ends together on the spring.

9. Pull the boom breakaway tip over center far enough to create slack in the breakaway cable closest to the end of the spring. Remove the cable from the end of the spring.

10. Push the boom breakaway tip over center the other direction and remove the other cable end from the spring.

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Frames and ballasting - Sprayer boom

11. Attach proper lifting device to the boom breakaway tip.

RAIL13SP01933AA

RAIL13SP01934AA

RAIL13SP01935AA

RAIL13SP01936AA

12. Remove upper hinge bolt (1), nut and nylon washers (2).

13. Remove lower hinge bolt (1), nut and nylon washers (2). Remove the boom breakaway tip.

14. Remove bushings in upper and lower hinge joints of the boom breakaway tip (upper hinge shown).

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Frames and ballasting - Sprayer boom

Boom breakaway - Install 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

1. Attach a proper lifting device to the boom breakaway tip.

RAIL13SP01933AA

RAIL13SP01936AA

2. Install bushings in upper and lower hinge joints on the boom breakaway tip. (upper hinge shown).

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3. Position boom breakaway tip onto the outer boom section. Install upper hinge bolt (1), three nylon washers (2), one nylon washer (3) and nut. NOTE: Leave bolt loose until lower hinge bolt is installed.

RAIL13SP01937AA

RAIL13SP01935AA

RAIL13SP01932AA

RAIL13SP01931AA

4. Install lower hinge bolt (1), one nylon washer (2), two nylon washers (3) and nut (4). Torque upper and lower hinge nuts to 67.8 NÂˇm (50.0 lb ft).

5. Pull the boom breakaway tip over center far enough to create slack in the breakaway cable and attach the cable end to the spring.

6. Push the boom breakaway tip over center the other direction and attach the other cable end to the spring.

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Frames and ballasting - Sprayer boom

7. Secure both cable ends together with two large tie straps on the spring.

RAIL13SP01938AA

RAIL13SP01928AA

RAIL13SP01929AA

8. Connect foam hose (1) to the foam drop assembly. Connect fence row line (2) to fence row nozzle (if equipped).

9. Connect product hose (1) to the elbow on the spray bar. Connect the Aim Command wire harness (2) (if equipped) to the nozzle valves. Secure wiring and hoses with cable ties as required.

10. Adjust spring tension as necessary. 100 ft and 120 ft boom (1) assembly spring adjustment. A. 11.43 cm (4.50 in) B. 121.92 cm (48.00 in) C. 31.75 cm (12.50 in) D. 19.05 cm (7.50 in) 60 ft and 90 ft boom (2) assembly spring adjustment. A. 40.64 cm (16.00 in). B. 119.38 cm (47.00 in) C. 33.02 cm (13.00 in) D. 15.24 cm (6.00 in)

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RAIL13SP01939FB

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Index Frames and ballasting - 39 Sprayer boom - 130 Boom breakaway - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom breakaway - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Center section - Install - Center section, all . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Center section - Install - Mid boom, 36 meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Center section - Remove - Center section, all . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Center section - Remove - Mid boom, 36 meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inner boom - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inner boom - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Outer boom - Install - 120 foot boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Outer boom - Install - 60, 90, and 100 foot boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Outer boom - Remove - 120 foot boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Outer boom - Remove - 27-, 30-, and 36-meter boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sprayer boom - Install - Assembled center section and mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sprayer boom - Install - Boom pivot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sprayer boom - Install - Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sprayer boom - Install - 27, 30, and 36 meters, with cradle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sprayer boom - Remove - Boom pivot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sprayer boom - Remove - Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sprayer boom - Remove - 27, 30, and 36 meters, with cradle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sprayer boom - Remove - Assembled center section and mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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CNH Industrial Latin America LTDA, Av. Jerome Case, 1801, Aparecidinha - Socoraba (SP) - Brasil, CEP:18087-220

SERVICE - Technical Publications & Tools

48149953 12/06/2018 EN

SERVICE MANUAL Steering SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Steering - 41

[41.101] Steering control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1 [41.206] Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2 [41.216] Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.3

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Steering - 41 Steering control - 101

SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Steering - 41 Steering control - 101

TECHNICAL DATA Steering column Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Steering column Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Steering - Steering control

Steering column - Torque Description Lock nut for steering column base Nut for steering wheel

Torque values 29 – 32 N·m (21 – 24 lb ft) 45 – 54 N·m (33 – 40 lb ft)

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Steering - Steering control

Steering column - Remove Prior operation: Park the tractor on a hard, level surface. Prior operation: Put the transmission shift lever in PARK. Prior operation: Turn the engine off and remove the key. 1. Place blocks in front of and behind the rear wheels.

RAIL13SP01365AA

RAIL13SP04671AA

RAIL13SP01366AA

2. Disconnect battery cables from negative posts.

3. Remove the two retaining screws that attach the left and right lower console panels.

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Steering - Steering control

4. Remove the three retaining screws (1) on the left lower console panel. Lift up on the mat and remove the left lower console panel. Repeat this procedure for the right lower console panel.

RAIL13SP01367AA

RAIL13SP01368AA

RAIL13SP01369AA

RAIL13SP01370AA

5. Disconnect the electrical connectors from the switches on the upper console panel and remove the panel.

6. Remove the heat duct retaining screw on the left heat duct. Lift up on the cab floor mat and remove the duct. Removal of the right heat duct is not necessary.

7. Remove the horn button.

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Steering - Steering control

8. Remove the steering wheel nut and washer. Mark the position of the steering wheel on the column for reassembly.

RAIL13SP01371AA

RAIL13SP01372AA

9. Remove the steering wheel with a swift, upward pull. NOTICE: If the steering wheel cannot be removed by the method above, use a steering wheel puller.

10. Remove the retaining screw from the steering column upper control housing.

RAIL13SP01373AA

RAIL13SP01374AA

11. Lift the housing and disconnect the electrical connector (1) for the turn signal indicator lamps. Loosen the socket head cap screw (2) for the transmission control switch clamp.

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Steering - Steering control

12. Use a Torx screwdriver to remove the upper and lower steering column covers.

RAIL13SP01375AA

RAIL13SP01376AA

RAIL13SP01377AA

RAIL13SP01378AA

13. Remove the electrical connector (1) for the transmission control switch at the steering column harness. Disconnect the two steering column electrical connectors (2) for the turn signal switch. Pull the harnesses through the steering column boot, and remove the lower control housing assembly from the steering column. Remove the cable clip with pin (3) from the steering column tilt mechanism cable. Loosen the cable lock nuts (4) from the anchor bracket, and move the cable aside.

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Steering - Steering control

14. Remove the boot support washer (1). Remove the steering column boot (2) along with the boot support plate, and wire stiffener.

RAIL13SP01379AA

RAIL13SP01358AA

RAIL13SP01380AA

15. From the outside of the firewall support the steering pump.

16. Remove the four steering column lock nuts and washers at the column base. Support the steering column in the cab while an assistant removes the steering hand pump from the cab firewall. Remove the steering column.

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Steering - Steering control

Steering column - Install

RAIL13SP01381GA

1. 2. 3. 4.

Bellow set Cover set Release device set Bearing set

5. 6. 7.

Steering column Segment set Spring set

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Steering - Steering control

1. Support the steering column in the cab while an assistant installs the steering hand pump. Install the steering column over the four studs and into the steering hand pump. Install the four washers and hand tighten the four new lock nuts at the column base. Install the steering wheel on the column just far enough to engage the steering mechanism.

RAIL13SP01380AA

RAIL13SP01379AA

RAIL13SP01378AA

RAIL13SP01377AA

2. Place the boot (1) with wire stiffener and boot plate installed, over the steering column. Partially install the boot support washer (2). Install the lower control housing wiring harnesses through the protruding opening in the boot (3). Fully install the washer (2).

3. Connect the two steering column electrical connectors (1) for the turn signal switch. Install the cable clip with pin (2) for the steering column tilt mechanism cable. Install the cable into the anchor bracket and tighten the lock nuts (3). Install the electrical connector (4) for the transmission control switch.

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Steering - Steering control

4. Use a Torx screwdriver to install the upper and lower steering column covers.

RAIL13SP01375AA

RAIL13SP01376AA

RAIL13SP01374AA

RAIL13SP01373AA

5. Install the lower control housing assembly. Make sure the alignment tab on the transmission control switch clamp is located in the hole on the steering column collar. Tighten the socket head cap screw (1) for the transmission control switch clamp. Connect the electrical connector (2) for the turn signal indicator lamps.

6. Install the upper control housing and tighten the retaining screw.

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Steering - Steering control

7. Using the steering wheel position alignment mark made during disassembly, and the steering column shaft centering mark, install the steering wheel. Install the steering wheel retaining nut and flat washer. Tighten the nut to a torque of 45 – 54 N·m (33 – 40 lb ft). Install the horn button.

RAIL13SP01371AA

RAIL13SP01364AA

RAIL13SP01369AA

RAIL13SP01368AA

8. Lift up on the cab floor mat. Position the left console heat duct into the floor duct and install the retaining screw.

9. Install the electrical connectors on the switches in the upper console panel and carefully install the panel.

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Steering - Steering control

10. Lift up on the mat and install the left lower console panel. Install the three retaining screws (1). Repeat this procedure for the right lower console panel.

RAIL13SP01367AA

RAIL13SP01366AA

RAIL13SP04671AA

RAIL13SP01365AA

11. Install the two retaining screws that attach the left and right lower console panels.

12. Connect battery cables to the negative posts.

13. Make sure the transmission shift lever is in PARK. Start the engine and check the operation of the steering hand pump. Turn the engine off and remove the key. Remove the blocks in front of and behind the rear wheels. NOTE: Do not hold the steering wheel during startup.

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Index Steering - 41 Steering control - 101 Steering column - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering column - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering column - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Steering - 41 Pump - 206

SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Steering - 41 Pump - 206

FUNCTIONAL DATA Steering hand pump Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Steering hand pump Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Steering - Pump

Steering hand pump - Overview Steering orbit motor Oil is supplied to the steering orbit motor from the pressure compensated pump. The oil enters the orbit via the “P” port and provided there is no input from the steering wheel, flow stops at that point. The check valve located on the inlet line allows flow only in one direction-towards the steering orbit. Once the steering wheel is turned, the valve inside the orbit changes positions. The oil is then given a path to travel that results in the front wheels changing position. The hydraulic valve inside the orbit is an infinitely variable style valve, meaning as the wheel is turned slightly, the valve changes positions slightly and only allows a small amount of hydraulic oil flow which turns the front wheels a minor amount. A greater turn of the steering wheel results in greater oil flow and the front wheels turn farther. It is relatively easy to determine an infinitely variable hydraulic valve as compared to a “bang-bang” style. The parallel lines on the top and bottom side of the valve symbol, this denotes a variable style cartridge. As the orbit is commanded to change paths of hydraulic flow, the oil is either ported out the “L” or “R” port depending on which direction the steering wheel is turned. Oil from the steering orbit enters the “blind” end of the cylinder and causes that particular cylinder to extend.

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RAIL13SP01421AA

Steering - Pump

Steering hand pump - Remove Prior operation: If replacing hardware must use the hardware noted in this Machineâ&#x20AC;&#x2122;s Parts Manual. Prior operation: Power wash entire machine, especially around area to be worked on. Prior operation: Remove front hood, see Front shield - Remove - Front hood (90.105). 1.

Slowly loosen breather to bleed tank pressure. Tighten breather after pressure is bled from hydraulic tank.

RAIL13SP04670AA

RAIL14SP00033AA

RAIL13SP01359AA

2. Remove the four steering pump hydraulic hoses. NOTE: Clean all connections to be removed with an aerosol degreaser and brush before loosening. Repeat flush with aerosol degreaser with fitting backed out 2-3 turns. NOTICE: Immediately cap or plug any connection that is opened with clean, threaded caps and plugs. NOTE: Mark hoses for proper installation.

3. Remove the air louvers from the top of the front console.

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Steering - Pump

4. Remove all the console retaining screws (1). Disconnect the cab wire harness from the switch (2) connectors. Remove the sides and top of the front console.

RAIL13SP01362AA

RAIL13SP01361AA

5. With an assistant securing the pump from the outside, remove the four pump retaining nuts.

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Steering - Pump

Steering hand pump - Install 1. From the outside, have an assistant apply #2 grease to the steering shaft, align the pump with the steering shaft and secure in place. Install the four retaining nuts. Tighten to a torque of 21 – 32 N·m (15 – 24 lb ft).

RAIL13SP01361AA

RAIL13SP01362AA

RAIL13SP01363AA

2. Install cab harness to the switch (1) connectors. Install the top and sides of the front console. Install and tighten the retaining screws (1).

3. Install the louvers into the top of the front console.

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Steering - Pump

4. Attach the four hydraulic hoses. 5. Install he front hood Front shield - Install - Front hood (90.105). 6.

7. Install a new in-tank return filter on the auxiliary hydraulic circuit. 8. Start the engine and run in neutral at a minimum of 1500 RPM. 9. Cycle motor five times through complete stroke to move any air and debris to the tank. 10. Allow the engine to run at 1500 RPM with the vehicle in neutral for a minimum of 20 min to filter and warm the hydraulic oil prior to any operation. 11. Run the machine for at least 1 h under light load to complete the hydraulic oil filtration. 12. Shut down machine and check for leaks. 13. Re-phase the steering cylinders: 1. Turn the steering wheel to the right until the front wheels have turned as far as they will go. Then turn the steering wheel at least another full turn. 2. Turn the steering wheel to the left until the front wheels have turned as far as they will go. Then turn the steering wheel at least another full turn.

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RAIL14SP00033AA

Index Steering - 41 Pump - 206 Steering hand pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering hand pump - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering hand pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Steering - 41 Cylinders - 216

SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Steering - 41 Cylinders - 216

TECHNICAL DATA Steering cylinder Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Steering cylinder Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Steering cylinder Service instruction Rephasing the steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Test - Leaking seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Remove Rephasing the steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Steering - Cylinders

Steering cylinder - Torque Description Steering cylinder mounting bolts and nuts Steering cylinder rod nut Steering cylinder gland nut

Torque values 393 – 419 N·m (290 – 309 lb ft) 271.2 – 305 N·m (200 – 225 lb ft) 271.2 – 338.9 N·m (200 – 250 lb ft)

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Steering - Cylinders

Steering cylinder - Overview Once hydraulic oil enters the “blind” end (1) of the steering cylinder, the cylinder rod starts to extend. Oil from the “rod” end (2) of that same cylinder must exit the cylinder tube as the rod extends and it is ported to the “rod” end of the opposing cylinder causing that rod to retract. As the opposing cylinder rod retracts, oil is expelled from the “blind” end of that cylinder and returns to the steering orbit motor. The steering cylinders on this machine are a re-phasing style cylinder. NOTE: It is normal for some drift in the steering toe-in setting to occur during operation of the machine. RAIL13SP01422AA

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Steering - Cylinders

Steering cylinder - Service instruction Rephasing the steering 1. To re-phase the steering, with the engine running turn the steering wheel completely to the left and several revolutions beyond. Next, turn the wheel back completely to the right and several revolutions beyond. Then, return the wheels to the center position. This completes the re-phasing process.

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Steering - Cylinders

Steering cylinder - Test - Leaking seals 1. Install cylinder stops as required to keep the stroke of the cylinder at approximately 1/2 of its full stroke. 2. Start the engine and warm the hydraulic oil to a minimum of 49 Â°C (120 Â°F). 3. Center the front tires. 4. Disconnect the hydraulic hose on the opposite end of cylinder being tested. NOTE: If testing the blind end of the cylinder, then disconnect the hydraulic hose at the rod end. Place the disconnected hose in a collection container. 5. Turn the wheel in the required direction and monitor the amount of oil, that is collected.

RAIL13SP01423AA

RAIL13SP04110AA

NOTE: If no oil is collected, or only drops per minute, the seal is ok. If leakage is substantial the cylinder will have to be repaired or replaced. See Steering cylinder - Remove Rephasing the steering (41.216) for cylinder removal. 6. Connect the hydraulic line and remove the cylinder stops.

7. Install a new in-tank return filter on the auxiliary hydraulic circuit. 8. Start the engine and run in neutral at a minimum of 1500 RPM. 9. Cycle the cylinder five times through complete stroke to move any air and debris to the tank. 10. Allow the engine to run at 1500 RPM with the vehicle in neutral for a minimum of 20 min to filter and warm the hydraulic oil prior to any operation. 11. Run the machine for at least 1 h under light load to complete the hydraulic oil filtration. 12. Shut down the machine and check for leaks.

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Steering - Cylinders

Steering cylinder - Alignment 1. Front wheels must be aimed straight ahead. 2. Steering arm assembly must be straight ahead (centered) on front axle. Adjust front wheel steering cylinders for 6.5 â&#x20AC;&#x201C; 12.5 mm (0.25 â&#x20AC;&#x201C; 0.5 in) less at front of tire than at rear (horizontal center of hub).

RAIL13SP01583AA

RAIL13SP01584AA

3. To adjust: 1.

Loosen the jam nut (1).

Turn the rod end (2) to adjust the steering cylinder length.

Cycle the cylinder five times through complete stroke.

Recheck the toe in.

When toe in is correct retighten the jam nut (1).

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Steering - Cylinders

Steering cylinder - Remove Rephasing the steering Prior operation: If replacing hardware must use the hardware noted in this Machineâ&#x20AC;&#x2122;s Parts Manual. Prior operation: Use kit #323763 when working on the hydraulic system. Prior operation: Power wash the machine and around cylinder to be worked on. NOTE: Kit number 323763 is sold through CNH parts system.

Steering cylinder removal 1.

Remove the pressure from the hydraulic tank by slowly loosening the breather cap until pressure is bled from the hydraulic tank. Tighten breather.

RAIL13SP04670AA

RAIL13SP01582AA

2. NOTE: Slowly loosen the hydraulic lines allowing the pressure to bleed off. NOTE: If necessary remove the pipe clamp (3) to remove the steering cylinder bolt. NOTE: Clean all connections to be removed with an aerosol degreaser and brush before loosening. Repeat flush with aerosol degreaser with fitting backed out 2-3 turns. NOTICE: Immediately cap or plug any connection that is opened with clean, threaded caps and plugs. Remove the hydraulic lines (1) from the cylinder, mounting hardware (2). Then remove the steering cylinder. NOTE: For cylinder overhaul see Hydraulic systems Overhaul - Cylinders (35.000).

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Steering - Cylinders

Steering cylinder - Install 1. Install the steering cylinder and secure with mounting hardware (1). Torque the nuts (2) to 393 – 419 N·m (290 – 309 lb ft) and install cotter pin. Connect the hydraulic lines (3). Reconnect the pipe clamp (4) if removed. NOTE: If the cotter pin cannot be installed, tighten to the next cotter pin hole.

RAIL13SP01582AA

RAIL13SP04110AA

Install a new in-tank return filter on the auxiliary hydraulic circuit. 3. Start the engine and run in neutral at a minimum of 1500 RPM.

4. Cycle the cylinder five times through complete stroke to move any air and debris to the tank. 5. Allow the engine to run at 1500 RPM with the vehicle in neutral for a minimum of 20 min to filter and warm the hydraulic oil prior to any operation. 6. Run the machine for at least 1 h under light load to complete the hydraulic oil filtration. 7. Shut down the machine and check for leaks. 8. Check and adjust toe in. See Steering cylinder Alignment (41.216).

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Index Steering - 41 Cylinders - 216 Steering cylinder - Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering cylinder - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering cylinder - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering cylinder - Remove Rephasing the steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering cylinder - Service instruction Rephasing the steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering cylinder - Test - Leaking seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering cylinder - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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CNH Industrial Latin America LTDA, Av. Jerome Case, 1801, Aparecidinha - Socoraba (SP) - Brasil, CEP:18087-220

SERVICE - Technical Publications & Tools

48149953 12/06/2018 EN

SERVICE MANUAL Wheels SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Wheels - 44

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

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Wheels - 44 Front wheels - 511

SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Wheels - 44 Front wheels - 511

TECHNICAL DATA Front wheels Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Front wheels Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Wheels - Front wheels

Front wheels - Torque Description

Torque values 608 – 675 N·m (448 – 498 lb ft)

Wheel lug nuts

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Wheels - Front wheels

Front wheels - Remove NOTE: If replacing hardware, must use the hardware noted in this Machineâ&#x20AC;&#x2122;s Parts Manual.

1. Park the machine on solid, level surface. 2. Shut down the engine. Remove the ignition key (1).

RAIL13SP00029FA

RAIL13SP01856AA

3. Chock wheels in front and rear of tire opposite axle of tire to be removed.

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Wheels - Front wheels

4. Use a heavy duty jack to lift the machine. NOTE: Hydraulic jack used for lifting must have a rating of 10 ton or more. Support machine using a proper jack stand. ( 15 ton jack stand shown)

RAIL13SP01857BA

RAIL13SP01858AA

RAIL13SP01859AA

5. Position the wheel/lift in place and secure the wheel to the lift.

6. Loosen the wheel lugs. NOTE: Wheel lift removed from picture for clarity.

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Wheels - Front wheels

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 the wheel lug nuts and remove the wheel. NOTE: Adjust jack tension on lift to ease tire removal. NOTE: Wheel lift taken off picture for clarity. RAIL13SP01860AA

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Wheels - Front wheels

Front wheels - Install WARNING Hazard to bystanders! Always know the location of all workers in your area. Warn them before you start working on the machine. Always keep all unauthorized bystanders clear of the area. Failure to comply could result in death or serious injury. W0176A

1. Raise the machine enough to roll in the wheel/lift and wheel. Align studs with holes and slide wheel on to studs.

RAIL13SP01858AA

RAIL13SP01861AA

2. Install lug nuts. Torque to 608 – 675 N·m (448 – 498 lb ft). NOTE: Use a star pattern when torquing the lug nuts.

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Wheels - Front wheels

3. Jack the machine high enough to remove the wheel lift from under the tire. Also remove the safety jackstand.

RAIL13SP01857BA

RAIL13SP01862BA

4. Lower the machine and remove the hydraulic jack.

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Wheels - Front wheels

5. Remove the wheel chocks.

RAIL13SP01856AA

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Index Wheels - 44 Front wheels - 511 Front wheels - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front wheels - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front wheels - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Wheels - 44 Rear wheels - 520

SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Wheels - 44 Rear wheels - 520

TECHNICAL DATA Rear wheel Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Rear wheel Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Wheels - Rear wheels

Rear wheel - Torque Description

Torque values 608 – 675 N·m (448 – 498 lb ft)

Wheel lug nuts

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Wheels - Rear wheels

Rear wheel - Remove NOTE: If replacing hardware, must use the hardware noted in this Machineâ&#x20AC;&#x2122;s Parts Manual.

1. Park the machine on solid, level surface. 2. Shut the engine off and remove key from switch.

RAIL13SP00029FA

RAIL13SP01856AA

3. Chock wheels in front and rear of tire opposite axle of tire to be removed.

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Wheels - Rear wheels

4. Use a heavy duty jack to lift the machine. NOTE: Hydraulic jack used for lifting must have a rating of 10 ton or more. Support machine using a proper jack stand. ( 15 ton jack stand shown)

RAIL13SP01857BA

RAIL13SP01858AA

RAIL13SP01859AA

5. Position the wheel/lift in place and secure the wheel to the lift.

6. Loosen the wheel lugs. NOTE: Wheel lift removed from picture for clarity.

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Wheels - Rear wheels

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 the wheel lug nuts and remove the wheel. NOTE: Adjust jack tension on lift to ease tire removal. NOTE: Wheel lift taken off picture for clarity. RAIL13SP01860AA

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Wheels - Rear wheels

Rear wheel - Install WARNING Hazard to bystanders! Always know the location of all workers in your area. Warn them before you start working on the machine. Always keep all unauthorized bystanders clear of the area. Failure to comply could result in death or serious injury. W0176A

1. Raise the machine enough to roll in the wheel/lift and wheel. Align studs with holes and slide wheel on to studs.

RAIL13SP01858AA

RAIL13SP01861AA

2. Install lug nuts. Torque to 608 – 675 N·m (448 – 498 lb ft). NOTE: Use a star pattern when torquing the lug nuts.

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Wheels - Rear wheels

3. Jack the machine high enough to remove the wheel lift from under the tire. Also remove the safety jackstand.

RAIL13SP01857BA

RAIL13SP01862BA

4. Lower the machine and remove the hydraulic jack.

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Wheels - Rear wheels

5. Remove the wheel chocks.

RAIL13SP01856AA

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Index Wheels - 44 Rear wheels - 520 Rear wheel - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear wheel - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear wheel - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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CNH Industrial Latin America LTDA, Av. Jerome Case, 1801, Aparecidinha - Socoraba (SP) - Brasil, CEP:18087-220

SERVICE - Technical Publications & Tools

48149953 12/06/2018 EN

SERVICE MANUAL Cab climate control SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

48149953 12/06/2018

Contents Cab climate control - 50

[50.100] Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.1 [50.200] Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.2 [50.300] Cab pressurizing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.3

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Cab climate control - 50 Heating - 100

SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Cab climate control - 50 Heating - 100

FUNCTIONAL DATA Evaporator/Heater coil Component identification - Blower and evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Heating Remove - Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install - Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Heater control valve Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Evaporator/Heater coil Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Service instruction - Sealing and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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Cab climate control - Heating

Evaporator/Heater coil - Component identification - Blower and evaporator

RAIL13SP01759GA

1. 2. 3. 4.

Thermal expansion valve Blower motor Box drainage Check valve

5. 6. 7. 8.

Condensate drain tube Evaporator box assembly Evaporator temp sensor Evaporator core

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Cab climate control - Heating

Heating - Remove - Radiator Prior operation: Console - Remove (90.151) 1. Remove the seal (1). 2. Disconnect the electrical wiring harness of the step motor actuator (2). 3. Disconnect the electrical wiring harness of the thermostat (3). 4. Remove the bolt (4). Move the thermostat (3) away from the cover (5). NOTICE: Be careful not to damage the thermostat sensor wire. PIIL17SP00052AA

PIIL17SP00053AA

PIIL17SP00056AA

PIIL17SP00054AA

5. Remove the bolts (2) to loosen the clamps (1). 6. Disconnect the fluid inlet line (3) and the fluid outlet line (4) from the radiator. NOTE: Discard the O-rings of the lines. NOTICE: Cover the end of the lines with plugs.

7. At the rear of the air box, remove the four union clamps (1).

8. Loosen the clamps (1). Move the air ducts (2). 9. Remove the nut, washer, and rubber shim (3). 10. Remove the eight bolts (4) that secure the cover (5) to the housing (6), three on each side and two at the rear. 11. Remove cover (5).

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12. Remove the radiator (1).

PIIL17SP00055AA

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Heating - Install - Radiator 1. Position the radiator (1) in the housing (2), as shown.

PIIL17SP00055AA

PIIL17SP00054AA

PIIL17SP00056AA

PIIL17SP00053AA

2. Install the cover (1) over the radiator (2). Fit the cover on the housing (3). 3. Secure the cover (1). To secure, install the eight bolts (4), three on each side and two at the rear. 4. Install the rubber shim, washer, and nut (5). 5. Connect the ducts (6) to the air box. Secure with the clamps (7).

6. At the rear of the air box, install the four union clamps (1).

7. Connect the fluid inlet line (1) and the fluid outlet line (2) to the radiator. NOTE: Install new lubricated O-rings on the lines. 8. Secure the lines with the clamps (3). Tighten the bolts (4).

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9. Attach the thermostat (1) on the cover (2). Use the bolt and washer (3). 10. Connect the electrical wiring harness of the thermostat (1). 11. Connect electrical wiring harness of the step motor actuator (4). 12. Install the seal (5).

PIIL17SP00052AA

Next operation: Console - Install (90.151)

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Heater control valve - Check Operational check 1. The controller opens or closes the heater control valve (1) based on the operator selected input at the temperature control and the temperature sensed at the cab and evaporator sensors. 2. The heater control valve (1) can fail mechanically in any position: open, closed or anywhere in the middle. 3. To confirm proper valve operation, observe the slot on the front of the valve. Rotation of the slot must mirror the movement of the temperature control. 4. The slot must rotate fully clockwise when the control is turned fully clockwise, the slot must rotate fully counterclockwise when the slot is turned fully counterclockwise.

RAIL13SP01612AA

RAIL13SP01613AA

5. If the valve does not mirror control movement or does not move, perform the valve motor electrical test. 2. Slotted actuator

Valve â&#x20AC;&#x153;leak throughâ&#x20AC;? 6. A common problem with the valve is hot coolant flow when cab cooling is desired. This usually occurs by a when a valve does not close completely. To test for leak through from the valve: 1.

Operate the A/C system at maximum cooling and blower speed for 15 min. See conditions for performance testing.

NOTE: Do not clamp off the heater supply or return lines (1) at the engine for this test. 2. Install a stem type thermometer in a mid-cab louver, and record the temperature. 3. Clamp off the coolant supply line before the valve with a vise grip pliers. (The supply line connects at the bottom of the valve.) Wait a few minutes and check the thermometer. If the temperature drops, valve leak through is the problem, replace the valve.

Electrical test NOTE: See electrical schematic sheets.

Power, signal and ground circuit The controller feeds 12 V to the heater valve motor from Pin 4 on the control module 36-pin connector to Pin 10 on the motor. The control signal ( 1.5 â&#x20AC;&#x201C; 11.5 V) is fed from the controller on Pin 3 of the connector to Pin 8 on the motor. The motor is grounded from Pin 7 at the motor to HVAC ground.

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Possible failure modes 1.

Motor failure or valve physical failure.

Open condition in power, signal or ground to heater control valve.

Controller failure.

Heater control valve power, signal and ground test Steps and test point Corrective actions NOTE: If both the heater control valve and mode door motor do not work, 12 V from Pin 4 at the controller is the likely suspect. Check power from Pin 4 on Wire 6D-Or Keyswitch ON and ATC switch to “AUTO” Test from Pin 8 on valve to chassis ground. While turning the temperature control from max cool to max heat setting, observe both voltmeter and slot on front of the valve If voltage change but no slot movement or slot movement is irregular, heater valve has failed physically or 1. actuator fault. Go to Step 2 If no voltage or no voltage change, go to Step 5 If voltage change and slot movement are continuous, heater valve tests okay Keyswitch OFF. Disconnect harness connector to YES - Replace the heater control valve assembly 2. motor. Measure resistance through the motor from NO - Go to next Step Pin 7 to Pin 10. Open line reading? YES - Go to next Step Measure resistance from Pin 7 on valve harness to 3. NO - Locate and repair open condition in ground from HVAC ground. Less than 1 Ω? Pin 7 Keyswitch ON and ATC switch to “AUTO.” Measure control signal at the harness connector on Pin 8 from YES - Go to Step 5 4. Pin 3 at the controller, while turning the temperature NO - Go to next Step control from max cool to max heat position. Is range from 11.5 V (max cool) to 1.5 V (max heat)? YES - Locate open condition and repair between Pin Measure control signal at Pin 3 at the controller while 3 at controller and Pin 8 at the heater valve 5. turning the control. Is range from 11.5 V (max cool) NO - Test the controller. See Automatic Temperature to 1.5 V (max heat)? Control (ATC) module - Test - Connector J8 test points (55.050) YES - Incorrect reading taken. Retest 6. Is 12 V present at Pin 10 at the harness connector? NO - Go to next Step YES - Locate open condition and repair between Pin 4 at the controller and Pin 10 at the valve NO - Test the controller. See Automatic Temperature 7. Is 12 V present at Pin 4 at the controller? Control (ATC) module - Test - Connector J8 test points (55.050)

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Heater control valve - Replace To replace the heater control valve: 1. See Air conditioning - Service instruction - Accessing the HVAC box (50.200). 2. Move the controller mounting plate forward to gain better access to the valve. 3. Disconnect the control valve from the harness. NOTE: Be prepared to collect a small amount of coolant when the valve hoses are disconnected.

RAIL13SP01748AB

RAIL13SP01625AA

4. Pinch the clamp (1) and disconnect the inlet hose to the core from the valve. Pinch the clamp (2) and disconnect the supply hose at the bottom of the valve. Remove the valve. 5. Install a new heater control valve to the same connecting hoses. Connect the valve to the harness.

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Heater control valve - Replace Prior operation: Radiator - Drain fluid (10.400) Prior operation: Console - Remove (90.151) 1. Loosen the clamps (1). Move the left-hand air duct (2).

PIIL17SP00052AA

PIIL17SP00058AA

PIIL17SP00057AA

2. Remove the bolts (1) that secure the heater control valve cradle.

3. Disconnect the electrical wiring harness (1) of the heater control valve. 4. Remove the bolts (2) and loosen the clamps (3), to release the lines (4) and (5). 5. Remove the valve (6), together with its cradle. NOTE: Discard the O-rings of the lines. NOTICE: Cover the end of the lines with plugs.

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6. Remove the straight fittings (1) and 90Â° (2). 7. Remove the bolts (3) to loosen the valve (4). 8. Fasten the fittings (1) and (2) on a new valve, Ensure a proper seal. 9. Use the bolts (3) to assemble the new valve on the cradle (5).

PIIL17SP00059AA

PIIL17SP00057AA

PIIL17SP00058AA

PIIL17SP00052AA

10. Install new lubricated O-rings on the lines (1) and (2). 11. Position the valve (3) beside the lines. 12. Apply the clamps (4). Tighten with the bolts (5). 13. Connect the electrical wiring harness (6) of the valve.

14. Secure the valve cradle with the bolts and nuts (1).

15. Connect the left-hand duct (1) to the air box. Secure with the clamps (2). 16. Re-fill the engine cooling system.

Next operation: Console - Install (90.151)

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Evaporator/Heater coil - Remove NOTE: The thermal expansion valve, heater valve and evaporator/heater assembly are located under the operator seat. See accessing the HVAC box Air conditioning Service instruction - Accessing the HVAC box (50.200). NOTE: Rotate the cab temperature control to the maximum heat position before shutting off the tractor for service. This fully opens the heater control valve and allows more coolant to drain from the evaporator/heater assembly. 1. Use a vise clamp to clamp off the heater supply hose on the right hand side of the engine. Close the valve on the heater return hose at the engine. See component locations in Air conditioning - Component identification - Air conditioning system components (50.200) for your engine. 2. Remove the thermal insulation tape from the expansion valve and the evaporator lines. 3. To test the valve see thermal expansion valve testing in this section. Recover the A/C system to remove the evaporator heater core.

RAIL13SP01741AA

RAIL13SP01742AA

RAIL13SP01749AA

4. Using the two hand, two wrench method, disconnect the air conditioning suction and liquid lines at the thermal expansion valve. Remove and discard the O-rings. Cap or plug the lines to prevent dirt and moisture from entering the system. NOTE: Clean packaging tape may be used to seal the expansion valve ports.

5. Pinch the clamp with a pliers to open it and move it to the side. Disconnect the heater return line (1) from the evaporator heater core. 6. Loosen the clamp and disconnect the short hose (2) between the heater valve and evaporator/heater core. Be prepared to collect a small amount of coolant that will drain into the HVAC box.

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7. Remove the two screws securing the blower speed driver and its mounting plate at the rear of the box. 8. Remove the 6-pin connector from the driver and move the blower driver assembly out of the way.

RAIL13SP01750AA

RAIL13SP01751AA

RAIL13SP01752AA

RAIL13SP01753AA

9. Remove the evaporator temperature sensor from the evaporator/heater assembly.

10. Remove the evaporator top gasket and save for reinstallation. Remove the grommet (1) and sensor harness from the evaporator by sliding it out of the slot opening. NOTE: The gasket seals the top of the evaporator and forces the air to move through the core rather than around it. Replace the gasket if it is worn or damaged. 11. Slide the evaporator assembly straight up and out of its side mounting brackets.

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12. Put the assembly on a clean bench. Remove the expansion valve from the evaporator heater core. Use the two wrench, two hand method when removing the thermal expansion valve to prevent damage to the tubes.

RAIL13SP01754AA

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Evaporator/Heater coil - Install 1. Lubricate new O-rings with clean mineral oil and install new O-rings on the evaporator suction and discharge lines.

RAIL13SP01755AA

RAIL13SP01754AA

RAIL13SP01757AA

RAIL13SP01752AA

2. Install the expansion valve. Tighten the fittings to a torque of 25 – 34 N·m (18 – 25 lb ft). Use the two wrench, two hand method when installing the expansion valve to prevent damage to evaporator lines. 3. Install the evaporator/heater assembly into the slide mounting brackets of the HVAC box.

4. Install the sensor harness with grommet in slot in the evaporator. Reinstall the top gasket on the evaporator. NOTE: The gasket seals the top of the evaporator and forces the air to move through the core rather than around it. Replace the gasket if it is worn or damaged

5. Install the evaporator temperature sensor in the evaporator/heater assembly. The evaporator temperature sensor MUST be installed 107 mm (4.2 in) from the left hand rear side of the evaporator. The sensor must be installed below the second refrigeration tube row at a 30° downward angle. Insert the sensor in the evaporator up to the angled section, being careful not to kink the sensor.

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6. Install the 6-pin connector on the blower speed driver. Install the two screws to secure the driver and its mounting plate at the rear of the box.

RAIL13SP01751AA

RAIL13SP01750AA

RAIL13SP01749AA

RAIL13SP01745AA

7. Connect the short hose (1) from the heater valve to the evaporator/heater core. Pinch the clamp to open it and secure the hose at the evaporator line. Connect the heater return line (2) to the evaporator heater core and secure with the clamp.

8. Remove the caps or plugs from the liquid and suction lines to the thermal expansion valve. nstall new O-rings on the lines before reconnecting. Lubricate the O-rings with clean mineral oil prior to installation.

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9. Using the two hand, two wrench method, reconnect the air conditioning suction and liquid lines to the valve.

RAIL13SP01742AA

Post replacement procedures 1. Since the evaporator assembly has been replaced, adjust compressor oil level. Evacuate and charge the air conditioning system. Test system performance following procedures on the foldout. Leak test the valve and evaporator connections with OEM1437.

RAIL13SP01647AA

RAIL13SP01623AA

2. The thermal expansion valve and line along with the inlet and outlet to the evaporator must be insulated for maximum evaporator performance. Apply thermal insulation tape around the expansion valve, connectors, and the inlet and outlet lines of the evaporator. NOTE: The thermal insulation tape is available in 9150 mm (360.2 in) bulk rolls - 1954475C1 - 3 mm (0.12 in) x 63.5 mm (2.5 in) x 9150 mm (360.2 in). 3. To remove air from the cooling system after installation of a replacement evaporator/heater assembly: A. Fill the radiator completely and fill the coolant recovery bottle to the full line. B. Operate the engine for 10 min. C. Stop the engine and allow the radiator to cool. D. Top off radiator and recovery bottle.

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Evaporator/Heater coil - Service instruction - Sealing and cleaning Sealing The top and bottom of the evaporator/heater assembly must be properly sealed to allow air movement through the assembly but not around it. Check the condition of the foam seal on the top of the assembly where it seals with the HVAC box cover. Check the condition of the sealing strip at the front of the evaporator/heater bottom. Replace/repair any seal which has deteriorated with age or which no longer seals properly. 1. Top foam seal 2. Sealing strip

RAIL13SP01758BA

Cleaning If the evaporator/heater assembly is plugged with dirt and debris, locate the source of the debris, correct and then clean the assembly. See Cab pressurizing system - Test - Cab pressurization test (50.300). If the assembly is dry, clean with low pressure compressed air. If the assembly is wet, flush with water using a low pressure hose. NOTE: Check that the condensate drain valves are not plugged before cleaning the assembly with low pressure wash.

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Index Cab climate control - 50 Heating - 100 Evaporator/Heater coil - Component identification - Blower and evaporator . . . . . . . . . . . . . . . . . . . .

Evaporator/Heater coil - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Evaporator/Heater coil - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Evaporator/Heater coil - Service instruction - Sealing and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heater control valve - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heater control valve - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heating - Install - Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heating - Remove - Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Cab climate control - 50 Air conditioning - 200

SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Cab climate control - 50 Air conditioning - 200

TECHNICAL DATA Air conditioning Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 General specification - Temperature and pressure chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Air-conditioning compressor General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

FUNCTIONAL DATA Air conditioning Component identification - Air conditioning system components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Dynamic description - Automatic temperature control operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Overview - Locating ATC problems without fault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Overview - Standard air-conditioning troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Overview - Refrigerant recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Air-conditioning compressor Overview - High and low pressure switch clutch circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Air-conditioning evaporator - Dynamic description - Cab and evaporator temperature sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 - Component localization - Cab and evaporator temperature sensor location . . . . . . . . . . . . . . . . . . . . . . 53

SERVICE Air conditioning Service instruction - Accessing the HVAC box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Recover - Recovering pure 134A refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Recover - Recovering contaminated refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Service instruction - System evacuation and recharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 48149953 12/06/2018

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Leakage test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Flush - System flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Connect of the pressure gauge set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Disconnect of the pressure gauge set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Startup test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Recover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Apply vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Air-conditioning compressor Check - Compressor and clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Magnetic clutch - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Magnetic clutch - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Disassemble - Electromagnetic clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Test - Electromagnetic clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 Air-conditioning compressor - Assemble - Electromagnetic clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 Adjust - Air clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

Air-conditioning condenser Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

Receiver-dryer Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

Expansion valve Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

Air-conditioning evaporator Test - Cab and evaporator temperature sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

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Air conditioning - Special tools Belt tension tool

RAIL13SP01591AA

RAIL13SP01592AA

RAIL13SP01593AA

RAIL13SP01594AA

Refrigerant recovery station 1.8 m (6.0 ft) length, quick disconnect refrigerant charging hoses: (Yellow, Blue, Red) 6.1 m (20.0 ft) length, quick disconnect refrigerant hoses - (Set includes Yellow, Blue and Red hoses)

Compressor tool set The compressor dipstick (1) can be found in the Compressor Tool Set or purchased separately.

228.6 mm (9.0 in) stem type thermometer 0 â&#x20AC;&#x201C; 250 Â°F

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Combination impact and chemical splash safety goggles

RAIL13SP01628AA

RAIL13SP01596AA

RAIL13SP01629AA

RAIL13SP01630AA

Refrigerant identifier

Air-powered recovery station with tank NOTE: Tool number is sold through CNH parts system.

Additional 22.7 kg (50.0 lb) contaminated refrigerant tanks

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.25 in FFLX to .5 in acme adapter

RAIL13SP01631AA

Electronic leak detector

RAIL13SP01632AA

RAIL13SP01633AA

RAIL13SP01634AA

UV leak detection lamp and goggles

Recovery station UV dye injector for R134A refrigerant

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UV leak detection dye for R134A refrigerant

RAIL13SP01635AA

RAIL13SP01636AA

RAIL13SP01637AA

RAIL13SP01638AA

R134A quick and easy dye injector tool

Quick and easy R134A charge cans - 6-pack

UV fluorescent dye cleaner

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Power flush model 17550 - A/C flushing solution Case of six, 3.8 l (1.0 US gal) containers

RAIL13SP01639AA

RAIL13SP01640AA

RAIL13SP01641AA

RAIL13SP01642AA

Flush gun kit model 17585 - A/C flushing solution Case of six, 3.8 l (1.0 US gal) containers

Coalescing air filter/dryer Similar to Ingersoll-rand model IR5CHE or Grainger model 4KR65

Pressure regulator Capable of providing 310 kPa (45 psi) at 0.11 cmm4 (4.0 cfm) with integrated pressure gauge

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17582 universal flush fitting kit

RAIL13SP01643AA

Air conditioning - General specification Air conditioning system refrigerant capacity Clutch front plate air gap

1.65 kg (3.63 lb) 0.41 – 0.79 mm (0.016 – 0.031 in)

Air conditioning - General specification - Temperature and pressure chart Ambient temperature 21 °C (70 °F)

Normal low side pressure Low relative High relative humidity** humidity 117 – 138 kPa 145 – 172 kPa (17 – 20 psi) ** (21 – 25 psi)

27 °C (81 °F)

145 – 172 kPa (21 – 25 psi)

172 – 207 kPa (25 – 30 psi)

32 °C (90 °F)

179 – 207 kPa (26 – 30 psi)

207 – 234 kPa (30 – 34 psi)

38 °C (100 °F)

200 – 241 kPa (29 – 35 psi)

228 – 276 kPa (33 – 40 psi)

43 °C (109 °F)

228 – 276 kPa (33 – 40 psi)

255 – 319 kPa (37 – 46 psi)

49 °C (120 °F)

255 – 319 kPa (37 – 46 psi)

283 – 345 kPa (41 – 50 psi)

Normal high side pressure Low relative High relative humidity** humidity 938 – 1117 kPa 1040 – 1214 kPa (136 – 162 psi) (151 – 176 psi) 1158 – 1262 – 1469 kPa 1379 kPa (183 – 213 psi) (168 – 200 psi) 1372 – 1482 – 1724 kPa 1641 kPa (215 – 250 psi) (199 – 238 psi) 1593 – 1662 – 2027 kPa 1951 kPa (241 – 294 psi) (231 – 283 psi) 1813 – 1875 – 2289 kPa 2213 kPa (272 – 332 psi) (263 – 321 psi) 2034 – 2089 – 2551 kPa 2482 kPa (303 – 370 psi) (295 – 360 psi)

Louver temperature* Low RH**

High RH

13 °C (55 °F)

17 °C (63 °F)

16 °C (61 °F)

19 °C (66 °F)

22 °C (72 °F)

25 °C (77 °F)

27 °C (81 °F)

28 °C (82 °F)

30 °C (86 °F)

*Temperatures shown are highest normal temperatures expected, actual louver temperatures may be cooler. Louver temperature measured in the louvers facing the operator. ** Compressor clutch cycling may occur under low humidity, low temperature condition. The pressure-temperature chart is based on the following conditions: 1.

Engine operating at 1500 RPM.

No engine load.

Blower speed control in the highest speed position.

Door and rear window open.

Air-conditioner temperature control set to maximum cooling.

Air-conditioner control switch set to “ON” (Standard A/C) or Defog/defrost (ATC) mode. 48149953 12/06/2018

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Gauge readings taken 15 min after start up.

Hood closed with all side panels in position.

Heater supply line clamped and return valve closed at the engine.

10. All cab air louvers open.

Air conditioning - General specification Refrigerant specification Refrigerant charge System delivery side pressure System suction side pressure Configuration of the high-pressure pressure switch Configuration of the low-pressure pressure switch Temperature of refrigerant fluid at compressor outlet Temperature of refrigerant fluid at condenser outlet Temperature of refrigerant fluid at evaporator outlet Maximum capacity of electric centrifugal fan I, II, III speed

Gas CNH REFRIGERANT HFC-134A 1600 g 16.0 – 24.0 bar (232.0 – 348.0 psi) 0.5 – 3.0 bar (7.2 – 43.5 psi) 25.0 bar (362.5 psi) 2.0 bar (29.0 psi) 60.0 – 120.0 °C (140.0 – 248.0 °F) 40.0 – 60.0 °C (104.0 – 140.0 °F) 0.0 – 15.0 °C (32.0 – 59.0 °F) 3500.0 – 8500.0 L/min (924.6 – 2245.5 US gpm)

Air conditioning - Special tools Special tools Always use approved, suitable equipment for the recovery, recycling, and recharging of the air-conditioning refrigerant of machines. The special equipment should be purchased from trustworthy suppliers. Contact the supplier for details about the latest equipment available for repairing the air-conditioning system. Acquire Acquire Acquire Acquire Acquire Acquire Acquire Acquire

Portable vacuum/charge system Recovery/recharge Portable system Condenser and evaporator cleaner Tape to expansion valve tool Electronic gas leak detector Gauge set Quick release joint tool Compressor tools

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locally locally locally locally locally locally locally locally

Cab climate control - Air conditioning

Air-conditioning compressor - General specification Model Number of Cylinders Volumetric displacement Maximum continuous rotation Direction of rotation, this by clutch side Lubricant oil Oil volume Drive pulley diameter Electrical voltage for clutch actuation

SANDEN SD 7H15 7 154.0 cm³/rev (9.4 in³/rev) 6000 RPM Clockwise SANDEN SP-10 LUBRICANT or equivalent 185.0 cm³ (11.3 in³) 119.0 cm³ (7.3 in³) 12 V

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Air conditioning - Component identification - Air conditioning system components Cab HVAC box components - Automatic temperature control 1.

ATC controller

Blower motor/Fan assembly

Heater control valve (not shown)

Blower speed driver

Compressor clutch relay

Cab temperature sensor

Evaporator temperature sensor

Thermal expansion valve

Low pressure switch

RAIL13SP01705AA

RAIL13SP01614AA

RAIL13SP01706AA

10. Evaporator/Heater assembly Fig. 3 shows Thermal tape removed for clarity

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Cab HVAC box components - Automatic temperature control

RAIL13SP01707GA

11. 12. 13. 14. 15. 16. 17. 18. 19.

Lid assembly ATC controller Blower speed driver Blower assembly A/C low pressure switch Heater control valve assembly Heater/evaporator assembly A/C suction line tube A/C liquid line tube

20. 21. 22. 23. 24. 25. 26. 27.

Heater supply hose Heater return hose Evaporator temperature sensor Base weldment Evaporator box assembly Thermal expansion valve Drain hose Check valve

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Cab HVAC components - Standard systems 1.

Standard controller

Compressor clutch relay

Evaporator/heater assembly

Evaporator temperature sensor

HVAC box ground

Heater control valve

Thermal expansion valve

Low pressure switch

Blower motor assembly with resistors

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RAIL13SP01708AA

RAIL13SP01619AA

RAIL13SP01709AA

RAIL13SP01623AA

Cab climate control - Air conditioning

RAIL13SP01710AA

Cab HVAC components - Standard systems

RAIL13SP01711FA

1. 2. 3. 4.

5. 6. 7. 8. 9.

Lid assembly Standard A/C controller Blower assembly Resistor assembly A. Resistor B. Mounting bracket Wire harness (not shown) Low pressure switch Heater/evaporator coil assembly Heater control valve assembly A/C suction line tube

10. 11. 12. 13. 14. 15. 16. 17. 18. 19.

A/C liquid line tube Heater supply hose Heater return hose Evaporator temperature sensor Base weldment Evaporator box assembly Thermal expansion valve Clutch relay Drain hose Check valve

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Chassis components NOTE: Make sure that all A/C hose and line connections are properly torqued. Check hoses for bends or cracks. Replace all hoses that have damage.

RAIL13SP01601GA

1. 2. 3. 4. 5.

Hose assembly, condenser to drier Engine compartment Condenser Hose assembly, condenser to compressor Receiver drier

6. 7. 8. 9. 10.

Hose assembly, cab to drier Compressor High pressure switch Hose assembly, cab to compressor HVAC compartment (below the cab)

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Air conditioning - Overview A/C Thermal operation The refrigerant circuit of the air-conditioning system contains five major components: compressor, condenser, receiver-drier, expansion valve and evaporator. These components are connected by tubes and hoses and operate as a closed system. The air-conditioner system is charged with HFC R134A refrigerant. (See below diagram to follow refrigerant flow.) The compressor receives the refrigerant as a low pressure gas. The compressor then compresses the refrigerant and sends it in the form of a high pressure gas to the condenser. Air flow through the condenser removes the heat from the refrigerant. As the heat is removed the refrigerant is â&#x20AC;&#x153;condensedâ&#x20AC;? to a high pressure liquid. The high pressure refrigerant liquid flows from the condenser to the receiver-drier. The receiver-drier is a container filled with moisture removing material, which removes any moisture that may have entered the air-conditioner system in order to prevent corrosion of the internal components. NOTE: Not all refrigerant leaves the condenser as a liquid. Some leaves as a gas without affecting system performance. Liquid refrigerant pools at the bottom of the receiver-drier, while the lighter gas collects at the top. Since the pick-up tube draws refrigerant from the bottom of the receiver-drier, only liquid refrigerant flows to the thermal expansion valve. The refrigerant, still in high pressure liquid form, flows from the receiver-drier to the expansion valve. The expansion valve provides a restriction to refrigerant flow to cause a pressure drop which allows the liquid refrigerant to expand, decreasing its temperature and pressure. NOTE: The thermal expansion is internally equalized, the need for refrigerant to handle the heat load is balanced with the ability to fully vaporize the refrigerant within the one valve. This low temperature, low pressure liquid or mist flows through the evaporator. The hot cab air passes through the evaporator fins cooling the air and evaporating the liquid refrigerant. The low pressure gas returns to the compressor and the cycle starts all over again.

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RAIL13SP01597GA

Low pressure gas Low pressure liquid High pressure gas High pressure liquid 1. 2. 3.

Compressor Condensor Receiver-drier

4. 5.

Thermal expansion valve Evaporator

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Air conditioning - Component identification Cab HVAC box components - Automatic temperature control

1. 2. 3. 4. 5.

Blower speed driver ATC controller Thermal expansion valve Heater control valve Blower motor assembly

RAIL13SP01598FA

RAIL13SP01599EA

6. 7. 8. 9.

Evaporator core Evaporator temperature sensor Cab temperature sensor Compressor clutch relay

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Cab HVAC box components - automatic temperature control

RAIL13SP01707GA

1. 2. 3. 4. 5. 6. 7. 8. 9.

Lid assembly ATC controller Blower speed driver Blower assembly A/C low pressure switch Heater control valve assy Heater/evaporator assembly A/C suction line tube A/C liquid line tube

10. 11. 12. 13. 14. 15. 16. 17.

Heater supply hose Heater return hose Evaporator temperature sensor Base weldment Evaporator box assembly Thermal expansion valve Drain hose Check valve

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Chassis components NOTE: Make sure that all A/C hose and line connections are properly torqued. Check hoses for bends or cracks. Replace all hoses that have damage.

RAIL13SP01601GA

1. 2. 3. 4. 5.

Hose assembly, condenser to drier Engine compartment Condenser Hose assembly, condenser to compressor Receiver drier

6. 7. 8. 9. 10.

Hose assembly, cab to drier Compressor High pressure switch Hose assembly, cab to compresser HVAC compartment (below the cab)

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Air conditioning - Dynamic description - Automatic temperature control operation The ATC controller is a closed loop control device which takes the data from a variety of inputs and executes output instructions to the devices it controls. The controlling parameter for the system is cab inside temperature. The operator selects a desired cab temperature with the temperature control. The controller uses the compressor, heater control valve and blower speed to drive to and maintain the desired setpoint. It also uses the mode door to effectively distribute the cooled or warmed air in the cab. The controller receives input from the following controls and sensors: ATC switch Cab temperature sensor Setpoint temperature Evaporator temperature sensor Low pressure switch High pressure switch Blower speed control And Â°F/Â°C display selector

On the desired operational mode for the system: Off, Automatic or Defog/Defrost Located at the recirculated air return, on current cab temperature Selected by the operator with temperature control, on desired cab temperature Inserted in the evaporator/heater assembly, on current cooling or heating temperatures On the status of abnormal system pressures on the low side On the status of abnormal system pressures on the high side When the operator chooses to override the blower speed selected by the controller Which changes temperature display from Fahrenheit to Celsius

To accomplish its heating and cooling functions, the controller uses the following output devices: Compressor clutch via clutch relay Heater control valve Blower speed via blower speed driver And instrument cluster display (in instrument cluster)

To engage or disengage the compressor to achieve the desired cab cooling setpoint By varying the valve opening, to achieve the desired cab heating setpoint To deliver the conditioned air from the evaporator/heater assembly at a speed proportional to the gap between the current cab temperature and the desired setpoint To display the desired cab temperature setpoint, operational modes, system status and fault codes

RAIL13SP01602EA

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RAIL13SP01603BA

Blower speed control

ATC switch

Defog/Defrost switch

Instrument cluster display (Fig. 2)

Temperature control

Manual selection of blower speed which overrides controller selection

A. Blower OFF B. Maximum blower speed

C. Automatic mode D. OFF E. Manual mode F. Defog/Defrost mode G. Digital temperature display: Displays current setpoint selected by the operator for desired cab temperature On startup flashes “88” for short time to indicate that the controller is initializing When system fault occurs, display toggles between temperature display and fault code number Displays temperature setpoint H. Displays °F or °C for Fahrenheit or Celsius. To change the display to °F or °C, press and hold the and system status key pad AUTO key for three seconds after the screen has been turned on I. Icon displays when system is operating in Defog/Defrost mode J. Auto/Manual switch status K. Blower control status L. Blower control level M. ATC temperature range: 15.5 – 32 °C (60 – Selects temperature setpoint, 90 °F) the controlling parameter for N. Maximum cooling zone: 15.5 °C (60 °F) the system O. Maximum heating zone: 32 °C (90 °F) Selects operational mode

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Operation modes Automatic mode Automatic mode is selected by placing the three position mode switch in auto mode (down position). The AUTO icon will display on the bottom right corner of the programmable display screen. In this mode the system attempts to maintain cab set point temperature selected by the operator with the temperature control knob (displayed on the programmable display screen) by modulating temperature and fan speed.

Manual override of the blower fan while in automatic mode If the blower fan knob is adjusted while in the automatic mode, the blower speed is changed to a manually selected setting and remains constant. The system will attempt to maintain cab set point temperature only by modulating air flow temperature at the blower speed selected by the operator. To return to automatic control mode, toggle the three position mode switch from AUTO to OFF and back to the AUTO mode.

Maximum cooling in automatic mode Maximum cooling is selected by moving the temperature control knob fully counter clockwise. In this mode, the blower fan is automatically set to full speed, pressurizer blower is disengaged (unless defog mode has been previously selected) and A/C system delivers maximum cooling capacity. Pressurizer blower is reengaged in two ways: 1. If defog function is selected by pressing momentary defog switch to provide additional fresh air required for defog operation. 2. Blower speed setting is manually reduced to a lower setting.

Maximum heating in automatic mode Maximum heating is selected by moving the temperature control knob fully clockwise. In that mode, the blower fan is automatically set to full speed and the heating system delivers maximum heating capacity. Blower speed can be manually changed to a lower speed. NOTE: In any heating operation blower speed remains at 25% until the circulated air flow warms to 12.8 Â°C (55 Â°F).

OFF mode OFF mode is selected by placing the three position mode switch in OFF mode. (center position) In OFF mode the blower fan is disengaged and the HVAC system provides no means of cooling or heating the cab. The pressurizer blower continues to operate to provide fresh air and to pressurize the cab.

Manual override of the blower fan while in OFF mode If the blower fan knob is adjusted while in OFF mode, the blower speed is changed to the manually selected setting and remains constant. To turn blower back OFF, either turn the blower speed control knob fully counterclockwise or toggle the three position mode switch from OFF to AUTO or Manual mode and back to OFF.

Manual mode Manual mode is selected by placing the three position mode switch in the manual mode (up position). In manual mode all control variables such as blower speed, level of cooling or heating are set by the operator. The system does not maintain cab temperature but rather maintains blower speed and cooling or heating level requested by the operator. If tractor cab heating or cooling load changes the operator may need to adjust the controls to maintain adequate comfort level in the cab.

Defog mode The purpose of Defog mode is removal of moisture from the cab which is fogging or frosting the windows. Defog mode is selected by pressing the momentary DEFOG switch when in either Auto mode or Manual mode. The switch lamp will illuminate and the defog icon will display in the lower left corner on the programmable display screen.

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The HVAC system enables the A/C compressor to run at all times, but otherwise functions according to the mode selected by the three position ATC selection switch. Defog function is stopped if the momentary defog switch is pressed again or the OFF mode is selected by the three position ATC switch. Once selected, Defog operation is retained if the three position mode switch is toggled quickly between Auto and Manual modes. Defog function is not retained if the mode switch is toggled slowly or the ignition key switch is cycled. Automatic operation summary (ATC switch set to “Auto”, and “Auto” displays on the instrument cluster display. No fault codes active) Controller needs a 1 °C (2 °F) difference between the setpoint and temperature sensed at cab sensor before responding - engaging the compressor or opening Temperature argument the heater valve. Selecting a setpoint one degree cooler or warmer than the temperature desired may increase operator comfort If difference between cab temperature Then the blower speed used by the and the setpoint is controller is Less than or equal to 1 °C (2 °F) 25% Greater than 1 °C (2 °F) but less than or 35%* equal to 2 °C (4 °F) Greater than 2 °C (4 °F) but less than or 45%* equal to 3 °C (6 °F) Blower speed Greater than 3 °C (6 °F) but less than or 55%* equal to 4 °C (8 °F) Greater than 4 °C (8 °F) but less than or 65%* equal to 5 °C (10 °F) Greater than 5 °C (10 °F) but less than or 75%* equal to 6 °C (12 °F) Greater than 6 °C (12 °F) 100%* Compressor clutch is cycled ON or OFF by the controller as needed to drive to or Compressor clutch cycling maintain the desired cab temperature setpoint Heater control valve is opened or closed as needed to drive to or maintain the Heater control valve desired cab temperature setpoint • Blower speed remains in position selected by operator Manual override of blower control

• Instrument cluster display no longer displays “Auto” for automatic • Temperature and mode door control remain automatic, but controller cannot use any speed beyond that selected to achieve the desired setpoint • Turning ATC switch OFF and then to “A” returns system to automatic operation • Blower speed at 100% • Mode door to mid-cab vents

• Compressor runs continuously. The clutch is only cycled OFF when the freeze setting 0 °C (32 °F) - is reached at the evaporator temperature sensor, and then Maximum cool setting selected ON again when temperature sensed warms to 3 °C (37 °F) • Instrument cluster display no longer displays “Auto” for automatic • Moving the temperature control outside the maximum range returns the system to automatic control of compressor, blower and mode door Blower speed at 100%.* • • Mode door to floor vents Maximum heat setting selected

Exception

• Heater control valve at full open position • Instrument cluster display no longer displays “Auto” for automatic • Moving the temperature control outside the maximum range returns the system to automatic control of valve, blower and mode door * When heating is selected, blower speed remains at 25% until temperature sensed at evaporator exceeds 12.8 °C (55 °F)

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Defog/Dehumidify operation summary (Defog/Dehumidify switch “ON”, Defog light ON. No fault codes active) Controller needs a 1 °C (2 °F) difference between the setpoint and temperature sensed at cab sensor before responding - engaging the compressor or opening Temperature argument the heater valve. Selecting a setpoint one degree cooler or warmer than the temperature desired may increase operator comfort If difference between cab temperature Then the blower speed used by the and the setpoint is controller is Less than or equal to 1 °C (2 °F) 25% Greater than 1 °C (2 °F) but less than or 35%* equal to 2 °C (4 °F) Greater than 2 °C (4 °F) but less than or 45%* equal to 3 °C (6 °F) Blower speed Greater than 3 °C (6 °F) but less than or 55%* equal to 4 °C (8 °F) Greater than 4 °C (8 °F) but less than or 65%* equal to 5 °C (10 °F) Greater than 5 °C (10 °F) but less than or 75%* equal to 6 °C (12 °F) Greater than 6 °C (12 °F) 100%* ** Compressor runs continuously to remove moisture from cab. The clutch is only cycled OFF when the freeze setting - 0 °C (32 °F) - is reached at the evaporator Compressor clutch cycling temperature sensor, and then ON again when temperature sensed warms to 3 °C (37 °F) Heater control valve is opened or closed as needed to drive to or maintain the Heater control valve desired cab temperature setpoint • Blower speed remains in position selected by operator • Instrument cluster display continues to display “defog” icon Manual override of blower control

Maximum cool setting selected

Maximum heat setting selected

Exceptions

• Temperature and mode door control remain automatic, but controller cannot use any speed beyond that selected to achieve the desired setpoint • Turning ATC switch OFF and then to the “snowflake” icon returns the blower to standard defog operation Improper use of the system, compressor is running continuously in defog mode. Temperature control must be in heating range to defog or defrost the cab • Blower speed at 100%.* • Heater control valve at full open position • Instrument cluster display continues to display “defog” icon • Moving the temperature control outside the maximum range returns the system to standard defog control of valve, blower and mode door * When heating is selected, blower speed remains at 25% until temperature sensed at evaporator exceeds 12.8 °C (55 °F) ** On very cold days, compressor does not engage until temperature at the evaporator sensor exceeds 0 °C (32 °F)

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Air conditioning - Overview - Locating ATC problems without fault codes Controller-based resistance tests Pin ID 36-Pin conn. --> 1 --> 2

Description CAN low CAN high

Wire/Color

-->

Heat signal output

9C-Or

-->

Heat actuator power

6D-Or

-->

Blower speed output

SBC-Or

-->

Blower actuator power

252-Or

-->

Mode 1 output

102-Or

8 9 10 11 12 13 14 15 16 17

--> --> --> --> --> --> --> --> --> -->

Mode 1 act power Mode 2 output Mode 2 act power Recirc output Recirc act power Pressurizer output Pressure act power Clutch relay coil Condenser fan relay coil Switch batt B+

19 20

-->

309-N

RCV from keypad TK to keypad

OPEN 262-Or

Cab temp

Outlet temp

SEN-Or

Evap temp

PB-S

Outside temp

OPEN

Manual switch

If open line, see Blower - Test - Blower and blower speed driver (55.050) If open line, see Air conditioning - Overview - Standard air-conditioning troubleshooting (50.200)

Less than 10 ÎŠ. If open line, see Automatic Temperature Control (ATC) module - Dynamic description - Controller power, ground, and ATC switch (55.050)

OPEN

If open line, see Heater control valve - Check (50.100)

MD-Or OPEN OPEN OPEN OPEN OPEN OPEN AC-ATC DEFLT-Or 252-Or

Ground

Expected result/Reference

CAN LOW CAN HIGH

Fault Code

266-Or

If open line, see Air-conditioning evaporator - Test - Cab and evaporator temperature sensors (50.200). Perform initial temperature versus resistance test to check if sensor is failing. See Air-conditioning evaporator - Test - Cab and evaporator temperature sensors (50.200). Retest at sensor location/temperature for most accurate result Less than 10 ÎŠ. If open line, see Automatic Temperature Control (ATC) module - Dynamic description - Controller power, ground, and ATC switch (55.050)

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Pin ID 36-Pin conn.

Description

Auto switch

27 28 29 30 31 32 33 34 35 36

C/F ground selection Blower input Set point input Air direction input Defog switch Cab pressure input High pressure + input High pressure - input Low pressure + input Low pressure - input

Wire/Color

Fault Code

136-Or

Expected result/Reference Less than 10 Ω. If open line, see Automatic Temperature Control (ATC) module - Dynamic description - Controller power, ground, and ATC switch (55.050)

143-N 326-Or 103-Or 154-Or DEFSW Or OPEN 80-Or HP-Bk LP-Or LP-N

To perform the above resistance tests at the controller, with the keyswitch “OFF”: 1. Disconnect the harness to the 36-pin connector at the ATC controller. 2. At the harness connector, test the resistance between the pins indicated and the battery negative post. NOTICE: Use an appropriately sized probe when testing to avoid damaging the pins.

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Air conditioning - Overview - Standard air-conditioning troubleshooting NOTE: Connectors and their pins or terminals are abbreviated throughout the troubleshooting section. J022-T represents pin T on connector 022, C333-15 represent s pin 15 on connector 333. NOTE: The standard controller and many components are grounded to the “HVAC ground.” The HVAC ground is both a grounding bolt at the back of the HVAC box and a chassis ground at ring terminal 172F – on wire 85_CCU-N inside the box and on wire 177FBK outside of the box. The stability of this ground is essential for reliable troubleshooting. NOTE: All operating controls must be in neutral or park lock position when performing these tests.

RAIL13SP01619AA

NOTE: Use a multimeter (DVOM) for these tests. Do NOT use a self-powered test light for any of these tests. NOTE: The batteries must be fully charged and all connections clean and tight. Inspect all connectors for damage, bent or dislocated pins or improper seating when troubleshooting. Fig. 1 shows Ground stud at rear of HVAC box

Standard A/C operation The standard A/C controller is an open loop control device. The controller provides electronic thermostat control. The compressor clutch is engaged and disengaged by the standard controller. The clutch is cycled from 0 – 19 °C (32 – 66 °F) evaporator temperature sensor values proportional to the temperature control potentiometer position from 12 o’clock to full counter-clockwise. The standard controller opens the heater control valve from full closed to full open position proportional to the temperature control potentiometer position from 12 o’clock to full clockwise. If cab temperature is to be made cooler or warmer or if blower speed is to be increased or decreased, it is the operator who makes the adjustment.

RAIL13SP01620EA

Standard A/C temperature control

Smart pressure switch cycling system The standard A/C system is equipped with pressure switch cycle counters. The compressor is latched OFF after four activations of the low pressure switch within a 60 s interval. The compressor is also latched OFF after two activations of the high pressure switch within a 60 s interval. The 60 s interval starts with the first activation of the switch in both cases. 48149953 12/06/2018

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NOTE: Actual interval may be as short as 10 s if the open condition is constant. The controller flashes the pressure warning lamp (mounted in the A/C On/Off switch) slowly, approximately 7 times in a 10 s period for the low pressure switch, or quickly, approximately 13 times in a 10 s period for the high pressure switch. The compressor clutch remains latched OFF until the A/C switch or keyswitch is toggled OFF and then ON. However, toggling the switch does not correct the pressure problem, and system service is required. NOTE: Your A/C systems are designed to prevent A/C compressor failure due to low pressure or low refrigerant charge. Operation on days below 4 °C (39 °F) may actuate the low pressure sensing system and shut down the A/C system. The system is not malfunctioning if this occurs. Toggle the A/C switch to OFF and then ON to reset the system.

Standard A/C controls and their function

RAIL13SP01621EA

Blower speed control

A/C ON/OFF switch

Temperature control

Manual selection of blower speed: Low, medium or high or OFF With A/C switch in the OFF position and any blower speed selected, the control provides fresh air circulation for the cab with outside ambient air introduced with the cab pressurizer blower to the HVAC box A. Pressure warning indicator: the warning lamp blinks slowly, approximately 7 times in a 10 s period for low Toggles cooling On or Off pressure switch activation, or quickly, approximately 13 times in a 10 s period for the high pressure switch activation B. Maximum cooling zone - 0 °C (32 °F); compressor runs continuously until the freeze setting at the evaporator Compressor is engaged temperature sensor cycles the clutch OFF. The clutch or heater valve is opened is turned on again when the evaporator thaws to 3 °C in direct proportion to the (37 °F). movement of the control C. Maximum heating zone, heater control valve at 100% open position

Symptom-based standard A/C troubleshooting Symptom A/C system is inoperative Compressor operates, but blower is inoperative

Possible cause Blower speed switch defective Fuse 27 Power and ground to blower motor Blower motor defective

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Test or reference See blower speed switch and blower motor. See blower speed switch and blower motor.

Cab climate control - Air conditioning

Symptom Possible cause Blower operates, compressor High pressure switch activated locking is inoperative out the clutch Standard A/C controller blinks warning lamp (in the A/C ON/OFF switch) quickly, approximately thirteen times in a 10 s period Low pressure switch activated locking out the clutch Standard A/C controller blinks warning lamp (in the A/C ON/OFF switch) slowly, approximately seven times in a 10 s period Evaporator temperature sensor â&#x20AC;&#x153;freezeâ&#x20AC;? setting reached cycling the clutch OFF Open in switched ground to relay from controller Power and ground to clutch relay Clutch relay defective Controller defective Fuse 26 or power and ground to controller Loose or broken drive belts Compressor clutch defective Compressor defective Blower operates, no heat, Heater control valve defective (Control too much heat or heat output valve can fail in any position - open, cannot be changed closed, midway.) Power and ground to heater control valve Temperature control potentiometer disconnected or defective Coolant not hot Blower operates but not at all Blower speed switch defective speeds: no low speed and/or Open line from in-line connector to motor no medium speed but high Motor resistor disconnected or defective speed operates Too little cooling, too little Evaporator temperature sensor failing heating with system pressures Open line to evaporator temperature and components normal sensor Power and ground to cab pressurizer blower Fuse 32 Cab pressurization blower does not run when switched Cab pressurizer relay disconnected or defective B+ is present Power and ground to cab pressurizer blower relay

Test or reference

See high and low pressure clutch latching.

See evaporator temperature sensor. See electrical test for clutch relay in Air-conditioning compressor - Check Compressor and clutch (50.200) See standard controller test See controller power and ground test. See operational check for compressor and clutch in Air-conditioning compressor - Check - Compressor and clutch (50.200) See heater control valve.

See temperature control pot. See engine cooling section. See blower speed switch and blower motor.

See evaporator temperature sensor.

See cab pressurizer blower.

Controller power, Ground and A/C switch NOTE: See electrical schematic sheets.

History HVAC Ground HVAC ground is both a grounding stud at the rear of the HVAC box and chassis ground at ring terminal 172F through J022-F on wire 178-Bk.

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Intermittent ground Intermittent HVAC ground can make reliable troubleshooting very difficult. The “intermittent” nature of the problem is further complicated since the fault can appear to move from component to component. Early testing for a stable and consistent ground at the ground bolt and ring terminal 172F can greatly simplify troubleshooting.

Power and Ground Circuit Standard controller Whenever switched B+ is present, 12 V is supplied to the controller from fuse 27 ( 5 A) through J022-R to pin A at the controller (CCU1). The controller is grounded through pin F (CCU1) to the HVAC ground stud.

A/C switch The controller feeds 5 V from pin E (CCU1) through J022-L to the switch at pin 6, grounding pin 6 with the switch provides the ON request to the controller. The switch is grounded from pin 5 to chassis at splice C14.

Pressure warning lamp The controller provides switched ground from pin C on (CCU2) through J022-M to the switch at pin 9 for the pressure warning lamp. The lamp is powered at pin 10 with switched B+ from fuse 28. Possible failure modes 1. Fuse 27 open condition in power or ground to controller. 2. A/C switch failure. 3. Open condition in power or ground to switch or pressure warning lamp.

Controller power supply and ground test

Steps and test point Corrective actions Key switch ON. Measure the voltage between pin A YES - Go to Step 3 at the controller (CCU1) and chassis ground. Is 12 V NO - Go to next Step present? YES - Locate and repair open condition between fuse 27 and pin A at the controller Check fuse 27 ( 30 A). Is 12 V present? NO - Locate and repair open condition from fuse 27 to switched B+. Go to next Step YES - Test the controller. See standard controller test Measure resistance from pin F at the controller NO - Locate and repair open condition from pin F to (CCU1) to the HVAC ground stud. Less than 1 Ω? HVAC ground

A/C switch and circuit test

1. 2. 3.

Steps and test point Disconnect A/C switch from harness. With switch ON, measure resistance across pins 5 and 6 on switch. Less than 1 Ω? Measure resistance across pins 9 and 10 at switch. Less than 1 Ω? Measure resistance from pin 5 at the harness connector to chassis ground. Less than 1 Ω?

Corrective actions YES - Go to next Step NO - Replace the switch YES - Go to next Step NO - Replace the switch YES - Go to next Step NO - Locate and repair open condition between pin 5 and ground

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Steps and test point Corrective actions Key switch ON. Is 5 V present at pin 6 at the harness YES - Go to Step 6 NO - Go to next Step connector? YES - Locate and repair open condition between pin E at controller and pin 6 at switch through J022-L Is 5 V present at pin E at the controller (CCU1)? and J029-A NO - Test the controller. See standard controller test YES - Go to next Step Is 5 V present at pin 10 at the harness connector to NO - Locate and repair open condition in switched B+ the switch? to pin 10 at switch. Check fuse 28. Reconnect the A/C switch to harness. Disconnect the harness to the low pressure switch. Key switch, YES - Test the controller. See standard controller test air conditioning switch, and blower control ON. NO - Locate and repair open condition between pin C Temperature control to maximum cool. Is 5 V present at controller and pin 9 at the switch through J029-A between pin C at the controller (CCU2) and chassis and J022-M ground?

High and low pressure switch clutch latching circuit History High pressure switch activation is generally caused by a restriction or clog on the high pressure side of the system. However, a refrigerant or PAG SP20 oil overcharge, the presence of refrigerants other than R134A or engine cooling problems can also cause high pressure switch activation. Fig. 4 shows High pressure switch at compressor

RAIL13SP01622AA

RAIL13SP01623AA

Low pressure switch activation is generally caused by low refrigerant level resulting from a leak(s). Sometime low pressure switch activation, however, is caused by a restriction, where because of the location either pressure switch may activate first. For example, a restriction at the output of the receiver-drier could cause either high or low pressure switch activation. Refer to the A/C troubleshooting foldout and performance testing to locate the cause for your system. NOTE: Your A/C systems are designed to prevent A/C compressor failure due to low pressure or low refrigerant charge. Operation on days below 4 Â°C (39 Â°F) may actuate the low pressure sensing system and shut down the A/C system. The system is not malfunctioning if this occurs. Toggle the A/C switch to OFF and then ON to reset the system. When either pressure switch opens within the smart pressure counting conditions, the pressure warning lamp flashes on the A/C switch, and the compressor clutch is latched OFF by the controller. Fig. 5 shows Low pressure switch at expansion valve

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Possible failure modes - Flashing pressure warning lamp Warning light

Warning lamp flashes rapidly, about 13 times in a 10 s period

Warning lamp flashes slowly, about 7 times in a 10 s period

Description Controller has detected an open condition in high pressure switch circuit. Compressor clutch is latched OFF. Clutch latching is not activated until two occurrences Pressure switch within a 60 s interval, starting with the first occurrence. counting Actual interval may be as short as 10 s if open condition is constant 1. High pressure switch has opened because of high side system pressures. High pressure switch opens at system pressures above 2689 – 2827 kPa (390 – 410 psi). The switch closes when system pressure drops below 1655 – Causes 1793 kPa (240 – 260 psi) 2. Any intermittent open at a connector in the circuit appears the same to the controller Controller has detected an open condition in low pressure switch circuit Compressor clutch is latched OFF Clutch latching is not activated until four occurrences Pressure switch within a 60 s interval, starting with the first occurrence. counting Actual interval may be as short as 10 s if open condition is constant 1. Low pressure switch has opened because of low side system pressures. Low pressure switch opens at system pressures below 14 – 42 kPa (2 – 6 psi). The switch closes when system pressures rise above 117 – 159 kPa Causes (17 – 23 psi) 2. Any intermittent opening at a connector in the circuit appears the same to the controller NOTE: Your A/C systems are designed to prevent A/C compressor failure due to low pressure or low refrigerant charge. Operation on days below 4 °C (39 °F) may actuate the low pressure sensing system and shut down the Exception A/C system. The system is not malfunctioning if this occurs. Toggle the A/C switch to OFF and then ON to reset the system.

Although system pressures may return to normal, the clutch remains latched OFF until the ignition key or air conditioning switch is toggled OFF and then ON. The controller disables the clutch by denying ground to the clutch relay. Cycling the power switch does not resolve the pressure problem, however, install the pressure test gauges and performance test the system.

Switch testing When disconnected from the system, the low pressure switch will test normally open, the high pressure switch will test normally closed. When installed in the A/C system under normal operating pressures, both pressure switches should test CLOSED.

Electrical test – Pressure switches NOTE: See electrical schematic sheets.

Power and ground The controller feeds 5 V from pin C (CCU1) to J813-A on the high pressure switch. Switch terminal J813-B is connected to chassis ground.

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The controller feeds 5 V from pin B (CCU2) to pin B on the low pressure switch. Switch terminal A is connected to chassis ground.

High pressure switch and circuit test

Steps and test point Refer to A/C troubleshooting foldout and follow the conditions for performance testing. Install A/C high and low side pressure gauges. High reading above 2689 – 2827 kPa (390 – 410 psi)? Shut down the tractor. Disconnect the switch from the harness and the unit. Check that switch is closed across pins A and B Reinstall the switch in the unit; do not reconnect the harness. Key switch and air conditioning switch ON, blower control on any speed, temperature control at maximum cooling position. Is 5 V present at Pin 1 at the harness to the switch?

Corrective actions YES - Perform corrective actions from A/C troubleshooting foldout NO - Go to next Step OK - Go to next Step NOT OK - Replace switch

YES - Go to next Step NO - Go to Step 5

YES - Go to next Step Key switch OFF. Measure resistance from pin A at the NO - Locate open condition and repair between pin A switch to ground. Less than 1 Ω? and ground YES - Locate open condition and repair between pin Key switch ON. Is 5 V present at pin C at the controller C at the controller and pin B at the switch (CCU1)? NO - Test the controller. See standard controller test

Low pressure switch and circuit test

Steps and test point Refer to A/C troubleshooting foldout and follow the conditions for performance testing. Install A/C high and low side pressure gauges. Low reading below 14 – 42 kPa (2 – 6 psi)? Shut down the tractor. Disconnect the switch from the harness and the unit. Check that switch is open across pins A and B Reinstall the switch in the unit; do not reconnect the harness. Key switch and air conditioning switch ON, blower control on any speed, temperature control at maximum cooling position. Is 5 V present at Pin B at the harness to the switch?

Corrective actions YES - Perform corrective actions from A/C troubleshooting foldout NO - Go to next Step OK - Go to next Step NOT OK - Replace switch

YES - Go to next Step NO - Go to Step 5

YES - Go to next Step Key switch OFF. Measure resistance from pin A at the NO - Locate open condition and repair between pin A switch to the HVAC ground stud. Less than 1 Ω? and ground YES - Locate open condition and repair between pin Key switch ON. Is 5 V present at pin B at the controller B at the controller and pin B at the switch (CCU2)? NO - Test the controller. See standard controller test

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Heater Control Valve Operational Check The controller opens or closes the heater control valve based on the operator selected input at the temperature control and the temperature sensed at the evaporator sensor. The heater control valve (1) can fail mechanically in any position: open, closed or anywhere in the middle. To confirm proper valve operation, observe the slot on the front of the valve. Rotation of the slot must mirror the movement of the temperature control. NOTE: Mark the actuator, if required, to better observe rotation. RAIL13SP01624AA

RAIL13SP01625AA

The slot must rotate fully clockwise when the control is turned fully clockwise. The slot must rotate fully counterclockwise when the slot is turned fully counter-clockwise. If the valve does not mirror control movement or does not move, perform the valve motor electrical test. 2. Slotted actuator

Valve â&#x20AC;&#x153;leak throughâ&#x20AC;? A common problem with the valve is hot coolant flow when cab cooling is desired. This usually occurs by a when a valve does not close completely. To test for leak through from the valve: 1. Operate the A/C system at maximum cooling and blower speed for 15 min. See conditions for performance testing. 2. Install a stem type thermometer in a cab louver, and record the temperature. 3. Clamp off the coolant supply line (1) before the valve with a vise grip pliers. (The supply line connects at the bottom of the valve.) Wait a few minutes and check the thermometer. If the temperature drops, valve leak through is the problem, replace the valve. NOTE: Do not clamp off the heater supply line or close the heater return line valve at the engine for this test.

Electrical test NOTE: See electrical schematic sheets.

Power, signal and ground circuit The controller feeds 12 V to the heater valve motor, from pin E (CCU2) to pin 10 on the motor. The control signal ( 1.5 â&#x20AC;&#x201C; 11.5 V) is fed from the controller on pin D (CCU2) to pin 8 on the motor. The motor is grounded from pin 7 at the motor to the HVAC ground stud. Possible failure modes: 1. Motor failure or valve physical failure.

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2. Open condition in power, signal or ground to heater control valve. 3. Controller failure.

Heater control valve power, signal and ground test

5. 6. 7.

Steps and test point Corrective actions Key switch and blower speed control ON. Test from pin 8 on valve to chassis ground. While turning the temperature control from max cool to max heat setting, observe both voltmeter and slot on front of the valve If voltage change but no slot movement or slot movement is irregular, heater valve has failed physically or actuator fault. Go to Step 2 If no voltage or no voltage change, go to Step 5 If voltage change and slot movement are continuous, heater valve tests okay Disconnect harness connector to motor. Measure YES - Go to next Step resistance through the motor from Pin 7 to Pin 10. NO - Replace the heater control valve assembly Open line? YES - Go to next Step Measure resistance from pin 7 on valve harness to NO - Locate and repair open condition in ground from HVAC ground stud. Less than 1 Ω? Pin 7 Ignition key and air conditioning switch ON. Measure control signal at the harness connector on pin 8 from YES - Go to Step 5 pin D at the controller, while turning the temperature NO - Go to next Step control. Is range from 1.5 – 11.5 V? YES - Locate open condition and repair between pin Measure control signal at pin D at the controller while D at controller and pin 8 at the heater valve turning the control. Is range from 1.5 – 11.5 V? NO - Test the controller. See standard controller test YES - Wrong reading taken. Retest Is 12 V present at Pin 10 at the harness connector? NO - Go to next Step YES - Locate open condition and repair between pin Is 12 V present at pin E at the controller? E at the controller and pin 10 at the valve NO - Test the controller. See standard controller test

Temperature control potentiometer History The controller uses the setting on the temperature control potentiometer and the input (resistance) from the evaporator temperature sensor to maintain cab temperature. The resistance rating for the temperature control potentiometer is 0 – 10 kΩ. If the potentiometer fails, the controller attempts to maintain the last temperature request it received when it had input. If the heater valve was opened 40% at the last request, that is the position it maintains. An operator experiences this as cab temperature cannot be varied with the control. An intermittent open condition in the control circuit and a faulty potentiometer act the same in this system.

Electrical test NOTE: See electrical schematic sheets.

Power and Ground Circuit The pot is grounded from pin C, through J022-S, to the HVAC ground stud. B+ read from the controller will vary with the position of the pot: 0.0-3.xV. B+ is fed from pin D at the controller (CCU1), through J022-T, to pin B on the pot. Possible failure modes: 1. Control potentiometer failure. 2. Open condition in power or ground to control potentiometer. 48149953 12/06/2018

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3. Controller failure.

Temperature control potentiometer and circuit test

Steps and test point Corrective actions Ignition key and air conditioning switch OFF. Open the right hand control panel. Disconnect the potentiometer from the harness. Check for variation in resistance ( 0 – 10 kΩ) across B and C on connector OK - Go to next Step 125F while turning the control. NOT OK - Replace potentiometer NOTE: Turn the control slowly and check for any dead spots - points of infinite resistance - across the range of the potentiometer. Key switch and air conditioning switch ON, blower control on any speed. Is 0.0 – 3.0 V present between YES - Go to Step 4 pin B at the harness and chassis ground while turning NO - Go to next Step the control? YES - Locate open condition and repair between pin Is 0.0 – 3.0 V present at pin D at the controller B at the pot through J022-T to the controller (CCU1)? NO - Test the controller. See standard controller test YES - Wrong reading taken. Retest Key switch OFF. Measure resistance between pin C NO - Locate open condition and repair between pin C at the pot to the HVAC ground stud. Less than 1 Ω? at the pot through J022-S to the HVAC ground stud

Blower speed switch and blower motor NOTE: See electrical schematic sheets.

History Various blower speeds are attained by passing voltage through step-down resistors for low and medium speeds. Voltage is jumpered directly to the motor for high speed. If only high speed operates, resistor failure or an open condition in the in-line connector are the likely suspects. Resistor failure requires replacement of the motor.

Power and Ground Circuit RAIL13SP01626AA

12 V is fed to blower motor from fuse 26 ( 30 A) whenever switched B+ is present and whenever the blower speed switch is set to any position other than OFF. Based on the speed switch position, 12 V is routed through the in-line connector to the step-down resistors. The blower motor is grounded from pin B to the HVAC ground stud and ring terminal 172F chassis ground. Possible failure modes 1. Fuse 26 or power and ground to blower speed switch. 2. Switch failure. 3. Blower motor failure. 4. Open condition in power or ground to blower motor. 5. Resistor failure.

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Blower speed switch and power circuit test Steps and test point Corrective actions NOTE: If the blower motor does not run at any speed, test the switch and power circuit - fuse 26. If the blower motor does not operate on all speeds, test the control circuit for the motor. YES - Go to Step 3 NO - Fuse 49 is bad or there is an open circuit in Key switch ON. Measure voltage at blower speed 1. blower speed switch power supply circuit. Go to next switch on pin 2. Is 12 V present? Step YES - Locate and repair open circuit in 820(R) 2. Measure voltage at fuse 26 ( 30 A). Are 12 V present? NO - Locate and repair open circuit in switched B+ power to fuse 26 While turning blower speed switch from LOW to YES - Go to next Step 3. MEDIUM to HIGH, is 12 V present at pin 6 in all NO - Replace the switch positions? Turn blower control to LOW. Measure voltage at YES - Go to next Step 4. blower speed switch pin 5. Is 12 V present? NO - Replace the switch Turn blower control to MEDIUM. Measure voltage at YES - Go to next Step 5. blower speed switch pin 4. Is 12 V present? NO - Replace the switch Turn blower control to HIGH. Measure voltage at YES - Go to next Step 6. blower speed switch on pin 3. Is 12 V present? NO - Replace the switch

Blower motor power, and control circuit test Steps and test point Corrective actions NOTE: If the blower motor does not run at any speed, test the switch and power circuit - fuse 26. If the blower motor does not operate on all speeds, test the control circuit for the motor. Key switch ON. Turn blower control to HIGH. Does YES - Go to Step 4 1. blower motor operate at high speed? NO - Go to next Step Disconnect the motor from the connector. Is there YES - Go to next Step 2. continuity through the motor between pins A and B? NO - Replace motor Measure voltage on connector to blower motor on pin YES - Go to next Step 3. A. Is 12 V present? NO - Go to next Step Turn blower control to LOW. Does blower motor YES - Go to Step 9 4. operate at low speed? NO - Go to next Step Measure voltage at blower motor resistor terminal L. YES - Replace motor 5. Is 12 V present? NO - Go to next Step YES - Locate and repair open circuit between in-line Measure voltage at terminal 2 of blower motor resistor connector terminal 2 and blower motor resistor 6. in-line Connector (CCU3,4). Is 12 V present? terminal L NO - Go to next Step YES - Repair open circuit between J022-D and in-line 7. Measure voltage at in-line J022-D. Is 12 V present? connector on terminal 2 NO - Go to next Step YES - Locate and repair open circuit between switch Measure voltage at blower speed switch pin 5. Is 8. pin 5 and J022-D 12 V present? NO - Test the switch Turn blower control to MEDIUM? Does blower motor YES - Go to Step 13 9. operate at medium speed? NO - Go to next Step Measure the voltage at blower motor resistor on YES - Replace blower motor 10. Terminal M. Is 12 V present? NO - Go to next Step YES - Locate and repair open circuit between in-line Measure voltage at terminal 3 of blower motor resistor connector terminal 3 and blower motor resistor 11. in-line connector (CCU3,4). Is 12 V present? terminal M NO - Go to next Step YES - Locate and repair open circuit between J022-E and in-line connector terminal 3 12. Measure voltage at J022-E. Is 12 V present? NO - Go to next Step

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Steps and test point 13.

Measure voltage at blower switch on pin 4. Is 12 V present?

14.

Turn blower control to HIGH. Does blower motor operate at high speed?

15.

Measure voltage at blower motor resistor in-line connector (CCU3,4) on terminal 4. Is 12 V present?

16. Measure voltage at J022-G. Is 12 V present?

17.

Measure voltage at blower speed switch on pin 3. Is 12 V present?

Corrective actions YES - Locate and repair open circuit between J022-E and the switch pin 4 NO - Test switch YES - Wrong reading taken. Retest NO - Go to next Step YES - Locate and repair open circuit between in-line connector and blower motor resistor on terminal H. NO - Go to next Step YES - Locate and repair open circuit between J022-G and blower motor resistor in-line connector terminal 4 NO - Go to next Step YES - Locate and repair open circuit between switch pin 3 and J022-G NO - Test switch

Evaporator temperature sensor Evaporator core rear view History The evaporator temperature sensor, sometimes called the “freeze” or ”core” sensor, is located in the evaporator/ heater assembly. The sensor measures the effectiveness of system response to the current demand for heating or cooling.

“Freeze” control

RAIL13SP01615AA

The evaporator sensor also prevents the system from operating in low ambient temperatures where damage to the system might occur. When temperature sensed at the evaporator falls to 0 °C (32 °F), the controller cycles the compressor clutch OFF. When temperature sensed at the evaporator rises to 3 °C (37 °F), the controller cycles the clutch back ON. At the maximum cooling setting where the compressor runs continuously, the freeze range controls the cycling of the compressor OFF or ON.

Sensor location Proper location of the evaporator sensor is essential to system performance. The evaporator temperature sensor must be installed 107 mm (4.21 in) (1) from the left hand rear side of the evaporator. The sensor must be installed below the second refrigeration tube row at a 30° downward angle. Insert the sensor in the evaporator core up to the angled section, being careful not to kink the sensor. 2. Evaporator core 3. Evaporator temperature sensor

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Electrical test – sensor NOTE: See electrical schematic sheets. The sensor has a well known resistance vs temperature response: It should measure 10 – 25 kΩ at room temperature for normal operation. The sensor is a thermistor - thermal resistors. With this thermistor, the colder the environment, the greater the electrical resistance, and the warmer the environment, the less electrical resistance. The sensor can fail without indicating an open condition. Measure the resistance of the sensor and the ambient temperature at the sensor, and compare the readings to the resistance versus temperature table. If the readings are not within the minus or plus 2.5% range, replace the sensor. NOTE: For the test to be valid, the thermometer used must be accurate, and the temperature recorded must be the temperature at the sensor.

Power circuit The sensor is grounded to the HVAC ground stud. Minimal voltage is fed to the sensor - about 0.5 V at 21 °C (70 °F) - and voltage drops as the temperature increases. Current is fed to the evaporator sensor from pin B at the controller (CCU1).

Service note: Too little cooling/too much heating without symptoms The sensor should be suspect when the complaint is too little cooling when cooling and too much heating when heating (“the cab is too hot or too cold all the time”), and obvious symptoms are absent: • System pressures are normal, and system is properly charged. • Coolant system operating normally. • Compressor and heater valve are functioning normally. The sensor fails in a consistent pattern: it senses a lower temperature than is actually present. In cooling mode, actual temperature at the evaporator is 10 °C (50 °F), but the sensor senses 7 °C (45 °F) and the compressor is not engaged with sufficient frequency. In heating mode, actual evaporator temperature is 27 °C (81 °F), but the sensor senses 24 °C (75 °F) and heater valve is opened too widely. Perform the resistance versus temperature test on the sensor.

Evaporator temperature sensor and circuit test

Steps and test point Corrective actions Key switch OFF. Disconnect the cab temperature sensor from harness. Measure the resistance across the sensor leads. Measure the ambient YES - Go to next Step temperature at the sensor. Compare the readings NO - Replace the sensor to the temperature versus resistance table. Is the resistance reading within the minus or plus 2.5% range in the table? Ignition key and air conditioning switch ON. Measure voltage at pin 1 to sensor. Is voltage present? YES - Go to next Step 4 NOTE: Voltage reading will be very low: 0.5 V at NO - Locate open and repair 21 °C (70 °F), and voltage decreases as temperature increases 48149953 12/06/2018

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Cab climate control - Air conditioning

Steps and test point

Corrective actions YES - Go to next Step 3. Is voltage present at pin B (CCU1) at the controller? NO - Locate and repair open condition between pin B and sensor Measure resistance from sensor to the HVAC ground YES - Test the controller. See standard controller test 4. NO - Locate open circuit and correct stud. Less than 1 Ω? NOTE: Verify that the evaporator temperature sensor is installed in the right location. The temperature sensor must be installed 107 mm (4.21 in) from the left hand rear side of the evaporator. The sensor must be installed below the second refrigeration tube row at a 30° downward angle. Insert the sensor in the evaporator core up to the angled section. NOTE: While installing the sensor in the wrong location causes faulty system performance, it will not cause the sensor to fail or provide a faulty resistance reading for a given temperature. Replace the sensor if it tests out of range for a given temperature.

Temperature versus resistance table Ambient temperature -17.78 °C (0 °F) -17.22 °C (1 °F) -16.67 °C (2 °F) -16.11 °C (3 °F) -15.56 °C (4 °F) -15 °C (5 °F) -14.44 °C (6 °F) -13.89 °C (7 °F) -13.33 °C (8 °F) -12.78 °C (9 °F) -12.22 °C (10 °F) -11.67 °C (11 °F) -11.11 °C (12 °F) -10.56 °C (13 °F) -10 °C (14 °F) -9.44 °C (15 °F) -8.89 °C (16 °F) -8.33 °C (17 °F) -7.78 °C (18 °F) -7.22 °C (19 °F) -6.67 °C (20 °F) -6.11 °C (21 °F) -5.56 °C (22 °F) -5 °C (23 °F) -4.44 °C (24 °F) -3.89 °C (25 °F) -3.33 °C (26 °F) -2.78 °C (27 °F) -2.22 °C (28 °F) -1.67 °C (29 °F) -1.11 °C (30 °F) -0.56 °C (31 °F) 0 °C (32 °F) 0.56 °C (33 °F) 1.11 °C (34 °F) 1.67 °C (35 °F) 2.22 °C (36 °F) 2.78 °C (37 °F) 3.33 °C (38 °F)

Range 170.82 – 179.58 kΩ 165.36 – 173.84 kΩ 160.095 – 168.305 kΩ 155.025 – 162.975 kΩ 150.15 – 157.85 kΩ 145.47 – 152.93 kΩ 140.985 – 148.215 kΩ 136.598 – 143.603 kΩ 132.308 – 139.093 kΩ 128.213 – 134.788 kΩ 124.313 – 130.688 kΩ 120.51 – 126.69 kΩ 116.805 – 122.795 kΩ 113.295 – 119.105 kΩ 109.785 – 115.415 kΩ 106.47 – 111.93 kΩ 103.35 – 108.65 kΩ 100.23 – 105.37 kΩ 97.227 – 102.213 kΩ 94.331 – 99.169 kΩ 91.533 – 96.227 kΩ 88.832 – 93.388 kΩ 86.219 – 90.641 kΩ 83.694 – 87.986 kΩ 81.247 – 85.413 kΩ 78.887 – 82.933 kΩ 76.596 – 80.524 kΩ 74.383 – 78.197 kΩ 72.248 – 75.953 kΩ 70.171 – 73.769 kΩ 67.47 – 70.93 kΩ 66.232 – 69.628 kΩ 64.35 – 67.65 kΩ 62.532 – 65.738 kΩ 60.771 – 63.887 kΩ 59.066 – 62.095 kΩ 57.414 – 60.358 kΩ 55.814 – 58.676 kΩ 54.265 – 57.047 kΩ

Ambient temperature 16.11 °C (61 °F) 16.67 °C (62 °F) 17.22 °C (63 °F) 17.78 °C (64 °F) 18.33 °C (65 °F) 18.89 °C (66 °F) 19.44 °C (67 °F) 20 °C (68 °F) 20.56 °C (69 °F) 21.11 °C (70 °F) 21.67 °C (71 °F) 22.22 °C (72 °F) 22.78 °C (73 °F) 23.33 °C (74 °F) 23.89 °C (75 °F) 24.44 °C (76 °F) 25 °C (77 °F) 25.56 °C (78 °F) 26.11 °C (79 °F) 26.67 °C (80 °F) 27.22 °C (81 °F) 27.78 °C (82 °F) 28.33 °C (83 °F) 28.89 °C (84 °F) 29.44 °C (85 °F) 30 °C (86 °F) 30.56 °C (87 °F) 31.11 °C (88 °F) 31.67 °C (89 °F) 32.22 °C (90 °F) 32.78 °C (91 °F) 33.33 °C (92 °F) 33.89 °C (93 °F) 34.44 °C (94 °F) 35 °C (95 °F) 35.56 °C (96 °F) 36.11 °C (97 °F) 36.67 °C (98 °F) 37.22 °C (99 °F)

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Range 29.179 – 30.675 kΩ 28.434 – 29.892 kΩ 27.71 – 29.132 kΩ 27.008 – 28.394 kΩ 26.327 – 27.677 kΩ 25.664 – 26.98 kΩ 25.02 – 26.304 kΩ 24.395 – 25.646 kΩ 23.787 – 25.007 kΩ 23.196 – 24.386 kΩ 22.623 – 23.783 kΩ 22.064 – 23.196 kΩ 21.522 – 22.626 kΩ 20.996 – 22.072 kΩ 20.483 – 21.533 kΩ 19.985 – 21.009 kΩ 19.5 – 20.5 kΩ 19.029 – 20.005 kΩ 18.571 – 19.523 kΩ 18.125 – 19.055 kΩ 17.691 – 18.599 kΩ 17.269 – 18.155 kΩ 16.859 – 17.723 kΩ 16.46 – 17.304 kΩ 16.071 – 16.895 kΩ 15.694 – 16.498 kΩ 15.325 – 16.111 kΩ 14.967 – 15.735 kΩ 14.618 – 15.368 kΩ 14.279 – 15.011 kΩ 13.948 – 14.664 kΩ 13.627 – 14.325 kΩ 13.314 – 13.996 kΩ 13.008 – 13.676 kΩ 12.712 – 13.364 kΩ 12.422 – 13.06 kΩ 12.141 – 12.763 kΩ 11.866 – 12.474 kΩ 11.599 – 12.193 kΩ

Cab climate control - Air conditioning

Ambient temperature 3.89 °C (39 °F) 4.44 °C (40 °F) 5 °C (41 °F) 5.56 °C (42 °F) 6.11 °C (43 °F) 6.67 °C (44 °F) 7.22 °C (45 °F) 7.78 °C (46 °F) 8.33 °C (47 °F) 8.89 °C (48 °F) 9.44 °C (49 °F) 10 °C (50 °F) 10.56 °C (51 °F) 11.11 °C (52 °F) 11.67 °C (53 °F) 12.22 °C (54 °F) 12.78 °C (55 °F) 13.33 °C (56 °F) 13.89 °C (57 °F) 14.44 °C (58 °F) 15 °C (59 °F) 15.56 °C (60 °F)

Range 52.764 – 55.47 kΩ 51.309 – 53.941 kΩ 49.901 – 52.46 kΩ 48.535 – 51.023 kΩ 47.211 – 49.633 kΩ 45.928 – 48.284 kΩ 44.684 – 46.976 kΩ 43.479 – 45.709 kΩ 42.31 – 44.48 kΩ 41.176 – 43.288 kΩ 40.076 – 42.132 kΩ 39.011 – 41.011 kΩ 37.976 – 39.924 kΩ 36.973 – 38.869 kΩ 36 – 37.846 kΩ 35.055 – 36.853 kΩ 34.139 – 35.889 kΩ 33.249 – 34.955 kΩ 32.387 – 34.047 kΩ 31.548 – 33.166 kΩ 30.735 – 32.311 kΩ 29.945 – 31.481 kΩ

Ambient temperature 37.78 °C (100 °F) 38.33 °C (101 °F) 38.89 °C (102 °F) 39.44 °C (103 °F) 40 °C (104 °F) 40.56 °C (105 °F) 41.11 °C (106 °F) 41.67 °C (107 °F) 42.22 °C (108 °F) 42.78 °C (109 °F) 43.33 °C (110 °F) 43.89 °C (111 °F) 44.44 °C (112 °F) 45 °C (113 °F) 45.56 °C (114 °F) 46.11 °C (115 °F) 46.67 °C (116 °F) 47.22 °C (117 °F) 47.78 °C (118 °F) 48.33 °C (119 °F) 48.89 °C (120 °F) 49.44 °C (121 °F)

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Range 11.338 – 11.92 kΩ 11.084 – 11.652 kΩ 10.837 – 11.393 kΩ 10.595 – 11.139 kΩ 10.36 – 10.892 kΩ 10.131 – 10.651 kΩ 9.908 – 10.416 kΩ 9.691 – 10.187 kΩ 9.479 – 9.965 kΩ 9.272 – 9.748 kΩ 9.07 – 9.536 kΩ 8.873 – 9.329 kΩ 8.681 – 9.127 kΩ 8.495 – 8.931 kΩ 8.312 – 8.738 kΩ 8.134 – 8.552 kΩ 7.961 – 8.369 kΩ 7.791 – 8.191 kΩ 7.626 – 8.018 kΩ 7.466 – 7.848 kΩ 7.308 – 7.682 kΩ 7.155 – 7.521 kΩ

Cab climate control - Air conditioning

Air conditioning - Overview - Refrigerant recovery NOTE: There are no repair procedures for the compressor or compressor clutch. If the clutch or compressor are defective, replace them.

WARNING Explosion hazard! Air-conditioning refrigerant boils at -12 °C (10 °F)! -NEVER expose any part of the air-conditioning system to a direct flame or excessive heat. -NEVER disconnect or disassemble any part of the air-conditioning system. Discharging refrigerant gas into the atmosphere is illegal in many countries. Failure to comply could result in death or serious injury. W0340A

NOTICE: Refrigerant contamination has become an issue since the introduction of R134A as a replacement for R-12. Contamination refers to a refrigerant blend and/or mixture of alternative refrigerants and R134A. Typically, R-12 systems which are in need of repair or recharge are suspect to refrigerant contamination due to the number of so called “drop-in” replacements or substitutes for R134A. Systems designed for R134A, such as the MX MAGNUM, may be at lower risk for contamination, but precautions should be taken to prevent contamination of service equipment and/or other A/C systems. NOTICE: A refrigerant identifier should be used to determine refrigerant contamination prior to recovery. It is recommended to use OEM4450 refrigerant identifier. If a refrigerant contamination level of 2% or greater is discovered, do not recover the system to a tank with pure R134A refrigerant. Recover only to a tank reserved for contaminated refrigerant with the air-powered station - OEM1691. NOTICE: OEM1415, and its predecessor OEM1418, were designed for the recovery and recycling of pure R134A refrigerant. Do NOT use OEM1415 and OEM1418 to recover contaminated refrigerant; you will void your warranty, you may damage the compressor and filter-drier in the recovery station, and you may expose yourself to the danger of an explosion. NOTICE: If contaminated refrigerant is discovered and recovered with the OEM1691, replace the receiver-drier in the tractor being worked on BEFORE you recharge the system with pure R134A. Use the OEM1415 or OEM1418 to evacuate and recharge the system after the contaminated refrigerant has been safely recovered. NOTE: Check with your local environmental agency for regulations on the proper disposition of contaminated refrigerant. NOTE: In the United States, EPA regulations require that tanks of contaminated refrigerant be sent to a refrigerant reclaimer for the contents to be purified or destroyed. Call 1-800-296-1996 to locate a reclaimer in your area

WARNING Avoid injury! Avoid breathing air-conditioning refrigerant, lubricant vapor or mist. If accidental system discharge occurs, ventilate the work area before resuming service. Failure to comply could result in death or serious injury. W1000B

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Cab climate control - Air conditioning

General view In many countries, recovery, recycling and reclamation have legal definitions and standard meanings in the mobile A/C industry. Recovery is transferring refrigerant in any condition from a system to a storage container without testing or purifying the refrigerant in any way. Recycling is the cleaning of refrigerant for reuse by oil-separation, non-condensable gas removal and single or multiple passes through filter/moisture absorption devices. Reclamation is processing refrigerant to a level equal to new product specifications as determined by chemical analysis, (testing to ARI 700).

RAIL13SP01592AA

In servicing A/C systems with OEM1415, when “recover” is depressed, the refrigerant in the vehicle is transferred to the recovery tank on the unit without testing or purifying. At the same time, PAG SP20 oil is separated from the refrigerant and stored separately in the reservoir. This oil requires proper disposal and should never be returned to the vehicle. When “vacuum” is depressed, the vacuum pump on OEM1415 evacuates the atmosphere in the vehicle A/C system to a vacuum of 28 – 29-1/2 in of mercury (Hg). Air and moisture are removed in the process, and only PAG SP20 oil remains in the vehicle’s A/C system. When “recycle” is depressed, the entire contents of the recovery tank on OEM1415 are “recycled.” The refrigerant in the tank is passed through a filter-drier on OEM1415 and cleaned. Non-condensables are removed and air is purged automatically. (Older recovery units like OEM1418 have manual air purge.) NOTE: In automatic operation, recycling begins about 5 s after the vacuum pump starts. NOTE: During recycling, some additional PAG SP20 oil is separated from the refrigerant and stored separately in the reservoir. Only new PAG SP20 oil is added to replace the oil which was separated during recovery, and when “recharge” is depressed, only clean “recycled” refrigerant is returned to the vehicle’s A/C system. OEM1415 (or OEM1418) does not perform “reclamation.” Fig. 1 shows OEM1415.

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Cab climate control - Air conditioning

Air conditioning - Component identification

PIIL17SP00066FA

Item (1) (2) (3) (4) (5) (6)

Description Compressor Condenser Filter/drier Evaporator Thermostat Expansion Valve

Item (7) (8) (9) (10) (11) (12)

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Description Front console air intake ducts Drain hoses Fan Air filters air filter Activated charcoal filter

Cab climate control - Air conditioning

Air conditioning - Dynamic description

PIIL17SP00066FA

The refrigerant is suctioned in a cold, low-pressure vapor state by the compressor (1), through the hose (2). The compressor directs the refrigerant in the hot, high-pressure vapor state to the condenser (3), through the hose (4). After the hot, high-pressure vapor passes through condenser coils, the vapor transmits heat to the outside air being drawn past the condenser cooling fins, which causes the vapor to condense. Now in a liquid state, the refrigerant passes through the filter-drier (5) under high pressure. The hot, high-pressure liquid is released to the evaporator (6) through the hose (7), through opening of the expansion valve (8). As the refrigerant passes through the orifice in the expansion valve, the refrigerant changes from a highpressure liquid to a low-pressure atomized liquid. When the liquid reaches the evaporator coils, the liquid begins to cool and absorbs the heat from the air drawn in by the fan (9) and blown through the side ducts (10). The air drawn is filtered by the elements (11) and (12), while the element (13) acts specifically on retention of chemical impurities. The refrigerant passes to the cold, low-pressure vapor state, leaves the evaporator, and moves to the compressor, to repeat the cycle. The line that directs the refrigerant from the compressor to the expansion valve is called the high pressure line. The line that directs the refrigerant from the expansion valve back to the compressor is called the low pressure line. During the heat loss, the humidity in the air will be condensed on the outside of the evaporator and drained off through the hoses (14). This action reduces the humidity in the cab. In summary, the heat in the cab is removed by the refrigerant in the evaporator and is transferred from the refrigerant to the outside air by the condenser unit.

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Cab climate control - Air conditioning

Air-conditioning compressor - Overview - High and low pressure switch clutch circuit General information Low pressure switch (1) activation is generally caused by low refrigerant level resulting from a leak(s). Sometime low pressure switch activation, however, is caused by a restriction, where because of the location either pressure switch may activate first. For example, a restriction at the output of the receiver-drier could cause either high or low pressure switch activation. High pressure switch (2) activation is generally caused by a restriction or clog on the high pressure side of the system. However, a refrigerant or PAG SP20 oil overcharge, the presence of refrigerants other than R134A or engine cooling problems can also cause high pressure switch activation.

RAIL13SP01611AA

RAIL13SP01604AA

When either pressure switch opens within the smart pressure counting conditions, a fault code displays on the Instrument Cluster Display, and the compressor clutch is latched OFF by the controller.

Possible failure modes - Fault codes 129 and 134 Fault code

129

Description Controller has detected an open condition in high pressure switch circuit Compressor clutch is latched OFF Code 129 is not activated until two occurrences within a 60 s interval, starting Smart pressure switch with the first occurrence. Actual interval may be as short as 10 s if open counting condition is constant. Controller must be fully initialized before first occurrence can be detected 1. High pressure switch has opened because of high side system pressures. High pressure switch opens at system pressures above 2689 – 2827 kPa (390 – 410 psi). The switch closes when system pressure drops below Causes 1655 – 1793 kPa (240 – 260 psi) 2. Any intermittent open condition at a connector in the circuit appears the same to the controller

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Cab climate control - Air conditioning

Fault code

Description Controller has detected an open condition in low pressure switch circuit Compressor clutch is latched OFF Smart pressure switch Code 134 is not activated until low pressure switch is open for >1 min counting Controller must be fully initialized before the first occurrence can be detected 1. Low pressure switch has opened because of low side system pressures. Low pressure switch opens at system pressures below 27 – 29 kPa (4 – 4 psi). The switch closes when system pressures rise above 117 – 159 kPa Causes (17 – 23 psi) 2. Any intermittent open condition at a connector in the circuit appears the same to the controller Code 02 may display when outside ambient air temperature is below -1 °C (30 °F). The system does not require service. Toggle the ATC switch to OFF and then the desired operation position to reset the system

134

Exception

NOTICE: Case A/C systems are designed to prevent A/C compressor failure due to low pressure or low refrigerant charge. Operation on days below 4 °C (39 °F) may actuate the low pressure sensing system and shut down the A/C system. The system is not malfunctioning if this occurs. Toggle the ATC switch to OFF and then the appropriate operational mode to reset the system

Although system pressures may return to normal, the clutch remains latched OFF until the key switch or ATC switch is toggled OFF and then ON. The controller disables the clutch by denying ground to the clutch relay. Cycling the power switch does not resolve the pressure problem, however, install the pressure test gauges and performance test the system.

Electrical test NOTE: Refer to electrical schematics sent with this manual.

Power and ground With high pressure switch activation, 5 V is present at ATC J8 Pin 33 at controller and Pin A at the switch. The switch is grounded to the chassis. With low pressure switch activation, 5 V is present at ATC J8 Pin 35 at the controller and Pin B at the switch. The switch is grounded to ATC J8 36 at the controller. With no pressure switch activation, both circuits test 0.0 V at the switch and at the controller.

High pressure switch circuit test

Steps and test point Refer to A/C Troubleshooting Foldout and follow the conditions for performance testing. Install A/C high and low side pressure gauges. High reading above 2689 – 2827 kPa (390 – 410 psi)? Shut off the engine. Disconnect the switch from the harness and the unit. Check that switch is closed across Pins 1 and 2

Corrective actions YES - Perform corrective actions from A/C Troubleshooting Foldout NO - Go to next Step OK - Go to next Step NOT OK - Replace switch

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Cab climate control - Air conditioning

Steps and test point Corrective actions Reinstall the switch in the unit, do not reconnect the YES - Go to next Step harness. Keyswitch ON and ATC switch to “A”. Is 5 V NO - Go to Step 5 present at Pin 1 at the harness to the switch? YES - Go to next Step Key switch OFF. Measure resistance from Pin 2 at the NO - Locate open condition and repair between Pin 2 switch to ground. Less than 1 Ω? and ground YES - Locate open condition and repair between ATC J8 Pin 34 and Pin B at the switch NO - Test the controller. See ATC controller test Key switch ON and ATC switch to “AUTO”. Is 5 V (Connector J8 test points) in Automatic Temperature present at ATC J8 Pin 34? Control (ATC) module - Test - Connector J8 test points (55.050)

Low pressure switch circuit test

Steps and test point Refer to A/C Troubleshooting Foldout and follow the conditions for performance testing. Install A/C high and low side pressure gauges. Low reading below 14 – 32 kPa (2 – 5 psi)? Shut off the engine. Disconnect the switch from the harness and the unit. Check that switch is closed across Pins A and B Reinstall the switch in the unit, do not reconnect the harness. Keyswitch ON and ATC switch to “Auto”. Is 5 V present at Pin B at the harness to the switch?

Key switch OFF. Measure resistance from Pin A at the switch to HVAC ground. Less than 1 Ω?

Key switch ON and ATC switch to “Auto”. Is 5 V present at ATC J8 Pin 36?

Corrective actions YES - Perform corrective actions from A/C Troubleshooting Foldout NO - Go to next Step OK - Go to next Step NOT OK - Replace switch YES - Go to next Step NO - Go to Step 5 YES - Go to next Step NO - Locate open condition and repair between Pin A and HVAC ground YES - Locate open condition and repair between ATC J8 Pin 36 at the controller and Pin A at the switch NO - Test the controller. See ATC controller test (Connector J8 test points) in Automatic Temperature Control (ATC) module - Test - Connector J8 test points (55.050)

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Cab climate control - Air conditioning

Air-conditioning evaporator - Dynamic description - Cab and evaporator temperature sensors Background The cab temperature sensor (1), located behind and under the recirculation air filter, supplies a key value to the controller for heating and cooling. Another key value is the desired setpoint. The greater the difference between the desired set point and the temperature sensed at the cab sensor, the greater the ATC system response. The evaporator temperature sensor (2), sometimes called the “freeze” or “core” sensor, is located in the evaporator/ heater assembly. The sensor measures the effectiveness of system response to the current demand for heating or cooling, another key value which the controller uses to engage the compressor or open the heater valve.

“Freeze” control The evaporator sensor also prevents the system from operating in low ambient temperatures where damage to the system might occur. When temperature sensed at the evaporator falls to 0 °C (32 °F), the controller cycles the compressor clutch OFF. When temperature sensed at the evaporator rises to 3 °C (37 °F), the controller cycles the clutch back ON. In Defog mode or in Automatic mode at the maximum cooling setting where the compressor runs continuously, the freeze range controls the cycling of the compressor OFF or ON.

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RAIL13SP01614AA

Cab climate control - Air conditioning

Sensor location Proper location of the evaporator sensor is essential to system performance. The evaporator temperature sensor must be installed 147 mm (6 in) from the right-hand rear side of the evaporator (heater valve end). The sensor must be installed the third row up at approximately a 30Â° downward angle. Insert the sensor in the evaporator core up to the angled section, being careful not to kink the sensor. 1. 2. 3.

147 mm (6 in) Third row up between the tubes Evaporator temperature sensor

RAIL14SP01120AA

RAIL14SP01121AA

The cab temperature sensor must be installed in the recirculation air stream which enters the HVAC box at the rear. Do not install the sensor in contact with any metal surface. Since the cab temperature sensor is located behind the recirculation air filter, any obstruction in the return air path will reduce system performance: The sensor will only detect air temperature in the HVAC box and not the true cab air temperature. Check the area behind the operatorâ&#x20AC;&#x2122;s seat for obstructions at the recirculation filter, and check the filter for cleanness before testing the sensor.

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Cab climate control - Air conditioning

Air-conditioning evaporator - Component localization - Cab and evaporator temperature sensor location The evaporator temperature sensor MUST be installed 147 mm (6 in) from the right-hand rear side of the evaporator (heater valve end). The sensor must be installed the third row up between the tubes at approximately a 30Â° downward angle. Insert the sensor in the evaporator up to the angled section, being careful not to kink the sensor. 1. 2. 3.

147 mm (6 in) Third row up between the tubes Evaporator temperature sensor

The cab temperature sensor must be installed without contact with any box components in the return air stream at the rear of the HVAC box.

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RAIL14SP01120AA

RAIL14SP01121AA

Cab climate control - Air conditioning

Air conditioning - Service instruction - Accessing the HVAC box NOTE: The following procedure applies to both the standard control units and Automatic Temperature Control (ATC) systems. 1. Disconnect the harness to the right hand control console. 2. Tilt the steering wheel to the full upright position. Adjust seat to the full upright and back position. 3. Remove four bolts in the seat base corners.

RAIL13SP01617AA

RAIL13SP01618AA

RAIL13SP01738AA

4. Disconnect the seat harness (1). 5. Hinge seat forward and rest on steering wheel. 6. After completion of service, reinstall the seat harness. Realign ATC controller mounting plate, if equipped, with mounting holes and reinstall seat mounting hardware. Reconnect right hand control harness. Ensure cab recirculation air filter is properly installed.

7. Remove the floor mat wrap (1) which surround the seat base. NOTE: If the return air filter covers are dislodged, be sure to reinstall later.

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Cab climate control - Air conditioning

8. Remove four bolts in the seat base corners.

RAIL13SP01739AA

RAIL13SP01740AA

RAIL13SP01705AA

9. Disconnect the seat harness.

10. ATC HVAC box shown Hinge seat forward and rest on steering wheel for access to the box. 11.

After completion of service: A. Return the seat to its operating position, and reinstall the four bolts removed earlier. B. Reinstall the seat harness and floor mat wrap. C. Reinstall right hand control console (if applicable). D. Reconnect right hand control harness. E. Ensure cab recirculation air filter is properly installed.

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Cab climate control - Air conditioning

Air conditioning - Recover - Recovering pure 134A refrigerant Standard A/C controls 1. Start the tractor and run the engine at 1500 RPM. If possible, operate the air conditioner for 15 min at maximum cooling and maximum blower speed. ATC switch set to DEFOG/DEFROST, standard A/C switch set to â&#x20AC;&#x153;ONâ&#x20AC;?.

RAIL13SP01644AA

RAIL13SP01645AA

RAIL13SP01646AA

ATC A/C controls 1.

Blower control

ATC or standard A/C switch

Temperature control

DEFOG/DEFROST switch

2. Clean the external surfaces of the compressor and hoses. Remove the caps from the service ports on the suction and pressure lines.

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3. With the charging station manifold gauge valves in the closed position, connect the hoses from the test gauges to the service ports. Connect the hose from the low pressure gauge to the port on the suction hose. Turn in valve depressor. Connect the hose from the high pressure gauge to the port on the discharge hose. Turn in valve depressor. NOTE: Use Refrigerant Identifier OEM4450 to verify refrigerant purity. If refrigerant is 98% pure HFC R134A and/or the only non-condensibles test as air and moisture, then proceed with Step 4. If not, go to Step 12. RAIL13SP01647AA

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4. Open the drain valve to make sure that the oil separator is drained prior to recovery. Oil may have mistakenly been left in the recovery unit itself from the previous service job. An oily mist will discharge if the separator has been drained. Check that the oil reservoir has been drained prior to recovery to avoid returning additional oil to the system. 1. Drain valve 2. Reservoir drain

5. Open the high and low valves.

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6. Make certain the refrigerant tank gas and liquid valves are open.

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7. Connect the main power plug to a 115 V AC outlet. Move the main power switch to the “ON” position and depress the RECOVER switch. 8. The compressor will shutoff automatically when recovery is complete. Wait for 5 min and observe the manifold pressure gauges for a pressure rise. If no pressure rise, recovery is complete. If pressure rises above 0 psi, depress the HOLD/CONT switch and repeat until pressure holds for 2 min. Then wait for the compressor to automatically shutoff. NOTE: Refrigerant may pool inside the tractor’s A/C system. When the recovery unit’s compressor is turned off, the refrigerant will vaporize in the ambient heat causing the system pressure to rise again. Repeat the recovery process until the system remains at a vacuum for at least 2 min. 9. Some recovery units require a manual air purge to remove non-condensables from the recovery tank. Refer to the operators manual for your unit. Air purge is automatic on an OEM1415 when it evacuates the A/C system.

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10. Slowly open the oil drain valve and drain the oil into the reservoir. When the oil stops draining, close the oil drain valve completely.

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11. Record the amount of oil in the reservoir. This amount of new oil should be added back to the system. Dispose of any oil in the bottle in an appropriate manner and return the bottle to the station. 12. All refrigerant has been removed from the A/C system, replace components or make any repairs at this time.

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Air conditioning - Recover - Recovering contaminated refrigerant NOTE: When contaminated refrigerant is discovered with refrigerant identifier OEM4450 , additional care is necessary to protect your safety and prevent the contamination of service equipment and your refrigerant supply. Recover the refrigerant with OEM1691 station to a recovery tank reserved for contaminated refrigerant. Do not use OEM1415 or OEM1418 to recover the contaminated refrigerant. NOTE: Read all safety warning and maintenance sections of the operator’s manual before operating the station.

Preparing the tank 1. The tank for the station may be filled with 10 – 15 psi of dry nitrogen which must be removed before it can be used. Remove the cap from the red valve outlet. Open the tank valve to release the nitrogen. Close the tank valve.

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2. Use the vacuum pump (1) on OEM1415 or OEM1418 to pull a 5 min vacuum on the tank. Connect the tank at the location (2) shown.

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3. A 1/4 in FFLX to 1/2 in Acme adapter ( OEM1693) should have been ordered with the unit. Connect the adapter to the red tank valve.

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4. Connect the 2.4 m (94.5 in) blue hose with the R134A service coupler to the adapter.

5. Connect the R134A service coupler to the tee fitting on top of the vacuum pump on OEM1415 or OEM1418. Open the valve on the service coupler by turning it clockwise.

6. Open the valve on the tank.

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7. Open the low side manifold on the control panel of OEM1415 or OEM1418.

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8. Press SHIFT/RESET and ENTER at the same time. Press 1. The vacuum pump starts and runs continuously until any other key is depressed. Run the vacuum pump for a minimum of 5 min. Then press 1 to stop the pump.

9. Press SHIFT/RESET again to return to the normal display mode. Close the valve on the tank. Close the valve on the service coupler by turning it counter-clockwise and disconnect the blue hose from the vacuum pump.

10. Set the tank on the platform at the rear of the station. Tighten the black strap securely around the tank.

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11. Disconnect the R134A hose from the adapter. Disconnect the adapter from the tank and store for future use. Reinstall the cap on the red valve outlet port. The tank is now prepared. See the Operatorâ&#x20AC;&#x2122;s Manual to prepare the recovery station for use.

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Recovery process NOTICE: If a recovery tank becomes full during a recovery, the float switch will automatically turn off the scavenger. See Step 35 for changing tanks in the middle of a recovery.

WARNING Avoid injury! Do not operate the machine while under the influence of alcohol or drugs. Failure to comply could result in death or serious injury. W0160A

12. Start the tractor and run the engine at 1500 RPM. If possible, operate the air conditioner for a few minutes at maximum cooling and maximum blower speed, with ATC switch set to DEFOG/DEFROST, or standard A/C switch to ON. Tests have shown that more refrigerant will be recovered if this action is performed. NOTE: Turn the system and tractor OFF before connecting the station. 13. Remove the cap on the low pressure port at the compressor. Connect the blue R134A recovery hose from the station to the low side service port at the compressor.

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14. Open the tank valve for the R134A hose. Open the valve at the service port.

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15. Turn the control panel valve to START. NOTE: This will equalize pressure on both sides of the compressor for easier starting.

16. Connect a compressed air line to the air inlet on the regulator at the rear of the station. NOTE: The air system must offer a 827 â&#x20AC;&#x201C; 1379 kPa (120 â&#x20AC;&#x201C; 200 psi) at sustained volume of 0.28 cmm (10 cfm).

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17. Connect the red power lead to the (+) (positive) post of the vehicleâ&#x20AC;&#x2122;s battery or to another 12 V DC power supply. Connect the black ground lead to a ground source away from the battery, not the battery (-) (negative) post. The compressor should start idling. NOTE: Batteries generate explosive gases during normal battery operation. Use the remote ground to reduce the risk of sparks around the contaminated system. NOTE: Use a jumper cable to extend the negative lead if necessary to reach an engine ground.

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18. Turn the control panel valve to RECOVERY. The compressor sound should change. Inlet pressure gauge should decrease and tank pressure increase on the gauges.

19. When inlet pressure gauge shows a vacuum, disconnect the air line. Wait 5 min. If inlet pressure rises above 0 psi, repeat Steps 33 and 35. NOTE: Refrigerant may pool inside the system. When the station is turned off, the refrigerant will vaporize in the ambient heat causing the system pressure to rise again. Repeat the recovery process until the system remains at a vacuum for at least 2 min.

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20. When the recovery process is complete, close the valve on the recovery tank. Close the low pressure hose valve and remove the hose from the port at the compressor.

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21. Disconnect the compressed air line from the inlet on the regulator.

22. Disconnect the black ground lead. Disconnect the red power lead from the 12 V power source.

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23. After each recovery, carefully open the accumulator oil drain and drain any collected compressor oil in a proper container. NOTE: Small amounts of refrigerant may remain in the accumulator and build a slight pressure. Drain the accumulator when the inlet pressure gauge shows a vacuum. There may or may not be any oil to drain; this will vary from tractor to tractor. Dispose any oil drained in a proper manner. NOTE: any significant amount of oil is drained, measure and record that amount. Add that equivalent of new PAG SP20 back into the system at the end of the evacuation process. RAIL13SP01672AA

NOTE: If the oil is suspected to be other than PAG SP20: See the flushing procedures in this Section for complete circuit flushing to remove the oil. Drain all oil from the compressor, and add back to the compressor 241.0 g (8.5 oz) of new PAG SP20. Back flush the thermal expansion valve. Reintroduce the fluorescent dye for R134A in the system. Replace the receiver-drier before evacuating and recharging the system. Operate the system for 15 min to circulate the new oil throughout the circuit. 24. If a recovery tank becomes full during a recovery, the float switch will automatically turn off the station. To change a full tank in the middle of a recovery: A. Close the blue tank valve and the valve on the black hose from the station. B. Unscrew and remove the float cable from the tank. C. Disconnect the hose from the tank valve. D. Remove the tank from the station. E. Replace the tank with a properly prepared tank (dry nitrogen charge released and vacuum drawn and held for 5 min). F.

Connect the tank valve hose and the float cable.

G. Open the tank valve and the tank hose valve. Recovery will continue as soon as both valves are open. NOTE: Do not use recovered contaminated refrigerant in any A/C system. Send full tanks to a reclamation center for purifying or disposal of the contents. 25. All refrigerant has been removed from the A/C system, replace components or make any repairs at this time. NOTE: Replace the receiver-drier on the tractor being serviced before you evacuate or recharge the system with OEM1415 or OEM1418. See evacuation and recharging to recharge the air-conditioning system with pure R134A refrigerant, using OEM1415 or OEM1418 Air conditioning - Service instruction - System evacuation and recharging (50.200).

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Air conditioning - Service instruction - System evacuation and recharging NOTE: Replace the receiver-drier if one or more of the following conditions occurs before you remove the air and moisture from the system: 1.

The system has been opened for service before.

Receiver-drier has operated two or more years.

Disassembly of compressor shows small particles of moisture removing material (gold or brown particles).

Large system leak (broken hose, break in line).

Too much air or moisture in system.

Removal of compressor or any other component caused the system to be open (uncapped) longer than 5 min.

Testing with refrigerant showed contamination.

identifier

OEM4450

1. With the charging station manifold gauge valves in the closed position, connect the hoses from the test gauges to the service ports as follows: 1.

Connect the hose from the low pressure gauge to the port on the suction hose (blue).

Connect the hose from the high pressure gauge to the port on the discharge hose (red).

Turn in both thumbscrews to depress the service valves.

2. Removal of air and moisture from the system is necessary after the system has been opened for maintenance. A vacuum pump must be used to lower the pressure enough to change the moisture to vapor which can be removed from the system.

RAIL13SP01647AA

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NOTE: Refer to the vacuum pump manufacturerâ&#x20AC;&#x2122;s user manual for additional information. 3. Connect the main power plug to a 115 V AC outlet. Move the main power switch to the ON position. If program and vacuum do not appear at the top of the display press the VACUUM key. Program a minimum of 45 min and press the ENTER key. The display will flash once indicating the programmed data has been accepted.

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4. Fully open the low and high pressure valves.

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5. Open the red (vapor) and blue (liquid) valves on the tank.

6. Press the VACUUM key. Automatic will show on the display. VACUUM will appear on the display and after a slight delay, the vacuum pump will start. The display will show the amount of time programmed and begin a countdown to zero. 7. When the programmed time has elapsed, an automatic hold occurs. Check the low pressure gauge to see that the A/C system maintains a 28 â&#x20AC;&#x201C; 29-1/2 in of mercury (Hg). NOTE: The low pressure gauge must not increase faster than one inch of mercury (Hg) in 15 min. If the system will not hold vacuum, a leak exists that must be corrected before recharging can begin. See leak test information in this section.

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8. NOTE: Do not inject the PAG oil until the system will hold a proper vacuum. OEM1415 has an injection system to return new SP- 20 PAG oil equal to the amount recovered at the end of the evacuation process. To add the new oil, adjust the O-ring around the oil return bottle to the required oil charge level. NOTE: If 71.0 ml (2.4 US fl oz) was recovered in the oil reservoir, 71.0 ml (2.4 US fl oz) of new SP-20 PAG must be returned. Open the oil injection valve to add the oil into the system. Close the valve when the oil level reaches the O-ring.

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NOTE: Do not let oil level fall below the dip tube in the return bottle or air will be introduced into the refrigerant circuit. 9. Press the CHARGE key. PROGRAM and CHARGE will appear on the display.

10. Program the proper refrigerant amount of 1.65 kg (3.63 lb) and press the ENTER key: 11. The display will flash once indicating the programmed data has been accepted.

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12. Press the CHARGE key to begin refrigerant charging. AUTOMATIC and CHARGE will appear on the display. The display shows the programmed amount and counts down to zero as charging proceeds. When charging is completed, the display shows CPL.

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13. Completely close the high and low pressure manifold valves.

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14. Start the sprayer and run the engine at 1500 RPM. Operate the air conditioner system at maximum cooling setting and blower speed with the door and service door open, Standard A/C switch ON or ATC switch in DEFOG/DEFROST position. NOTE: The compressor does not operate if the system pressure is too low or too high because the clutch is latched off by the controller. Standard A/C units blink the indicator light on the A/C ON/OFF switch indicating a system pressure problem. To restart the compressor, the switch must be turned to the OFF position and then ON. On ATC units, if the system pressure is to low or to high, a fault code will toggle between the current cab temperature setpoint and the fault code on the Instrument Cluster Display 1.

Blower control

ATC or standard A/C switch

Temperature control

Defog/defrost

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15. Observe the pressure gauge readings to determine that the correct amount of refrigerant has entered the system. See chart on page 30 for temperature and pressure variations. Check louver temperature for proper cooling at the mid-cab vents.

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16. Close any open valves on the couplers and carefully remove the gauge hoses from the ports on the suction and discharge lines.

17. Install the caps on the service ports on the suction and discharge lines.

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Air conditioning - Leakage test WARNING Explosion hazard! Air-conditioning refrigerant boils at -12 Â°C (10 Â°F)! -NEVER expose any part of the air-conditioning system to a direct flame or excessive heat. -NEVER disconnect or disassemble any part of the air-conditioning system. Discharging refrigerant gas into the atmosphere is illegal in many countries. Failure to comply could result in death or serious injury. W0340A

Two methods are recommended to test the A/C system for refrigerant leaks: Electronic leak testing with OEM1437 (Fig. 1) and UV-florescent leak detecting (Fig. 2). Whatever method is used, the following components or areas should be checked, always looking for signs of leakage - oily residue, dust accumulation: A. Compressor: Line connections, surfaces where parts are joined, compressor to clutch seal. NOTE: When checking compressor seal for a leak, remove the dust cover and rotate the compressor shaft clockwise. B. Condenser: Line connections, all welded joints, any visible damage. C. Receiver-drier: Line connections. D. Thermal expansion valve: Line connections. NOTE: Remove the thermal insulation tape to check the expansion valve for leaks, replace the tape when completed.

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E. Service ports: Valve core under the caps. F. Low and high pressure switches: Check around the entire switch body where it is threaded into the line. G. Hoses: Line connections where the hose end meets a metal connector, any area that shows damage or rubbing contact.

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Electronic testing with OEM1437 When performing electronic leak detection with OEM1437, follow these general guidelines: 1. There must be enough refrigerant in the system to produce normal pressures (at least 50 psi). 2. Leak test in an area free of wind and drafts. 3. Operate the tractor long enough to circulate the refrigerant and produce normal system pressures. 4. Shut the tractor and system off when leak testing. 5. Clean oily spots with dry shop cloths, solvents can leave a residue which may confuse OEM1437. 6. Hold the leak detector probe under the point being checked, since refrigerant is heavier than air. 7. The probe on the leak detector should never come into contact with the component being checked. 8. If OEM1437 indicates a leak, move the probe away, blow out the area with clean shop air and verify the leak with the detector. 9. If the leak cannot be found with OEM1437, use UV fluorescent leak testing to locate the problem. 10. Repair all leaks and recharge the system.

Fluorescent Leak Detection Fluorescent tracer or dye solutions are now commonly used to detect refrigerant leaks. Your MX tractor had an ultraviolet fluorescent tracer or dye introduced into the A/C system at the time of manufacture. This dye will glow a bright yellow/green at a leak location under ultraviolet light. The dye has been tested for compatibility with HFC R134A systems and approved for use in all NEW HOLLAND HFC R134A A/C systems. Special tools are also available to aid in injection and leak detection. The dye, which dissolves into the PAG SP20 oil in the system, is particularly helpful in detecting intermittent leaks that occur only when the system is running because of change of temperature, high system pressures, vibration or contact between components.

WARNING Avoid chemical burns! Wear protective goggles and non-permeable gloves when working with the fluorescent dye and leak testing an air-conditioning system. Failure to comply could result in death or serious injury. W0918A

This fluorescent dye will normally remain useful over the life of the system. However, due to a large refrigerant leak, system flush or major component failure, it may become necessary to reintroduce the dye into the refrigerant circuit.

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Cab climate control - Air conditioning

Fluorescent dye injection Many methods are available to introduce the dye to a system for the first time or to reinject the dye into an A/C system. Select the method most appropriate to the needs of the A/C system and where you are in the service process: 1.

Recovery station dye injector tool with a system in a vacuum

Recovery station dye injector tool with a charged system

Quick and easy dye injector tool with a charged system

Compressor oil port

PAG SP20 oil return bottle

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Recovery station dye injector tool with a system in a vacuum Valves shown in open position The R134A dye injector tool is designed to be used with the OEM1415 recycling station. 1.

Valve toward recycling station

Reservoir cap

Valve toward tractor

Reservoir

1. Disconnect the low pressure hose (blue) from the .5 in Acme flare fitting on the rear of the station. Connect the dye injector to the fitting. 2. Connect the low pressure hose to the dye injector. NOTE: The dye injector can be permanently mounted on the recycling station with the two threaded holes on the bottom of the reservoir. 3. Open the valves on either side of the reservoir on the dye injector. 4. Recover and recycle the refrigerant from the A/C system and evacuate the system. 5. With the system in a vacuum, close the valves on either side of the reservoir on the dye injector. 6. Remove the cap from the reservoir and fill the reservoir with the contents of one bottle of fluorescent dye. Reinstall the cap on the reservoir and tighten securely. 7. Open the valve on the tractor side of the reservoir on the dye injector. 8. Recharge the A/C system with the proper amount of refrigerant. Star t the recharging process and immediately open the valve on the station side of the dye injector to prevent drawing the dye into the charging station. The dye will be injected into the system while recharging. 9. Install the dye identification sticker on a clearly visible area on the compressor body close to the service ports. This will alert service personnel in the future to the presence of the dye in the system. 10. Operate the A/C system for about 15 min to circulate the dye throughout the system. Turn off the system and use the UV lamp and goggles to locate leaks. The exact location of the leak will be shown by a bright yellow/green glow of the dye. NOTICE: The operating time needed for the dye to penetrate a leak and show will depend on the size of the leak. A very small leak could take hours or days of system operation to appear. 11. After repairing the system, use fluorescent dye cleaner to remove any traces of dye from around the leak location to avoid false diagnosis in the future.

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Recovery station dye injector tool with a charged system Valves shown in open position The R134A dye injector tool is designed to be used with the OEM1415 recycling station. 1.

Valve toward recycling station

Reservoir cap

Valve toward tractor

Reservoir

1. Disconnect the low pressure hose (blue) from the .5 in Acme flare fitting on the rear of the station. 2. Connect the dye injector to the fitting. 3. Connect the low pressure hose to the dye injector. NOTICE: The dye injector can be permanently mounted on the recycling station with the two threaded holes on the bottom of the reservoir. 4. Open the valves on either side of the reservoir on the dye injector. 5. Recover 0.23 kg (0.5 lb) of refrigerant from the system. This amount of refrigerant will act as a carrier to inject the dye. 6. Close the valve on the tractor side of the dye injector and continue to recover. This will draw the refrigerant out of the reservoir on the dye injector. 7. Close the valve on the station side of the dye injector and stop recovering. 8. Remove the cap from the reservoir and fill the reservoir with the contents of one bottle of fluorescent dye. Reinstall the cap on the reservoir and tighten securely. 9. Open the valve on the tractor side of the reservoir on the dye injector. 10. Recharge the A/C system with the proper amount of refrigerant removed earlier 0.23 kg (0.5 lb). Star t the recharging process and immediately open the valve on the station side of the dye injector to prevent drawing the dye into the charging station. The dye will be injected into the system while recharging. 11. Install the dye identification sticker on a clearly visible area on the compressor body close to the service ports. This will alert service personnel in the future to the presence of the dye in the system. 12. Operate the A/C system for about 15 min to circulate the dye throughout the system. Turn off the system and use the UV lamp and goggles to locate leaks. The exact location of the leak will be shown by a bright yellow/green glow of the dye. NOTE: The operating time needed for the dye to penetrate a leak and show will depend on the size of the leak. A very small leak could take hours or days of system operation to appear.

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13. After repairing the system, use fluorescent dye cleaner to remove any traces of dye from around the leak location to avoid false diagnosis in the future.

Quick and easy dye injector tool with a charged system The quick and easy R134A dye injector tool is designed to insert the dye in a charged system. The dye injector tool has a quick coupler, for connecting to the low pressure port of the tractor A/C system, and a valve with T-handle on the other end. 1.

Quick coupler

Valve

T-handle

Supply can

1. Examine the threaded end of the valve to see if the point of the valve stem is flush with the rubber washer. If not, turn the T-handle until the point is flush. 2. Screw the quick and easy can and the valve together until the can seats on the rubber washer. NOTE: Do not turn the T-handle at this time to tap the can. 3. Connect the quick coupler to the low pressure service port under the instructional seat in the cab. 4. To purge air from the hose, slowly unscrew the untapped can a half turn or more. Allow refrigerant from the A/C system to force the air out of the hose, and then retighten the can on the valve. 5. Turn the T-handle clockwise to tap the can. 6. Hold the can upside down to allow the can contents to enter the A/C system. When complete, turn the T-handle counterclockwise to close the valve. Disconnect the tool from the low pressure port. NOTE: You may have to operate the tractor and the A/C system for a few minutes to completely empty the can. 7. Install the dye identification sticker on a clearly visible area on the compressor body close to the service port. This will alert service personnel in the future to the presence of the dye in the system. 8. Operate the A/C system for about 15 min to circulate the dye throughout the system. Turn off the system and use the UV lamp and goggles to locate leaks. The exact location of the leak will be shown by a bright yellow/ green glow of the dye. NOTE: The operating time needed for the dye to penetrate a leak and show will depend on the size of the leak. A very small leak could take hours or days of system operation to appear. 9. After repairing the system, use fluorescent dye cleaner to remove any traces of dye from around the leak location to avoid false diagnosis in the future.

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Cab climate control - Air conditioning

Compressor oil port 1. Recover the refrigerant from the A/C system. 2. Remove the oil filler plug and pour the contents of one bottle of fluorescent dye into the compressor. 3. Check the O-ring on the oil filler plug and replace if necessary. Reinstall the oil plug on the compressor and torque to 15 – 24 N·m (11 – 18 lb ft). 4. Evacuate and recharge the A/C system with the proper amount of refrigerant. 5. Install the dye identification sticker on a clearly visible area on the compressor body close to the service ports. This will alert service personnel in the future to the presence of the dye in the system. 6. Operate the A/C system for about 15 min to circulate the dye throughout the system. Turn off the system and use the UV lamp and goggles to locate leaks. The exact location of the leak will be shown by a bright yellow/ green glow of the dye. NOTE: The operating time needed for the dye to penetrate a leak and show will depend on the size of the leak. A very small leak could take hours or days of system operation to appear. 7. After repairing the system, use fluorescent dye cleaner to remove any traces of dye from around the leak location to avoid false diagnosis in the future.

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Cab climate control - Air conditioning

PAG SP20 oil return bottle NOTICE: This is the least preferred method for injecting the dye since it requires very careful measurement of the PAG SP20 oil in the bottle and risks the introduction of air into the system if the dip tube in the bottle is exposed. 1. Recover the refrigerant from the A/C system. 2. Carefully measure the amount of PAG SP20 oil in the reservoir which was separated from the refrigerant. 3. Pour the new replacement oil into the oil return bottle plus some additional oil to prevent uncovering the dip tube. 4. Pour the contents of one bottle of fluorescent dye into the oil return bottle and seal the bottle. 5. Evacuate the system and inject the oil and dye mixture into the system, making sure the oil level in the oil return bottle does not drop below the dip tube. 6. Recharge the A/C system with the proper amount of refrigerant. 7. Install the dye identification sticker on a clearly visible area on the compressor body close to the service ports. This will alert service personnel in the future to the presence of the dye in the system. 8. Operate the A/C system for about 15 min to circulate the dye throughout the system. Turn off the system and use the UV lamp and goggles to locate leaks. The exact location of the leak will be shown by a bright yellow/ green glow of the dye. NOTE: The operating time needed for the dye to penetrate a leak and show will depend on the size of the leak. A very small leak could take hours or days of system operation to appear. 9. After repairing the system, use fluorescent dye cleaner to remove any traces of dye from around the leak location to avoid false diagnosis in the future.

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Cab climate control - Air conditioning

Fluorescent leak testing To perform UV fluorescent leak testing: 1. Operate the tractor long enough to circulate the refrigerant and produce normal system pressures. 2. Shut the tractor and system off when leak testing. 3. Always wear fluorescent enhanced safety glasses when leak testing. 4. Attach the lamp to a fully charged 12 V battery or an alternate 12 V power supply for best lamp performance. 5. Shine the high intensity ultraviolet light at the various A/C components, hoses and lines to search for a glowing fluorescent trail or puddle which identifies the leak location. 6. The ultraviolet lamp is intended for intermittent use only. The lamp has a momentary contact push button switch to briefly light suspected leak locations. 7. Do not work with the lamp On for more than 5 min. If the lamp heats up uncomfortably, cease operation. 8. Do not expose eyes or skin to ultraviolet light. Do not stare into an ultraviolet light beam or operate the lamp without the ultraviolet lens filter in place. 9. In direct sun sunlight or very bright ambient light, use a cover of any type over the suspected area to reduce this light. 10. If the lamp cannot be directed straight at a suspected leak location, use a mechanics mirror to reflect the light at the location. Or wipe the suspected leak site with a clean shop cloth, and shine the lamp at the cloth to check for traces of fluorescent dye. 11. The exact location of a small leak at a connection point or sealing point can be further narrowed by daubing a wet film of soap solution over the suspected area. Watch for bubbles to confirm the exact point of leakage. 12. Repair all leaks and recharge the system. 13. Use fluorescent dye cleaner to remove any traces of dye from around the leak location to avoid false diagnosis in the future.

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RAIL13SP01633AA

Cab climate control - Air conditioning

Air conditioning - Flush - System flushing When flushing is necessary, all effected components should be flushed to eliminate the possibility of contaminants remaining in the system. There are two methods of A/C system flushing: Individual component flushing and complete circuit flushing. The complete circuit is the system minus the compressor, receiver-drier and thermal expansion valve. The compressor, receiver-drier and thermal expansion valve are always bypassed (removed) during circuit flushing and serviced individually. The receiver-drier is always replaced anytime a system is flushed. The expansion valve, due to its small orifices, is removed from the system and cleaned (or replaced). The compressor is either replaced or reused, but is NEVER flushed. The preferred method of system flushing is individual component flushing. Given the size of NEW HOLLAND equipment and the distance between components, individual component flushing will dislodge and flush out more contamination than complete circuit flushing. Which individual components are flushed will depend on the source of the contamination and is left to the discretion of the technician. For â&#x20AC;&#x153;mildlyâ&#x20AC;? contaminated systems, complete circuit flushing may be used, where the contamination is oxidized refrigerant oil or small amounts of receiver-drier desiccant. Complete circuit flushing requires little system disassembly, minimal special connectors and the least amount of service time. The most likely sources of contamination are compressor failure and receiver-drier failure.

Compressor failure A failed compressor generally sends debris downstream to the condenser, the receiver-drier and towards the thermal expansion valve. If the compressor fails internally, it must be replaced. Also individual flushing of the hose between the compressor and condenser, of the hose between the condenser and receiver-drier, of the condenser itself and replacing the receiver-drier are appropriate service actions for compressor failure. For most NEW HOLLAND condensers with a single flow path, flushing effectively removes debris. For condensers with parallel flow paths, since flushing takes the path of least resistance around any blockage, condenser replacement may be the only option. The receiver-drier has a fine mesh screen to capture contaminants, but the contaminants may penetrated the screen. Check the discharge port of the receiver-drier to see if contaminants have penetrated the screen. If so, individual flushing of the hose between the receiver-drier and the expansion valve and cleaning the thermal expansion valve are appropriate. If the thermal expansion valve is damaged, replace it as well.

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Additional flushing of the system beyond the thermal expansion valve is at the discretion of the service technician who can best judge how far the contamination has traveled.

Receiver-drier failure Receiver-driers should not normally fail if replaced: A. When system has been opened before. B. When receiver-drier has been in service two or more years. C. When the system has been open for a long period of time because of a leak (broken hoses, loose connection) that has permitted air and moisture to enter the system. D. When contaminated refrigerant was recovered from the system. However, if the desiccant pouch is punctured by a debris from a failed compressor or fails from age, desiccant particles may flow downstream toward the thermal expansion valve and the evaporator. An indicator of receiver-drier failure is soft golden-brown particles found at its outlet. The thermal expansion valve should always be checked after receiver-drier failure. If the receiver-drier fails, it must be replaced. Also individual flushing of the liquid hose between the receiverdrier and the thermal expansion valve and cleaning the valve are appropriate. Check the suction line from the valve to the compressor and the compressor suction port. If golden brown particles is found, flush the evaporator and suction line individually. The compressor may be reused AFTER all contaminants are removed: 1. Use the dipstick to measure the compressor oil level. 2. Drain and refill the compressor with PAG oil until the drained oil is free of particles. 3. Rotate the compressor clockwise to check for binding caused by the presence of particles. 4. Drain or add PAG to return the compressor to measured dipstick level. NOTE: Flushing solvent CANNOT be used to remove compressor contaminants. Additional system flushing is at the discretion of the service technician who can best judge how far the contamination has traveled and what components may have been damaged and require replacement.

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Required tools The following tools are required when flushing an A/C system or components: • Power flush 17550 (Fig. 1) • Flush gun kit 17585 (Fig. 2) • NEW HOLLAND A/C flushing solvent, one case of six one gallon containers, BS33801 • Dry shop air source, use filter below or equivalent: Coalescing air filter/dryer (Ingersoll-Rand IR5CHE or Grainger 4KR65). Desiccant-type air driers should not be used. • Adapters to connect flush unit to the various A/C system components. These adapters can be purchased in kit form or built in the shop.

RAIL13SP01639AA

RAIL13SP01640AA

• Clear plastic reinforced Hose to connect the tank to various components and small lengths for bypassing components like the receiver-drier or thermal expansion valve. Please see Air conditioning - Special tools (50.200) . Optional tools include: • Pressure regulator to control flow to the flush unit, regulator must be capable of delivering 310 – 620 kPa (45 – 90 psi) at 4.0 cfm ( 310 kPa (45 psi) at 0.11 cmm). Do not exceed 620 kPa (90 psi). • Pressure indicator gauge (which may be integrated into the pressure regulator)

Precautions NOTE: Do NOT use solvent containing alcohol, lacquer thinner, brake cleaner or other non-approved solvents. Use only NEW HOLLAND approved flushing solvent. Other flushing agents or solvents may damage A/C system components. NEW HOLLAND A/C flushing solvent is a hazardous material. Read all warnings on the flushing solvent container prior to use and observe these safety precautions: 1. The flushing solvent is combustible. Avoid heat, sparks and open flame. 2. Use only in a well ventilated area. Mechanical exhaust and an appropriate respirator may be needed in warm and confined areas to protect your safety. 3. Avoid breathing mist and vapor. 4. Wear chemical splash safety goggles. 5. Wear rubber gloves and a rubber apron when handling the solvent or flushing components. 6. Observe all local, state and federal regulations regarding the safe disposal of used flushing solvent. The goal of flushing is to remove contaminants from the A/C system. Your shop air must be properly filtered and dried with coalescing filter, or you will simply replace one source of contamination with another using dirty, moisture saturated air. 48149953 12/06/2018

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The compressor, receiver-drier and thermal expansion valve must be bypassed (removed) when performing circuit flushing. The compressor and receiver-drier may never be flushed, the thermal expansion valve can be back flushed. Keep the lid on the flushing recovery bucket closed when flushing to minimize the circulation of solvent vapors. Never allow the flushing solvent to remain in or on the hoses for an extended period of time. Overexposure of the hoses to the solvent, especially the exterior, may cause hose swelling. Do not open the fill cap on the flush reservoir when the reservoir is under pressure. Release pressure before removing cap.

Component flushing procedure with power flush 17550 1. All refrigerant must be recovered from the system before flushing.

Evaporator and universal fittings shown 2. The 17550 power flush unit uses shop air to atomize the flushing solvent and a pulsing action to scrub residue and contaminants out of components. 3. Attach flushing adapters to the component to be flushed. These adapters can be shop built or a universal A/C flushing fitting set is available - Model 17582.

RAIL13SP01682AA

RAIL13SP01683AA

4. Fill the flushing reservoir 3/4 full with approved NEW HOLLAND flushing solvent. Do not overfill the reservoir or you will restrict the pulsing action of the unit.

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5. Close the air and the flushing valves. 1. Air valve 2. Flush valve

RAIL13SP01684AA

RAIL13SP01685AA

RAIL13SP01686AA

RAIL13SP01687AA

6. Remove the flushing tank hose quick coupler from the evaporation plug.

7. Connect the flushing tank hose quick coupler to an extension or an adapter hose.

8. Connect CLEAN and DRY shop air supply to the quick coupler on the flushing valve.

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9. Connect flushing and drain hoses to flushing adapters on component being flushed so the flushing solvent moves in the opposite direction of refrigerant flow - back flushing. Reinforced clear hose is preferred to monitor the condition and removal of the used solvent. 1. From the flush pump 2. To the return bucket NOTE: Secure the lid on the return bucket so all flush vapors pass through the bucket filter. NOTE: Back flushing is done first to dislodge any contaminants, and then forward flushing is performed to remove the contaminants.

RAIL13SP01688AA

10. Open the air valve 1/2 to 3/4 turn. NOTE: Do not exceed this rate of air delivery. This rate delivers one gallon per minute of flush solvent which is ideal for the orifice openings on the components being flushed. Turn the flushing valve to the FLUSH position and flush the component for 30 s. 1. Air valve 2. Flush valve

RAIL13SP01689AA

RAIL13SP01690AA

RAIL13SP01691AA

11. Close the flushing and air valves. Reverse hose connections for forward flushing. Open flushing and air valves and repeat flushing until the solvent is clear. 1. From the flush pump 2. To the return bucket

12. Turn the flushing valve to the AIR position. Allow air to flow through the component until no noticeable mist is discharged. NOTE: Air pressure is the only means to remove the flushing solvent from the A/C system, and no solvent must remain in the system when it is evacuated and recharged. Turn the component so gravity can assist in solvent removal.

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13. Turn the flushing valve to the CLOSED position. Disconnect the flushing and drain hoses and adapters from the component.

RAIL13SP01692AA

RAIL13SP01685AA

RAIL13SP01693AA

14. Install the flushing tank hose quick coupler on the evaporation plug to prevent evaporation of the solvent left in the tank during storage. See heading post flushing procedures.

Complete circuit flushing procedure with power flush 17550 1. All refrigerant must be recovered from the system before flushing. 2. The 17550 power flush unit uses shop air to atomize the flushing solvent and a pulsing action to scrub residue and contaminants out of components. Fill the flushing reservoir 3/4 full with approved NEW HOLLAND flushing solvent. Do not overfill the reservoir or you will restrict the pulsing action of the unit.

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3. Remove the receiver-drier and join the hoses together with an adapter hose. Discard the receiver-drier.

RAIL13SP01694AA

RAIL13SP01695BA

4. Remove the thermal expansion valve and use adapters to connect the hose lines to the evaporator.

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Universal A/C flush fittings shown 5. Disconnect the suction and discharge lines from the compressor. Attach flushing adapters to the lines.

RAIL13SP01696BA

RAIL13SP01683AA

RAIL13SP01685AA

6. Close the air and the flushing valves. 1. Air valve 2. Flush valve

7. Remove the flushing tank hose quick coupler from the evaporation plug.

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8. Connect the flushing tank hose quick coupler to an extension or adapter hose.

RAIL13SP01686AA

RAIL13SP01687AA

RAIL13SP01696BA

9. Connect CLEAN and DRY shop air supply to the quick coupler on the flushing valve.

10. Connect flushing and drain hoses to adapters on compressor lines so flushing solvent moves in the opposite direction of refrigerant flow - back flushing. Connect the hose from the flush tank to the suction line, connect the hose to the return bucket to the discharge line. Reinforced clear hose is preferred to monitor the condition and removal of the used solvent. 1. From the flush tank 2. To the return bucket NOTE: Back flushing is done first to dislodge any contaminants, and then forward flushing is performed to remove the contaminants. NOTE: The suction and discharge ports on the compressor are marked with the letters S and D, respectively. NOTE: Secure the lid on the return bucket so all flush vapors pass through the bucket filter.

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11. Open the air valve 1/2 to 3/4 turn. 1. Air valve 2. Flush valve NOTE: Do not exceed this rate of air delivery. This rate delivers one gallon per minute of flush solvent which is ideal for the orifice openings in the circuit being flushed. Turn the flushing valve to the FLUSH position and flush the circuit until the solvent appears clear at the return hose to the solvent waste container.

RAIL13SP01689AA

RAIL13SP01696BA

RAIL13SP01691AA

12. Close the flushing and air valves. Reverse hose connections for forward flushing. Connect the hose from the flush tank to the discharge line, connect the hose to the return bucket to the suction line. Open flushing and air valves and repeat flushing until the solvent is clear. 1. From the flush tank 2. To the return bucket

13. Turn the flushing valve to the AIR position. Allow air to flow through the circuit until no noticeable mist is discharged. NOTE: Air pressure is the only means to remove the flushing solvent from the A/C system, and no solvent must remain in the system when it is evacuated and recharged.

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14. Turn the flushing valve to the CLOSED position. Disconnect the flushing and drain hoses and adapters from the compressor lines. Install the flushing tank hose quick coupler on the evaporation plug to prevent evaporation of the solvent left in the tank during storage. See heading post flushing procedures.

RAIL13SP01685AA

RAIL13SP01640AA

RAIL13SP01697AA

RAIL13SP01698AA

Back flushing the thermal expansion valve or refrigerant line 1. Flush gun 17585 can be used to back flush the thermal expansion valve or a refrigerant line. Solvent is added to the canister, and then the canister is pressurized with CLEAN and DRY shop air. Pulse the trigger on the flush gun for greater flushing effectiveness.

2. To fill the canister, remove the cap assembly. Add no more than 590 ml (20 US fl oz) of NEW HOLLAND flushing solvent to the canister. Replace the cap assembly.

3. Pressurize the canister to a maximum of 620 kPa (90 psi) with CLEAN and DRY shop air.

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4. Connect the hose with flush gun to the canister.

RAIL13SP01699AA

RAIL13SP01700AA

RAIL13SP01701AA

Back flush the discharge port 5. When back flushing the thermal expansion valve, the suction and discharge ports must be flushed in different directions. Collect used solvent in a container for proper disposal. NOTE: To prevent sprayback, press the rubber nose cone on the gun into the opening on the refrigerant line or thermal expansion valve when flushing.

Back flush the suction port 6. Use CLEAN and DRY shop air to purge the solvent and dry the valve.

Post flushing procedures 1. Identify and remove the source of the contamination.

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2. Reconnect all fittings using new HNBR â&#x20AC;&#x153;greenâ&#x20AC;? HFC R134A compatible O-rings. Lubricate the O-rings with mineral oil prior to installation.

RAIL13SP01702AA

RAIL13SP01703AA

RAIL13SP01700AA

RAIL13SP01704AA

3. Install a new receiver-drier. NOTE: The receiver-drier should be replaced just before the system is drawn to a deep vacuum to avoid saturating it with moisture.

4. Clean or replace the thermal expansion valve.

5. Install a new compressor if required.

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6. Adjust the level of PAG SP20 oil in the system. When each component was flushed, some PAG SP20 oil was removed from the system. Use the following guidelines when adjusting PAG oil: If the compressor is to be replaced and the entire system was flushed, the new compressor will contain all the PAG SP20 oil needed and no further adjustment is required. If the compressor is not to be replaced and the entire system was flushed, drain the oil from the compressor to remove any remaining contaminants. Add back to the compressor one container, 250 ml (8.5 US fl oz), of new PAG SP20 oil. (Some oil, about 35 ml (1.2 US fl oz), will remain in the compressor even after it has been drained.) If the entire system was not flushed, drain the oil from the compressor to be installed. Add back new PAG SP20 oil equal to 250 ml (8.5 US fl oz) minus oil amounts still in the components that were not flushed. Use the table below.

RAIL13SP01681AA

NOTE: Total system PAG oil should be 285 ml (9.6 US fl oz) and about 35 ml (1.2 US fl oz) will remain in a drained compressor. Component flushed

Amount of PAG SP20 oil to add 50 ml (1.7 US fl oz) 40 ml (1.4 US fl oz) 25 ml (0.85 US fl oz) 10 ml (0.34 US fl oz)

Condenser Evaporator Receiver/Dryer Each hose Because the system has been open for a prolonged time, it is very important to draw the system to a deep vacuum to remove all moisture. Evacuate the system for at least 45 min to a vacuum of 0.75 mm (0.030 in) of mercury.

Final system oil check After the system has been drawn to a deep vacuum and recharged. 1. Operate the A/C system for 15 min to thoroughly circulate the PAG oil throughout the system. 2. Install the gauge set and test the A/C system for proper operation referring to the pressure/temperature table on Air conditioning - General specification - Temperature and pressure chart (50.200). NOTE: If oil level was measured and adjusted properly according to the guidelines, Steps 3 and 4 are unnecessary. 3. Recover refrigerant from the system. Use the dipstick method to check the PAG oil level in the compressor. If needed, adjust the oil level. For all Tractor Models, the oil should cover five lines on the dipstick. 4. Evacuate and recharge the system.

Flushing solvent disposal Never reuse contaminated flushing solvent.

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Good stewardship of our natural resources is everyoneâ&#x20AC;&#x2122;s business. NEW HOLLAND flushing solvent is a hazardous material. Never dispose of this solvent by pouring it down the drain or treating it as water soluble waste. Observe all local, state and federal regulations when disposing the solvent.

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Air conditioning - Connect of the pressure gauge set DANGER Avoid injury! Observe ALL precautions listed below when servicing the air-conditioning system and handling refrigerant. Failure to comply will result in death or serious injury. D0043A

WARNING Explosion hazard! Air-conditioning refrigerant boils at -12 Â°C (10 Â°F)! -NEVER expose any part of the air-conditioning system to a direct flame or excessive heat. -NEVER disconnect or disassemble any part of the air-conditioning system. Discharging refrigerant gas into the atmosphere is illegal in many countries. Failure to comply could result in death or serious injury. W0340A

If the workshop has a modern automatic suction, evacuation, recycling and filling device, the manometers are already built into the device. The following instructions for performing a functional test of the air conditioning unit apply to the manometer shown in the figure to the side. In principle, a unit test using a suction and filling device with built-in manometers is performed according to the same procedure. NOTICE: It is essential that the manufacturer's operating instructions are read before using such equipment.

LAIL11TL0094A0A

NOTE: In the closed valves, the refrigerant flows along the rod of the valve for the manometers. As a result, after connection of the pressure battery, both manometers indicate the pressure. Never unscrew or open the manual shut-off valve (2) on the pressure side when the system is operating. Always unscrew or open the manual shut-off valve (6) on the suction side to top up the refrigerant level. NOTICE: The manual shut-off valves should always be bolted and closed during the entire test (clockwise, to the end of the track).

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To connect the pressure gauge set on the machine, perform the following procedures: NOTE: Before connecting the pressure gauge set, determine the positioning of the connections for the high-pressure gauge (pressure side) and low-pressure gauge (suction side). The connection valve of the pressure side is located on the air-conditioning compressor line for the condenser. 1. The connection valves are closed with a protective cap, which must be removed to connect the pressure gauge. 2. The connection valves are closed with a protective cap. Remove the caps (1) and (2) to connect the pressure gauge.

PIIL17SP00024AA

PIIL17SP00025AA

3. Connect the high pressure gauge hose (1), figure 1, on the pressure side shut-off valve (1). NOTE: You will need to move the hood from the fuel tank to make this connection. See the procedure at Front shield - Remove (90.105) 4. Connect the low pressure gauge hose (7), figure 1, to the connection valve (1) on the suction side. Check the tightness of all hose connections. NOTE: The high- and low-pressure-side connection valves on the vehicle are spring-loaded valves and open automatically when the pressure test hose is connected. NOTE: A pin of suitable pressure should be inserted in the pressure test tube to trigger this type of valve. Next operation: Air conditioning - Startup test (50.200)

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Air conditioning - Disconnect of the pressure gauge set NOTE: A significant amount of steam from the refrigerant may have condensed into a liquid at the service joint on the compressor's high pressure side. Use a thick cloth or other protective material when disconnecting the manifold tube from that joint to avoid personal injury to the hands or face. 1. Disconnect the low pressure connection valves (1).

PIIL17SP00025AA

PIIL17SP00024AA

2. Disconnect the high pressure connection valves (1).

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Air conditioning - Startup test DANGER Avoid injury! Observe ALL precautions listed below when servicing the air-conditioning system and handling refrigerant. Failure to comply will result in death or serious injury. D0043A

Prior operation: Connection of the pressure gauge set. Consult the procedures in Air conditioning - Connect of the pressure gauge set (50.200). The system should be stabilized after connection of the pressure gauge set and before the pressure tests are performed. Carry out the following procedures: 1. Check that the high-pressure valve (2) and the lowpressure valve (6) on the pressure gauge set are completely closed. 2. Apply the park brake. 3. Place the multi-function handle in neutral. 4. Close the cab door. 5. Start the engine. Accelerate to a speed of approximately 1500 RPM. 6. Keep the heating system off. 7. Turn on the air conditioning and set to the maximum ventilation and maximum cooling. Continue to run the air conditioning for 10 min.

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Cab climate control - Air conditioning

8. Check that the reading on the low pressure gauge (7) is within the specific values, approximately 0.28 – 2.48 bar (4.1 – 36 psi). 9. Check the high pressure gauge reading (1) and compare it with that indicated on the pressure and temperature chart in table 01.

LAIL11TL0094A0A

Table 01: Ratio of temperature by pressure High pressure gauge reading 10 – 11.6 bar (145.0 – 168 psi) 11.2 – 12.7 bar (162.4 – 184 psi) 12.3 – 13.8 bar (178.4 – 200 psi) 13.3 – 15.2 bar (192.9 – 220 psi) 14.5 – 16.7 bar (210.2 – 242 psi) 16.0 – 18.3 bar (232.0 – 265 psi) 17.3 – 20 bar (250.9 – 290 psi)

Ambient air temperature 27.0 °C (80.6 °F) 29.00 °C (84.20 °F) 32.0 °C (89.6 °F) 35.0 °C (95.0 °F) 38.0 °C (100.4 °F) 41.0 °C (105.8 °F) 43.0 °C (109.4 °F) 10. Measure and compare the temperature of the conditioned air entering the cab through the air vents with the temperature of the ambient air in the filter inlet (1). 11. If the system is working correctly, the air entering the cab should be 6.0 – 9.0 °C (42.8 – 48.2 °F) cooler than the outside ambient air temperature.

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Air conditioning - Recover DANGER Avoid injury! Observe ALL precautions listed below when servicing the air-conditioning system and handling refrigerant. Failure to comply will result in death or serious injury. D0043A

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There are numerous laws prohibiting the release of refrigerant into the atmosphere. Whenever checking the air-conditioning system or carrying out other tasks that involve disarming the system, the refrigerant must be discharged before starting the operation. Before disassembling the air conditioner for repairs, discharge and recover the refrigerant using a certified recovery machine according to the manufacturer's instructions. The figure to the side shows a combined refrigerant recovery, drainage, and recycling/recharging machine. This equipment removes the R134A refrigerant from the air-conditioning system, recycles it, and does the recharging all in one consecutive operation. This unit was designed to be used with the set of gauges installed in its control panel. There are several other recovery systems on the market that do not include the set of gauges. A separate gauge set must be used when using this type of equipment. Perform the following procedures to discharge the system using a recovery/recharge unit: NOTICE: Never discharge refrigerant into the atmosphere. Always wear safety goggles and gloves when working with these fluids. Use only certified packages. NOTICE: Always follow the manufacturer's instructions when working with recovery equipment.

LAIL11TL0939B0A

PIIL17SP00024AA

PIIL17SP00025AA

1. Start the engine. Accelerate to a speed of approximately 1500 RPM. Turn on the air conditioning and set to the maximum ventilation and maximum cooling. Let the air conditioning run for 15 min. 2. Adjust the recovery unit as recommended by the manufacturer. Make sure that the red tube (high pressure side) (2) is connected to the high joint and that the blue tube (low pressure side) (1) is connected to its respective joint. NOTE: If you are using a unit with pressure gauges, the low and high pressure sides of the pressure gauge are connected to the low and high pressure sides of the machine's system. The recovery unit tube is then connected to the set's central output. 3. To recover the refrigerant, open the high and low pressure valves of the control panel. If using a pressure gauge set, open the valves of the pressure gauge set. 4. Open the valves labelled "gas" and "liquid" in the refrigerant tank of the recovery unit. 5. Turn on the recovery unit. 6. Operate the recovery unit according to the manufacturer's instructions. NOTE: The compressor will stop automatically when the refrigerant removal is complete.

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Air conditioning - Apply vacuum DANGER Avoid injury! Observe ALL precautions listed below when servicing the air-conditioning system and handling refrigerant. Failure to comply will result in death or serious injury. D0043A

Prior operation: Air conditioning - Recover (50.200) . NOTICE: A system from which the refrigerant has been recovered to facilitate any repairs must be evacuated before being refilled with new refrigerant. A vacuum pump is used to eliminate the air and moisture from the system. The automatic recycling, recharging and drainage systems, or the draining and charging systems provided by the air conditioning manufacturer, also include a vacuum pump. If this type of equipment is not available, use a vacuum pump and an independent set of gauges. When a system is being evacuated, the boiling point of any moisture is also lowered. When the vacuum increases, the boiling point ends up falling below the ambient temperature and under these conditions the moisture boils and is eliminated. The information in table 01 is the ratio between the system vacuum and the boiling temperature at which water steam is eliminated from the system. Table 01: Ratio between the system vacuum and the boiling temperature Mercury system vacuum 710.0 mm Hg (28.0 in Hg) 734.0 mm Hg (28.9 in Hg)

Temperature 38.0 °C (100.4 °F) 27.0 °C (80.6 °F) 48149953 12/06/2018

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Mercury system vacuum 746.0 mm Hg (29.4 in Hg) 754.0 mm Hg (29.7 in Hg) 757.0 mm Hg (29.8 in Hg) 759.0 mm Hg (29.9 in Hg)

Temperature 16.0 °C (60.8 °F) 5.0 °C (41.0 °F) -7.0 °C (-44.6 °F) -18.0 °C (-64.4 °F)

NOTE: For every 305 m above sea level, 25.4 mm Hg (1.0 in Hg) must be added to the vacuum meter reading to compensate for the change in atmospheric pressure. 1. If using a pressure gauge set, connect the low pressure side (1) and the high pressure side (2) of the pressure gauges to the low and high sides of the machine's airconditioning system. NOTICE: Make sure the system is completely discharged as the refrigerant will damage the vacuum pump. 2. Connect the central tube of the pressure gauges to the vacuum pump's inlet port, according to the manufacturer's instructions. 3. Completely open the low and high pressure shut-off valves. 4. If a combined recovery/drainage unit is used, connect it to the air-conditioning system according to the manufacturer's instructions. Read carefully all the instructions before putting the unit in operation. 5. After starting the drainage cycle, check the low gauge to see if a vacuum is forming in the system. 6. Calculate the drainage time as at least 20 min after reaching the lowest vacuum point. 7. When the gauge on the low pressure side reaches the lowest constant vacuum, stop the drainage process. NOTE: The vacuum pump reaches its maximum efficiency when the discharge valve is closed. 8. Check the system by closing the valves, turning off the vacuum pump, and noting the low gauge readout. A loss of more than 5.0 cm (2.0 in) of vacuum in 5 min, means a leak or the presence of humidity in the system. 9. If the gauge pointer remains stopped and the vacuum is maintained for 3 – 5 min, close both the high and low valves, turn and disconnect the central tube of the pump. The system is ready for charging. 10. If a leak is detected, charge the system with around 400 g of refrigerant and identify the leak using a detector. 11. When a leak is detected, discharge and recover the refrigerant, repair the leak and repeat the drainage process. Next operation: Charging the air-conditioning system. See the procedures in Air conditioning - Charging (50.200).

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Air conditioning - Charging DANGER Avoid injury! Observe ALL precautions listed below when servicing the air-conditioning system and handling refrigerant. Failure to comply will result in death or serious injury. D0043A

Prior operation: Apply vacuum to the system. See the procedures in Air conditioning - Apply vacuum (50.200).

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1. Check if the charge unit is correctly connected to the machine's air-conditioning system according to manufacturer's instructions. 2. Open the high and low pressure valves on the gauges if a charge unit is going to be used with the gauge set. 3. Charge the system with refrigerant according to the manufacturer's instructions. 4. If the charging process is very slow, close the high pressure side valve and start the engine and the air conditioning so that the compressor can pull the rest of the refrigerant into the system. 5. If the refrigerant charge does not go fully into the air conditioning, recover and recharge it. 6. Close the high- and low-pressure valves on the unit’s control panel, or on the pressure gauge set if one is being used. 7. After charging a system, use the following start-up procedure to make sure the lubrication oil is adequately spread through the system: • Check that the air conditioning is off. • Start the engine and run at idle. • Turn the air conditioner on and allow the system to run for at least a minute before increasing the engine speed.

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Air-conditioning compressor - Check - Compressor and clutch Operational check 1. When functioning normally, the compressor clutch is always grounded to the engine, and switched 12 V is supplied by a controller-activated relay to energize the clutch coil and engage the compressor. With key switch “ON”, ATC switch to “AUTO,” temperature control on maximum cool, check that clutch is engaged and the compressor is operating.

RAIL13SP01604AA

RAIL13SP01605AA

RAIL13SP01604AA

2. Disconnect the clutch at the harness. The clutch should disengage smoothly with little noise from the pulley or the bearings. Reconnect the harness to the clutch. The clutch should engage rapidly and operation should be smooth and quiet.

WARNING Rotating parts! Do not attempt to check the compressor clutch for vibration directly with your hand. Rotating belts can cause severe personal injury. Failure to comply could result in death or serious injury. W1203A

If operation is noisy, check the compressor next to the clutch for vibration. If the compressor is vibrating next to the clutch and the noise changes when the clutch disengages, the clutch has failed. If the compressor is vibrating, the compressor has failed. The vibrating component is usually the source of the problem.

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4. With the clutch still engaged, check the suction (1) and discharge (2) hoses at the compressor for temperature difference. The suction line should be cool to cold, and the discharge line should be hot to very hot. Little or no temperature difference between the hoses is another indication of compressor failure: internal leakage between discharge and suction sides. NOTE: The compressor end plate is stamped with a “D” and “S” to indicate the discharge and suction ports.

RAIL13SP01604AA

RAIL13SP01606AA

RAIL13SP01607AA

RAIL13SP01608AA

5. Verify an internal problem when compressor failure is suspected. Turn the A/C system and engine “OFF”. Remove the three screws (1) to remove dust cover (2) from clutch.

6. Use a wrench to slowly rotate the compressor clockwise. Compressor rotation should be smooth and not require much effort. If severe rough spots or catches are felt when turning the shaft, the compressor has been damaged internally and must be replaced.

7. Check for loose mounting bolts on the bracket for the compressor (1). Tighten the bolts to the correct torque. If bracket has breaks or cracks, replace it. NOTE: Loose mounting brackets can cause a “knocking” sound at the compressor. A refrigerant overcharge also causes a knocking sound at the compressor.

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8. Clutch drive belt should be running smooth and straight. Clutch pulley (1) and the drive pulley (2) must be aligned within 1.60 mm (0.06 in) of each other. Use a straight edge to check pulley alignment. Adjust the compressor on the mounting bracket if required. The drive belt should be located in the rear clutch groove. Check for too much belt wear: Cracking, cord wear, piling, chunking, glazing or separated layers. Replace a worn or deteriorated belt. Adjust the tension on a new belt to 422 – 516 N·m (311 – 381 lb ft), and to 400 – 489 N·m (295 – 361 lb ft) after a minimum of 10 min run-in time. Tension on a used belt must be 400 – 489 N·m (295 – 361 lb ft).

RAIL13SP01609AA

Electrical test NOTE: Refer to electrical schematics sent with this Manual.

General information The compressor clutch is cycled On or Off by the controller based on the difference between the selected cab temperature set point and the temperature sensed at the cab temperature sensor. When functioning normally, the clutch is always grounded to the engine through the compressor mounting bracket. The controller grounds the compressor clutch relay to provide 12 V from Fuse27 to energize the clutch coil and engage the compressor.

Power and ground circuit Switched 12 V is fed to the compressor clutch relay on pin 3 through ATC J8 pin 17 switched power at ATC Controller. The controller energizes the relay by supplying power through ATC J8 pin 15 to pin 2 on the clutch relay. 12 V is fed from pin 5 on the relay - through ATC J6R1-C and P086 to energize the clutch coil on J814.

Possible failure modes: 1. Short circuit or open circuit in clutch coil. 2. Open circuit in power or ground between controller and relay. 3. Open circuit in power and ground between clutch and relay. 4. Controller fault.

Circuit test NOTE: This procedure assumes that the clutch has NOT been latched OFF by the controller due to high or low pressure switch activation and that no fault codes are displayed on the Instrument cluster display.

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Steps and test point 1

Key switch and ATC switch “OFF”. Test continuity between clutch screw and ground screw on compressor mounting bracket. Less than 1 Ω?

Measure resistance from A/C clutch connector J814 to clutch ground screw on bracket. Is resistance between 3.6 – 4.2 kΩ?

10 11 12

Key switch “ON” and DEFOG/DEHUMIDIFY switch “ON”. Is 12 V present at male harness connector to clutch? Turn key switch “ON”. Check connector ATC J8, pin 17. Is there 12 V present?

Corrective actions YES - Go to next Step NO - Repair open circuit or replace wire. Retry the unit NOT OK - Go to next Step YES - Go to next Step NO - If open line or resistance is severely out of range, replace the clutch NOTICE: If clutch is shorted, also check condition of Fuse27 ( 5 A). The clutch draws enough amperage to cause Fuse27 to blow YES - Clutch tests okay. Check for fault codes on Display NO - Go to next Step

YES - Go to next Step NOTICE: See Accessing the HVAC box in Air condi- NO - Check condition of Fuse27 ( 5 A) tioning - Service instruction - Accessing the HVAC box (50.200) if required. YES - Go to Next Step Check clutch relay, pin 5. Is 12 V present? NO - Go to Step 9 OKAY - Go to next Step Check continuity from clutch relay, pin 5 to connector NOT OKAY - Locate and repair the open condition between the clutch relay, pin 5 to connector ATC ATC J6R1-C J6R1-C OKAY - Go to next Step Check continuity from connector ATC J6R1-C through NOT OKAY - Locate and repair the open condition connector P086 to connector BH8 pin 4 between the connector P086 to connector BH8 pin 4 OKAY - Go to next Step Check continuity from connector BH8, pin 4 to NOT OKAY - Locate and repair the open condition connector J814 on the clutch between the connector P086 to connector BH8, pin 4 YES - Go to next Step NOT OKAY - See Automatic Temperature Control Check connector ATC J8 pin 15 to ground. Is 12 V (ATC) module - Test - Connector J8 test points present? (55.050) OKAY - Go to next Step Check continuity from clutch relay, pin 1 to pin 2 NOT OKAY - Replace the clutch relay OKAY - Go to next Step Check continuity from clutch relay, pin 1 to ground NOT OKAY - Locate and repair the open condition between clutch relay pin 1 to ground Trouble may be intermittent Double check all test points

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Service note: Adjusting clutch air gap When replacing a clutch in the field, pay special attention to the air gap between the clutch plate and pulley. Too little gap will increase voltage draw at the clutch, resulting in premature failure. Too much gap will introduce too much foreign material into the clutch. A spark plug gauge with 90° wire feelers may be used to check the gap. Slip the wires between the clutch plate and the pulley, and check the gap at the three rivets. The gap must be 0.41 – 0.790 mm (0.016 – 0.031 in). The gap must be even all the way around the plate. If necessary, lightly lift or push down on the plate to make the gap even. NOTE: If the gap does not meet the above specifications, remove the front plate and add or subtract clutch shims as required. NOTE: See A/C system service in this manual for clutch disassembly and adjusting the air gap during clutch replacement.

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RAIL13SP01610AA

Cab climate control - Air conditioning

Air-conditioning compressor Magnetic clutch - Remove Prior operation: If replacing hardware, must use the hardware noted in this Machineâ&#x20AC;&#x2122;s Parts Manual. Prior operation: There are no repair procedures for the compressor or compressor clutch. If the clutch or compressor are defective, replace them. Prior operation: Air-conditioning compressor clutch testing can be found in Air-conditioning compressor - Check - Compressor and clutch (50.200). Prior operation: Clean external surfaces of the compressor before doing any work on the compressor. Prior operation: Remove the compressor. 1. Remove the screws for the clutch dust cover.

RAIL13SP01712AA

RAIL13SP01713AA

RAIL13SP01714AA

2. Remove clutch dust cover.

3. Remove retaining nut for the front plate. Use special spanner wrench from service tool set to keep the plate and shaft from turning.

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4. Install the special puller from service tool set on clutch front plate.

RAIL13SP01715AA

RAIL13SP01716AA

RAIL13SP01717AA

RAIL13SP01718AA

5. Turn center screw to pull the clutch front plate.

6. Remove shim(s) from the shaft.

7. Carefully remove dust cover.

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8. Remove the key from rotor shaft.

RAIL13SP01719AA

RAIL13SP01720AA

9. Remove the external snap ring for the bearing and pulley assembly.

10. Install the special puller internal collars into groove on pulley. Install the special tool onto the shaft. Tighten mounting screws finger tight.

RAIL13SP01721AA

RAIL13SP01722AA

11. Turn center screw on the puller.

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12. Remove the pulley and bearing assembly.

RAIL13SP01723AA

RAIL13SP01724AA

RAIL13SP01725AA

RAIL13SP01726AA

13. Remove snap ring for the clutch coil assembly.

14. Disconnect the clip for the lead wire.

15. Remove clutch coil assembly.

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16. Remove internal snap ring and remove bearing from the pulley.

RAIL13SP01727AA

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Air-conditioning compressor Magnetic clutch - Install 1. Install a new clutch coil assembly. Align coil so the lead wire is next to the clip mounting hole.

RAIL13SP01726AA

RAIL13SP01725AA

RAIL13SP01724AA

RAIL13SP01727AA

2. Install clip for the coil lead wire.

3. Install snap ring for the clutch coil assembly.

4. Install bearing in pulley and install the internal snap ring.

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5. Put pulley and bearing assembly on the front housing hub. Install a driver on pulley assembly. Make sure that the tool is on the inner race of the bearing.

RAIL13SP01728AA

RAIL13SP01720AA

RAIL13SP01729AA

6. Support compressor on the four mounting ears at the compressor rear. Press pulley assembly on front housing hub. Make sure bearing is against bottom of the hub.

7. Install the external snap ring on the front housing hub.

8. Install key in the rotor shaft.

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9. Place bearing dust cover in the bore. Place driver from special tool kit over dust cover.

RAIL13SP01730AA

10. Install dust cover.

RAIL13SP01731AA

RAIL13SP01717AA

RAIL13SP01732AA

11. Install shim(s) on the rotor shaft.

12. Install front plate on rotor shaft. Make sure keyway in the plate is aligned with the key in the shaft. Install the driver over the shaft.

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13. Use a hammer to tap the plate onto the shaft. Make sure the plate is against the clutch shims. As the plate is tapped onto the shaft there will be a difference in sound when the plate is fully installed.

RAIL13SP01733AA

RAIL13SP01714AA

RAIL13SP01734AA

RAIL13SP01735AA

14. Install nut on the rotor shaft. Use spanner wrench and a torque wrench to tighten the nut to a torque of 15 – 20 N·m (11 – 15 lb ft).

15. Two methods can be used to measure and adjust the air gap between the clutch plate and pulley: Magnetic dial - Mount a magnetic base dial indicator on the outer face of the pulley so that there is no interference with the clutch plate. Apply battery ground to compressor body and 12 V B+ to clutch wire lead. Position the dial indicator pointer on the flat surface on the outer diameter of the clutch plate midway between any two outer rivets or on one of the outer rivet heads. Clutch plate travel should measure from 0.41 – 0.79 mm (0.016 – 0.031 in). This measurement should be taken between each of the three rivets or on each outer rivet head to get an average measurement. If necessary, lightly lift or push down on plate to even the gap. 16. Spark plug gauge - If a dial indicator is not available to check air gap clearance, a spark plug gauge with 90° wire feelers may be used to check initial air gap in the field. Slip the wire between the clutch plate and the pulley and check the gap at the three rivets. The gap must be 0.41 – 0.79 mm (0.016 – 0.031 in). The gap must be even all the way around the plate. If necessary, lightly lift or push down on the plate to make the gap even. NOTE: If the gap does not meet the above specifications remove the front plate and add or subtract clutch shims as required.

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17. Install clutch dust cover. Torque the screws to 7 – 11 N·m (5 – 8 lb ft).

RAIL13SP01713AA

RAIL13SP01712AA

18. Install and tighten the screws that attach the dust cover to the compressor clutch. Torque to 7 – 11 N·m (5 – 8 lb ft). 19. Install compressor onto machine.

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Air-conditioning compressor - Remove Prior operation: Air conditioning - Recover (50.200) 1. Disconnect the cable plug of the compressor electromagnetic clutch (1). 2. Disconnect the pressure (2) and refrigerant suction lines (3) from the compressor (1). NOTE: Cover the connection points with plugs. 3. Remove the protective grate (4).

PIIL17SP00027AA

PIIL17SP00028AA

4. Eliminate the tension of the compressor belt (1). 5. Remove the nuts (2). Remove the bolts (3). 6. Remove the compressor (4).

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Air-conditioning compressor - Install 1. Secure the compressor (1) to the cradles (2) and (3). Install the three bolts (4) and nuts (5) to secure. 2. Install the drive belt (6) onto the compressor pulley. NOTE: Adjust the belt tension after assembly. 3. Connect the cable plug (7) of the electromagnetic clutch of the compressor.

PIIL17SP00029AA

PIIL17SP00027AA

4. Install the protective grate (1). 5. Connect the pressure (2) and refrigerant suction (3) lines to the compressor (4).

Next operation: Air conditioning - Apply vacuum (50.200) Next operation: Air conditioning - Charging (50.200)

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Air-conditioning compressor - Filling The oil level in the air-conditioning compressor must be checked after removing a system component or if a leak is suspected. 1. Start the engine and run at idle. 2. Switch on the air conditioning. Let the compressor (1) run for 10 min. 3. Remove refrigerant from the system. See the procedure in Air conditioning - Recover (50.200). 4. Remove the level plug installed at the rear of the compressor (1). The oil level should reach the edge of the hole of this plug. PIIL17SP00068AA

5. If necessary, remove the filler plug. Top up the oil level. 6. Clean the level and filing holes. 7. Reinstall plugs. Next operation: Air conditioning - Apply vacuum (50.200) Next operation: Air conditioning - Charging (50.200)

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Air-conditioning compressor - Disassemble - Electromagnetic clutch Prior operation: Air-conditioning compressor - Remove (50.200) 1. Clean the outer surfaces of the compressor. 2. Remove the three TorxÂŽ bolts (1). Remove the clutch dust guard (2).

PIIL17SP00032AA

PIIL17SP00033AA

PIIL17SP00034AA

3. Remove the retaining nut (1) for the front plate (2). NOTE: Use the special wrench from the service tool set 380050012 to lock the plate (2).

4. Install the extractor from the service tool set 380050012 on the front plate (1). 5. Turn the center bolt to extract the front plate (1).

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6. Remove the shims (1) from the shaft.

PIIL17SP00035AA

PIIL17SP00036AA

PIIL17SP00037AA

PIIL17SP00038AA

7. Remove the dust guard (1) with care. 8. Remove the keyway (2).

9. Remove the snap ring (1).

10. Install the extractor from the service tool set 380050012 on the groove of the pulley (1). 11. Hand tighten the bolts (2). 12. Turn the center bolt to extract the pulley (1).

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13. Remove the pulley (1).

PIIL17SP00039AA

PIIL17SP00043AA

14. Remove the snap ring (1). 15. Remove the bearing (2) from the pulley.

16. Disconnect the electric wire clip (1).

PIIL17SP00041AA

PIIL17SP00040AA

17. Remove the snap ring (1).

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18. Remove the clutch coil assembly (1).

PIIL17SP00042AA

Next operation: Air-conditioning compressor - Test - Electromagnetic clutch (50.200)

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Air-conditioning compressor - Test - Electromagnetic clutch Prior operation: Air-conditioning compressor - Disassemble - Electromagnetic clutch (50.200) Two methods can be used to test the clutch coil. See step 1 to test the coil current draw with an ammeter. See step 2 to test the resistance across the coil. Only one test method is required. 1. Use a ammeter (1), a voltmeter and a 12 V (2) battery to check the power of the clutch coil current. The current draw must be 3.6 – 4.2 A, at 12 V. A reading of more than 4.2 A indicates a short within the coil. No current reading indicates an open circuit in the coil. Replace the coil if the current reading is not correct. 2. Measure the resistance, which should be 2.86 – 3.3 Ω. Replace the clutch coil if the resistance reading is not correct. Next operation: Air-conditioning compressor - Assemble - Electromagnetic clutch (50.200)

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Cab climate control - Air conditioning

Air-conditioning compressor - Assemble - Electromagnetic clutch Prior operation: Air-conditioning compressor - Test - Electromagnetic clutch (50.200) 1. Install the clutch coil assembly (1). NOTE: Align the coil so the electric wire is next to the clip assembly hole.

PIIL17SP00042AA

PIIL17SP00040AA

PIIL17SP00041AA

PIIL17SP00043AA

2. Assemble the elastic ring (1).

3. Secure the electric wire clip (1).

4. Install the bearing (1) on the pulley (2). 5. Install the elastic ring (3).

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6. Place the pulley (1) on the clutch coil assembly, as shown. 7. Place a pressure device on the pulley (1), supported on the inner race of the pulley bearing. 8. With the compressor properly supported, press the pulley (1) the pulley is fully seated.

PIIL17SP00044AA

PIIL17SP00037AA

PIIL17SP00045AA

PIIL17SP00046AA

9. Install the elastic ring (1).

10. Install the keyway (1) on the shaft (2).

11. Install the dust guard (1) on the pulley (2). Use the pressure device from service tool set 380050012.

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12. Install the shims (1) on the shaft.

PIIL17SP00035AA

13. Fit the front plate (1) on the pulley (2). NOTE: The keyway groove in the plate (1) should be aligned with the keyway installed on the shaft. 14. Install the mounting shim (3) over the shaft, which is part of the service tool set 380050012.

PIIL17SP00047AA

PIIL17SP00048AA

PIIL17SP00033AA

15. Tap the mounting shim (1) with a hammer, until the front plate (2) is completely installed. 16. Remove the mounting shim (1).

17. Install the retaining nut (1) of the front plate (2). NOTE: Use the special wrench from the service tool set 380050012 to lock the plate (2). NOTE: Torque the nut (1) to 15.0 – 20.0 N·m (11.1 – 14.8 lb ft) . 18. Check the adjustment of the air gap between the plate (2) and the pulley (3), as per the instructions of the procedure in Air-conditioning compressor - Adjust - Air clearance (50.200).

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19. Install the clutch dust guard (1) with the three TorxÂŽ bolts (2).

PIIL17SP00032AA

Next operation: Air-conditioning compressor - Install (50.200)

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Air-conditioning compressor - Adjust - Air clearance Two methods can be used to measure and adjust the gap between the clutch plate (1) and the pulley (2). See step 1 for the dial gauge method. See step 2 for the calibration method. Use only one method to check the gap. 1. Dial gauge with magnetic base: • Attach the magnetic base on the outer face of the pulley (2), so that there is no interference on the plate (1). • Apply battery ground to compressor body and 12 V B+ to clutch wire lead. • Position the dial gauge feeler on the surface of the plate (1), on its outer diameter, midway between any two outer rivets or on one of the outer rivet heads. • The travel of the plate (1) should measure 0.400 – 0.790 mm (0.016 – 0.031 in). This measurement should be taken between each of the three rivets or on each outer rivet head to get an average measurement. If necessary, lightly lift or push on the plate (1) to make the gap even.

PIIL17SP00026AA

PIIL17SP00049AA

2. Calibration: • Slip the wire between the plate (1) and the pulley (2). Check the gap at the three rivets. • The gap must be 0.400 – 0.790 mm (0.016 – 0.031 in), all the way around the plate (1). If necessary, lightly lift or push on the plate to make the gap even. NOTE: If the gap does not meet the above specifications, remove the plate (1) and add or subtract clutch shims as required.

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Air-conditioning condenser - Remove Prior operation: Recover refrigerant. See Air conditioning - Overview - Refrigerant recovery (50.200). 1. Remove the engine cowling side grills. NOTE: Left hand side is shown, remove both sides.

RAIL13SP04840AA

RAIL13SP05088AA

RAIL13SP05087AA

WARNING Escaping refrigerant may cause frostbite! Always wear protective goggles when handling refrigerant. If you get refrigerant in your eye, immediately flush your eyes with water for 15 minutes. Seek medical assistance immediately. Failure to comply could result in death or serious injury. W0339A

Disconnect the two high pressure hoses from the condenser. NOTE: Install clean threaded caps and plugs on the hoses and fittings.

3. Support the condenser and remove the four mounting bolts. Remove the condenser out the right hand side of the cooling package. (The two right-hand bolts are shown.)

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Air-conditioning condenser - Install 1. Install the condenser from the right hand side of the cooling package. 2. Support the condenser and assemble the four mounting bolts. (The two right-hand bolts are shown.)

RAIL13SP05087AA

RAIL13SP05088AA

RAIL13SP04840AA

3. Remove caps and plugs. Lubricate with clean A/C compressor oil and install new O-rings on the high pressure hoses. Connect and tighten the hoses to the condenser.

4. Recharge the air-conditioning system. Please see Air conditioning - Service instruction - System evacuation and recharging (50.200) . 5. Start engine and run A/C. Check air temperature. Shutoff engine. Leak check condenser and connections. Please see Air conditioning - Leakage test (50.200) . 6. Install the hood grill screens that were removed.

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Air-conditioning condenser - Remove Prior operation: Air conditioning - Recover - Recovering contaminated refrigerant (50.200) 1. Loosen the latches (2) to remove both side shields (1).

SOIL16SP00058AA

PIIL17SP00030AA

PIIL17SP00031AA

2. Disconnect the refrigerant inlet hose (1) and the refrigerant outlet hose (2) from the condenser (3). NOTE: Discard the O-rings installed on the hose fittings. NOTICE: Cover the connection points with plugs.

3. Remove the four bolts (1). 4. Remove the condenser (2) from the right-hand side of the machine.

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Air-conditioning condenser - Install 1. From the right-hand side of the machine, position the condenser (1) on the bottom of the cooling assembly. NOTE: The connection points (2) should face toward the left-hand side of the machine. 2. Secure the condenser (1) with the four bolts (3).

PIIL17SP00031AA

PIIL17SP00030AA

SOIL16SP00058AA

3. Connect the refrigerant inlet hose (1) and the refrigerant outlet hose (2) to the condenser (3). NOTE: Install new lubricated O-rings on the hose fittings.

4. Install the side shields (1). Secure the shields with the latches (2).

Next operation: Air conditioning - Apply vacuum (50.200) Next operation: Air conditioning - Charging (50.200)

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Receiver-dryer - Remove Replace the receiver-drier if: • System has been opened before. • Receiver-drier has been used two or more years. • Disassembly shows small particles of moisture removing material (gold or brown particles). • If the system has been open for a long period of time because of a leak (broken hoses, loose connection) that has permitted air and moisture to enter the system. • If contaminated refrigerant was recovered from the system. The receiver-drier is normally the last item replaced when servicing the system, just before the system is evacuated. This prevents saturating the drier with moisture.

Receiver/drier removal 1. Recover refrigerant. See Air conditioning - Overview - Refrigerant recovery (50.200). 2. Disconnect the hoses (1). Remove the bolts (2) and remove the receiver drier (3). NOTICE: Cap and plug lines to prevent contamination.

RAIL13SP01737AA

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Receiver-dryer - Install 1. Install the receiver-drier (1). Tighten the straps (2) and connect the hoses (3). NOTE: Always install new O-rings when the receiver-drier is connected to the system. Lubricate the O-rings with clean mineral oil. NOTE: The receiver-drier orientation is critical. Make sure the outlet flange is within 5 degrees of true level (the decal should face up). NOTE: The receiver-drier must be installed with the inlet connected to the hose from the condenser and the outlet connected to the hose going to the thermal expansion valve. 2. Recharge the A/C system with pure R134A refrigerant. See Evacuation and recharging of air-conditioning system at Air conditioning - Service instruction - System evacuation and recharging (50.200).

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RAIL13SP01737AA

Cab climate control - Air conditioning

Expansion valve - Replace 1. Recover all refrigerant from the system. Remove the thermal insulation tape from the fittings and expansion valve to replace the expansion valve. 2. Using the two hand, two wrench method, disconnect the liquid and suction lines from the thermal expansion valve. Discard the O-rings in the fittings.

RAIL13SP01742AA

RAIL13SP01743AA

RAIL13SP01744AA

3. Using the two hand, two wrench method, disconnect the thermal expansion valve from the evaporator tubes. Discard the O-rings on the tubes.

4. NOTE: Lubricate O-rings with mineral oil NOT SP-20 PAG. Lubricate new O-rings with clean mineral oil and install between the evaporator core and thermal expansion valve. Connect the new valve to the evaporator using the two hand, two wrench method.

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5. Lubricate new O-rings with clean mineral oil and install in the fittings on the suction and liquid lines. Connect the liquid and suction lines to the expansion valve using the two hand, two wrench method. 6. Remove air and moisture from the system and charge the system. Leak test all connections with OEM1437 before reapplying any thermal insulation tape. 7. Replace all thermal insulation tape and reconnect the low pressure cutout switch. NOTE: The thermal insulation tape is available in 9150 mm (360 in) bulk rolls - 1954475C1 - 3.00 mm (0.12 in) x 63.5 mm (2.5 in) x 9150 mm (360 in)

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RAIL13SP01745AA

Cab climate control - Air conditioning

Expansion valve - Test NOTE: The following test is performed with the thermal expansion valve mounted in the system. No repair or adjustment is recommended for the valve. 1. See Accessing the HVAC box at Air conditioning - Service instruction - Accessing the HVAC box (50.200). See standard HVAC box in right. 2. Disconnect the low pressure cutout switch. Install a jumper wire across the harness leads. 3. Start the tractor and run the engine at 1500 RPM. Turn blower speed control to maximum position, temperature control valve fully clockwise, ATC switch to DEFOG/DEFROST or standard A/C switch to â&#x20AC;&#x153;ONâ&#x20AC;?, and check the low pressure gauge reading. Compare the gauge readings to the temperature/pressure chart for your ambient temperature and humidity. RAIL13SP01623AA

RAIL13SP01741AA

4. Remove thermal insulation tape from top of valve. Use the palm of your hand to warm the expansion valve and watch the low pressure gauge. The valve will open and pressure should rise. 5. Use ice to cool the expansion valve and watch the low pressure gauge. Within seconds, the expansion valve will close and the pressure must drop at the low pressure gauge. 6. If there is little or no change at low pressure gauge, the thermal expansion valve must be replaced.

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Expansion valve - Replace Prior operation: Front shield - Remove (90.105) Prior operation: Air-conditioning evaporator - Remove (50.200) 1. From the outside of the cab, remove the seal (1).

PIIL17SP00060AA

PIIL17SP00061AA

PIIL17SP00062AA

2. Pull the caps (1) and (2) out of the housing (3).

3. Remove two screws (1).

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4. From inside the cab, remove the expansion valve (1) from the housing (2).

PIIL17SP00063AA

PIIL17SP00064AA

PIIL17SP00063AA

PIIL17SP00062AA

5. Replace all of the O-rings (1) installed between the lines and the expansion valve (2).

6. Position a new expansion valve (1) in the housing (2). Pay attention to the correct fitting of the lines (3) and (4).

7. Secure the expansion valve (1) to the union lock installed on the internal lines. Use the two bolts (2).

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8. Push the caps (1) and (2) into the housing (3), until the stop.

PIIL17SP00061AA

PIIL17SP00060AA

9. Install the seal (1).

Next operation: Front shield - Install (90.105) Next operation: Air-conditioning evaporator - Install (50.200)

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Air-conditioning evaporator - Test - Cab and evaporator temperature sensors Both sensors have the same resistance vs temperature response even though they look dramatically different. Both sensors should measure 10 – 25 kΩ at room temperature for normal operation. Both sensors are thermistors - thermal resistors. With these thermistors the colder the environment, the greater the electrical resistance, and the warmer the environment, the less electrical resistance. If a fault 111, 115 or 116 is displayed, the most likely problem is wiring to the sensor. The out of range values are so high or low 82 °C (180 °F) and -19 °C (-2 °F) that occurrence is unlikely except as noted below in the fault code explanations. More importantly, these sensors can fail without generating a fault code. Measure the resistance of the sensor and the ambient temperature at the sensor, and compare the readings to the resistance versus temperature table. If the readings are not within the minus or plus 2.5% range, replace the sensor. NOTE: For the test to be valid, the thermometer used must be accurate, and the temperature recorded must be the temperature at the sensor. NOTE: See electrical schematic sheets.

Power circuit Minimal voltage is fed to the sensors: About 0.5 V at 21 °C (70 °F), and voltage drops as the temperature increases. Current is fed to the evaporator sensor from CJ8-23 and the cab sensor from CJ8-21.

Service note: Too little cooling/too much heating without symptoms The sensors should be suspect when the complaint is too little cooling when cooling and too much heating when heating (“the cab is too hot or too cold all the time”), and obvious symptoms are absent: • System pressures are normal, and system is properly charged. • Coolant system operating normally. • No faults codes displayed on the display. • Compressor and heater valve are functioning normally. The sensors fail in a consistent pattern: They sense a lower temperature then is actually present. In cooling mode, actual cab temperature is 24 °C (75 °F), but the cab sensor senses 21 °C (70 °F) and the compressor is not engaged with sufficient frequency. In heating mode, actual cab temperature is 22 °C (72 °F), but the cab sensor senses 19 °C (66 °F) and heater valve is opened too widely.

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Perform the resistance versus temperature test on both sensors.

Possible failure modes - Fault codes 111, 115 and 116 Since input from the sensors is essential for automatic control of heating and cooling functions, the controller displays fault codes on the instrument cluster display when it detects a sensor failure. Fault Code

111

115

116

Description Controller has detected an open, or shorted to power condition in the cab temperature sensor circuit Controller provides a default sensor value of 20 °C (68 °F), the set point must be adjusted to 23 °C (73 °F) or higher to enable cab heating, to 19 °C (66 °F) or lower to enable cab cooling “AUTO” displays on the instrument cluster display with ATC switch set to automatic, but automatic temperature control does not function, operator must assume manual control 1. Open condition in wiring to the cab temperature sensor Cause 2. Cab temperature sensor has failed out of range At cab temperature below -19 °C (-2 °F) at the sensor, the fault code displays Exception until the cab warms above this temperature. If fault code does not clear when cab warms, the sensor requires service Controller has detected an open, or shorted to power condition in the evaporator temperature sensor circuit Compressor clutch does not engage for cooling, but heater valve opens and closes for cab heating. “A” displays on instrument cluster display, but only heating is automatic 1. Open condition in wiring to evaporator temperature sensor Cause 2. Evaporator temperature sensor has failed out of range Controller has detected a short to ground in the evaporator temperature sensor circuit Compressor clutch does not engage for cooling, but heater valve opens and closes for cab heating. “A” displays on instrument cluster display, but only heating is automatic 1. Wiring shorted to evaporator temperature sensor Cause 2. Evaporator temperature sensor has failed out of range At temperature above 82 °C (180 °F) at the sensor, the fault code displays until Exception the evaporator cools below this temperature. If fault code does not clear when the evaporator cools, the sensor requires service

Cab temperature sensor and circuit test

Steps and test point Corrective actions Key switch “OFF”. Disconnect the cab temperature sensor from harness. Measure the resistance across the sensor leads. Measure the ambient YES - Go to next Step temperature at the sensor. Compare the readings NO - Replace the sensor to the temperature versus resistance table. Is the resistance reading within the minus or plus 2.5% range in the table? Key switch “ON” and ATC switch to “Auto”. Measure voltage at female connector on sensor. Is voltage present? YES - Go to next Step 4 NO - Go to next Step NOTE: Voltage reading will be very low: 0.5 V at 21 °C (70 °F), and voltage decreases as temperature increases

Measure voltage at CJ8-21 at the controller. Is voltage present?

YES - Locate and repair open condition between CJ8-21 at the controller and the sensor NO - Test the controller. See ATC controller test in Automatic Temperature Control (ATC) module Test - Connector J8 test points (55.050). Perform tests 1, 2, and 10

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Steps and test point

Corrective actions YES - Wrong reading taken. Retest Measure resistance from ring terminal on the sensor NO - Locate and repair open condition between to HVAC ground. Less than 1 Ω? sensor and HVAC ground

Evaporator temperature sensor and circuit test

Steps and test point Corrective actions Key switch “OFF”. Disconnect the cab temperature sensor from harness. Measure the resistance across the sensor leads. Measure the ambient YES - Go to next Step temperature at the sensor. Compare the readings NO - Replace the sensor to the temperature versus resistance table. Is the resistance reading within the minus or plus 2.5% range in the table? Key switch “ON” and ATC switch to “Auto”. Measure voltage at female connector on sensor. Is voltage present? YES - Go to next Step 4 NOTE: Voltage reading will be very low: 0.5 V at NO - Go to next Step 21 °C (70 °F), and voltage decreases as temperature increases

YES - Locate and repair open condition between CJ8-23 and the sensor NO - Test the controller. See ATC controller tests in 3 Measure voltage at CJ8-23. Is voltage present? Automatic Temperature Control (ATC) module Test - Connector J8 test points (55.050) YES - Wrong reading taken. Test again Measure resistance from the sensor to HVAC box NO - Locate and repair open condition between 4 ground stud. Less than 1 Ω? sensor and HVAC box ground stud NOTE: Verify that the evaporator temperature sensor is installed in the right location. The temperature sensor must be installed 107 mm (4.2 in) from the right end of coil. The sensor must be properly installed. See evaporator sensor location in Air-conditioning evaporator - Test - Cab and evaporator temperature sensors (50.200) NOTE: While installing the sensor in the wrong location causes faulty system performance, it will not cause the sensor to fail or provide a faulty resistance reading for a given temperature. Replace the sensor if it tests out of range for a given temperature

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Ambient temperature -7.78 °C (18 °F) -7.22 °C (19 °F) -6.67 °C (20 °F) -6.11 °C (21 °F) -5.56 °C (22 °F) -5 °C (23 °F) -4.44 °C (24 °F) -3.89 °C (25 °F) -3.33 °C (26 °F) -2.78 °C (27 °F) -2.22 °C (28 °F) -1.67 °C (29 °F) -1.11 °C (30 °F) -0.56 °C (31 °F) 0 °C (32 °F) 0.56 °C (33 °F) 1.11 °C (34 °F) 1.67 °C (35 °F) 2.22 °C (36 °F) 2.78 °C (37 °F) 3.33 °C (38 °F) 3.89 °C (39 °F) 4.44 °C (40 °F) 5 °C (41 °F) 5.56 °C (42 °F) 6.11 °C (43 °F) 6.67 °C (44 °F) 7.22 °C (45 °F) 7.78 °C (46 °F) 8.33 °C (47 °F) 8.89 °C (48 °F) 9.44 °C (49 °F) 10 °C (50 °F) 10.56 °C (51 °F) 11.11 °C (52 °F) 11.67 °C (53 °F) 12.22 °C (54 °F) 12.78 °C (55 °F) 13.33 °C (56 °F) 13.89 °C (57 °F) 14.44 °C (58 °F) 15 °C (59 °F) 15.56 °C (60 °F)

Range 97.227 – 102.213 kΩ 94.331 – 99.169 kΩ 91.533 – 96.227 kΩ 88.832 – 93.388 kΩ 86.219 – 90.641 kΩ 83.694 – 87.986 kΩ 81.247 – 85.413 kΩ 78.887 – 82.933 kΩ 76.596 – 80.524 kΩ 74.383 – 78.197 kΩ 72.248 – 75.953 kΩ 70.171 – 73.769 kΩ 67.47 – 70.93 kΩ 66.232 – 69.628 kΩ 64.35 – 67.65 kΩ 62.532 – 65.738 kΩ 60.771 – 63.887 kΩ 59.066 – 62.095 kΩ 57.414 – 60.358 kΩ 55.814 – 58.676 kΩ 54.265 – 57.047 kΩ 52.764 – 55.47 kΩ 51.309 – 53.941 kΩ 49.901 – 52.46 kΩ 48.535 – 51.023 kΩ 47.211 – 49.633 kΩ 45.928 – 48.284 kΩ 44.684 – 46.976 kΩ 43.479 – 45.709 kΩ 42.31 – 44.48 kΩ 41.176 – 43.288 kΩ 40.076 – 42.132 kΩ 39.011 – 41.011 kΩ 37.976 – 39.924 kΩ 36.973 – 38.869 kΩ 36 – 37.846 kΩ 35.055 – 36.853 kΩ 34.139 – 35.889 kΩ 33.249 – 34.955 kΩ 32.387 – 34.047 kΩ 31.548 – 33.166 kΩ 30.735 – 32.311 kΩ 29.945 – 31.481 kΩ

Ambient temperature 26.11 °C (79 °F) 26.67 °C (80 °F) 27.22 °C (81 °F) 27.78 °C (82 °F) 28.33 °C (83 °F) 28.89 °C (84 °F) 29.44 °C (85 °F) 30 °C (86 °F) 30.56 °C (87 °F) 31.11 °C (88 °F) 31.67 °C (89 °F) 32.22 °C (90 °F) 32.78 °C (91 °F) 33.33 °C (92 °F) 33.89 °C (93 °F) 34.44 °C (94 °F) 35 °C (95 °F) 35.56 °C (96 °F) 36.11 °C (97 °F) 36.67 °C (98 °F) 37.22 °C (99 °F) 37.78 °C (100 °F) 38.33 °C (101 °F) 38.89 °C (102 °F) 39.44 °C (103 °F) 40 °C (104 °F) 40.56 °C (105 °F) 41.11 °C (106 °F) 41.67 °C (107 °F) 42.22 °C (108 °F) 42.78 °C (109 °F) 43.33 °C (110 °F) 43.89 °C (111 °F) 44.44 °C (112 °F) 45 °C (113 °F) 45.56 °C (114 °F) 46.11 °C (115 °F) 46.67 °C (116 °F) 47.22 °C (117 °F) 47.78 °C (118 °F) 48.33 °C (119 °F) 48.89 °C (120 °F) 49.44 °C (121 °F)

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Range 18.571 – 19.523 kΩ 18.125 – 19.055 kΩ 17.691 – 18.599 kΩ 17.269 – 18.155 kΩ 16.859 – 17.723 kΩ 16.46 – 17.304 kΩ 16.071 – 16.895 kΩ 15.694 – 16.498 kΩ 15.325 – 16.111 kΩ 14.967 – 15.735 kΩ 14.618 – 15.368 kΩ 14.279 – 15.011 kΩ 13.948 – 14.664 kΩ 13.627 – 14.325 kΩ 13.314 – 13.996 kΩ 13.008 – 13.676 kΩ 12.712 – 13.364 kΩ 12.422 – 13.06 kΩ 12.141 – 12.763 kΩ 11.866 – 12.474 kΩ 11.599 – 12.193 kΩ 11.338 – 11.92 kΩ 11.084 – 11.652 kΩ 10.837 – 11.393 kΩ 10.595 – 11.139 kΩ 10.36 – 10.892 kΩ 10.131 – 10.651 kΩ 9.908 – 10.416 kΩ 9.691 – 10.187 kΩ 9.479 – 9.965 kΩ 9.272 – 9.748 kΩ 9.07 – 9.536 kΩ 8.873 – 9.329 kΩ 8.681 – 9.127 kΩ 8.495 – 8.931 kΩ 8.312 – 8.738 kΩ 8.134 – 8.552 kΩ 7.961 – 8.369 kΩ 7.791 – 8.191 kΩ 7.626 – 8.018 kΩ 7.466 – 7.848 kΩ 7.308 – 7.682 kΩ 7.155 – 7.521 kΩ

Cab climate control - Air conditioning

Air-conditioning evaporator - Remove Prior operation: Air conditioning - Recover - Recovering contaminated refrigerant (50.200) Prior operation: Heating - Remove - Radiator (50.100) 1. The sensor wire (1) of the thermostat (2) remains attached to the body of the evaporator (3). Remove the retaining clamp (4). Move the sensor wire (1). NOTE: Measure the distance from the clamp (4) to the top and to the right-hand side of the evaporator (3). This position must be maintained in the installation of the assembly, so as not to affect the measurement of the sensor (1).

PIIL17SP00050AA

PIIL17SP00051AA

2. Remove the foam cover (1). 3. Disconnect the refrigerant inlet line (2) and the refrigerant outlet line (3) from the evaporator (4). 4. Remove the evaporator (4).

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Air-conditioning evaporator - Install 1. Position the evaporator (1) in the housing (2), as shown. 2. Connect the refrigerant inlet line (3) and the refrigerant outlet line (4) to the evaporator (1). 3. Install the foam cover (5).

PIIL17SP00051AA

PIIL17SP00050AA

4. Secure the wire sensor (1) of the thermostat (2) to the body of the evaporator (3). Install the retaining clamp (4) to secure. NOTE: Secure the clamp (4) in the correct position in relation to the evaporator (3), as per the measurements made in the removal procedure.

Next operation: Heating - Install - Radiator (50.100) Next operation: Air conditioning - Apply vacuum (50.200) Next operation: Air conditioning - Charging (50.200)

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Index Cab climate control - 50 Air conditioning - 200 Air conditioning - Apply vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

105

Air conditioning - Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

107

Air conditioning - Component identification - Air conditioning system components . . . . . . . . . . . . . .

Air conditioning - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air conditioning - Connect of the pressure gauge set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air conditioning - Disconnect of the pressure gauge set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

100

Air conditioning - Dynamic description - Automatic temperature control operation . . . . . . . . . . . . . . .

Air conditioning - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air conditioning - Flush - System flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air conditioning - General specification - Temperature and pressure chart . . . . . . . . . . . . . . . . . . . . .

Air conditioning - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air conditioning - Leakage test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air conditioning - Overview - Locating ATC problems without fault codes . . . . . . . . . . . . . . . . . . . . . .

Air conditioning - Overview - Refrigerant recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air conditioning - Overview - Standard air-conditioning troubleshooting . . . . . . . . . . . . . . . . . . . . . . . .

Air conditioning - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air conditioning - Recover - Recovering contaminated refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air conditioning - Recover - Recovering pure 134A refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air conditioning - Recover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

103

Air conditioning - Service instruction - Accessing the HVAC box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air conditioning - Service instruction - System evacuation and recharging . . . . . . . . . . . . . . . . . . . . .

Air conditioning - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air conditioning - Startup test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

101

Air-conditioning compressor - Assemble - Electromagnetic clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . .

132

Air-conditioning compressor - Adjust - Air clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

136

Air-conditioning compressor - Check - Compressor and clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

109

Air-conditioning compressor - Disassemble - Electromagnetic clutch . . . . . . . . . . . . . . . . . . . . . . . . . .

127

Air-conditioning compressor - Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

126

Air-conditioning compressor - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air-conditioning compressor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

125

Air-conditioning compressor - Overview - High and low pressure switch clutch circuit . . . . . . . . . . .

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Air-conditioning compressor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

124

Air-conditioning compressor - Test - Electromagnetic clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

131

Air-conditioning compressor Magnetic clutch - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

119

Air-conditioning compressor Magnetic clutch - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

114

Air-conditioning condenser - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

138

Air-conditioning condenser - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

140

Air-conditioning condenser - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

137

Air-conditioning condenser - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

139

Air-conditioning evaporator - Component localization - Cab and evaporator temperature sensor location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air-conditioning evaporator - Dynamic description - Cab and evaporator temperature sensors . . . .

Air-conditioning evaporator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

154

Air-conditioning evaporator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

153

Air-conditioning evaporator - Test - Cab and evaporator temperature sensors . . . . . . . . . . . . . . . . . .

149

Expansion valve - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

143

Expansion valve - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

146

Expansion valve - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

145

Receiver-dryer - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

142

Receiver-dryer - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

141

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Cab climate control - 50 Cab pressurizing system - 300

SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Cab climate control - 50 Cab pressurizing system - 300

SERVICE Cab pressurizing system Test - Cab pressurization test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Cab pressurizing system - Test - Cab pressurization test NOTE: Perform the cab pressurization test whenever an unusual amount of dirt accumulates in the cab or in the evaporator box or if the evaporator core is plugged. NOTE: When performing this test, the door and window must be closed and latched. 1. Insert the sensing tube from a digital manometer through the access panel in the right hand corner of the rear cab window provided for monitor harness routing between the cab and the implement. NOTE: Do not attempt this test through the door since the metal reinforcement in the seal will pinch off the sensing tube.

RAIL13SP01767AA

RAIL13SP01768AA

RAIL13SP01769AA

2. Start the engine. Take a reading from the digital manometer. Cab pressurization must be between 6 â&#x20AC;&#x201C; 25.4 mm (0.24 â&#x20AC;&#x201C; 1 in) of H2O.

3. If a digital manometer is not available, a simple one can be made with 2.8 m (9 ft) of 3/8 in OD clear vinyl tubing and a yard stick. Tape the vinyl tubing to a yard stick as shown.

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Cab climate control - Cab pressurizing system

4. Partially fill the looped section of tubing with water. (Food coloring may be added to the water to improve visibility.)

RAIL13SP01770AA

RAIL13SP01767AA

RAIL13SP01771AA

5. Insert the long end of the tube through the access panel in the right hand corner of the rear cab window provided for monitor harness routing between the cab and the implement. NOTE: Do not attempt this test through the door since the metal reinforcement in the seal will pinch off the sensing tube.

6. Hold the yard stick vertical. Record the water level reading without the engine running. Start the engine and measure the movement of water on one side of the yard stick. Multiply that value by two. Cab pressurization must be between 6 – 25.4 mm (0.24 – 1 in) of H2O. 7. If the reading is below 6 mm (0.24 in) of H2O, check the following seals and retest: • Door and rear window seals • Window seals • Customer supplied radio/telephone antenna cable routing 8. If the reading is above 25.4 mm (1 in) of H2O, check for extra cab sealing, missing filter or broken fresh air inlet.

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Index Cab climate control - 50 Cab pressurizing system - 300 Cab pressurizing system - Test - Cab pressurization test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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CNH Industrial Latin America LTDA, Av. Jerome Case, 1801, Aparecidinha - Socoraba (SP) - Brasil, CEP:18087-220

SERVICE - Technical Publications & Tools

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SERVICE MANUAL Electrical systems SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Electrical systems - 55

[55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.019] Hydrostatic drive control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 [55.DTC] FAULT CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3

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SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Electrical systems - 55 Harnesses and connectors - 100

FUNCTIONAL DATA Wiring harnesses Wiring schema - Index - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Wiring schema - Electrical schematic legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Wiring schema - Optional codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Wiring schema - Batteries / Distribution / Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Wiring schema - Unswitched fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Wiring schema - Switched fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Wiring schema - Switched fuses 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Wiring schema - Switched fuses 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Wiring schema - Switched fuses 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Wiring schema - Ignition switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Wiring schema - Wklts fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Wiring schema - Cab ground cable / Roof ground cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Wiring schema - Cleaning system ground cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Wiring schema - Neutral/Reverse/TPS/Cab pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Wiring schema - Parking brake/Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 - Wiring schema - Service lights/Headlights switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Wiring schema - Power points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Wiring schema - Axle/Mixer/Flow divider adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Wiring schema - HVAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Wiring schema - Wiper/Seat/Pressurizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Wiring schema - Cab lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Wiring schema - Rexroth control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Wiring schema - Lights relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Wiring schema - Icu 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Wiring schema - FNR/Lock control interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Wiring schema - Turn signals/Signal unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Wiring harnesses - Wiring schema - Console wiring harness junctions . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Wiring schema - Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Wiring schema - Boom Section 1 - 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Wiring schema - Boom section 5 - 7/Range select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Wiring schema - Product pressure switches/Mixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

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Wiring schema - Product/Supply modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Wiring schema - Hydraulic frame fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Wiring harnesses - Wiring schema - Main supply switch/Ball valve relay . . . . . . . . . . . . . . . . . . . . . . . . . . 72 - Wiring schema - LH boom controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Wiring schema - RH boom controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Wiring schema - Height/Fold controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Wiring schema - Controller interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Wiring schema - One-touch control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Wiring harnesses - Wiring schema - Application of CAN network bus 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Wiring schema - Application of CAN network bus 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Wiring schema - Reserve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Wiring schema - Veh CAN/Service input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Wiring schema - Product CAN network bus - Chassis/Control supply/ACC input . . . . . . . . . . . . . . . . . . . 92 Wiring schema - Traction, Rotation limit, Bypass, axle, Backup alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Wiring schema - Junctions of the frame wiring harness and ground cable of the cleaning system . . . . 96 Wiring schema - Main cab bulkhead - Inside of cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Wiring schema - Main cab bulkhead - Outside of cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Wiring schema - Engine chassis interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Wiring schema - Hood lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Wiring schema - Light extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Wiring schema - Hydraulic sensors, Radar, Charge PSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Wiring schema - LTS marker, Fuel sender, WIF sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Wiring schema - Washer, Mirror, Midship wklt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Wiring schema - Propulsion valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Wiring schema - Remote control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Wiring schema - Tier 3 engine interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Wiring schema - Tier 3 engine ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Wiring schema - Reserve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Wiring schema - Road/Cab interface switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Wiring schema - NAV controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Wiring schema - GPS receiver/AG CAN network bus (EST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Wiring schema - Steering control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Wiring schema - GPS antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 Wiring schema - LH boom - Section 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 Wiring schema - RH boom - Section 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 Wiring schema - Direct injection 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 - Wiring schema - Direct injection 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Wiring schema - Auto leveling 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Wiring schema - Auto leveling 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Wiring schema - AutoFold 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 Wiring schema - AutoFold 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 Wiring schema - SH073 - Autofold 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

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Wiring schema - Sprayer boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 Wiring schema - A-pillar Viper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 Wiring schema - SCS5000 A-pillar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 Wiring schema - A-pillar AFS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 Wiring schema - Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

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Wiring harnesses - Wiring schema - Index -

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SOIL18SP00069JA

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Wiring harnesses - Wiring schema - Electrical schematic legend

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SOIL18SP00070JA

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Wiring harnesses - Wiring schema - Optional codes

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SOIL18SP00071JA

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Wiring harnesses - Wiring schema - Batteries / Distribution / Start-up

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SOIL18SP00072JA

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Wiring harnesses - Wiring schema - Unswitched fuses

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SOIL18SP00073JA

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Wiring harnesses - Wiring schema - Switched fuses

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SOIL18SP00074JA

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SOIL18SP00075JA

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SOIL18SP00076JA

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SOIL18SP00077JA

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Wiring harnesses - Wiring schema - Ignition switch

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SOIL18SP00078JA

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Wiring harnesses - Wiring schema - Wklts fuses

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SOIL18SP00079JA

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Wiring harnesses - Wiring schema - Cab ground cable / Roof ground cable

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SOIL18SP00080JA

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Wiring harnesses - Wiring schema - Cleaning system ground cable

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SOIL18SP00081JA

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Wiring harnesses - Wiring schema - Neutral/Reverse/TPS/Cab pressure

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SOIL18SP00082JA

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Wiring harnesses - Wiring schema - Parking brake/Brake

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SOIL18SP00083JA

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Wiring harnesses - Wiring schema - Service lights/Headlights switch

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SOIL18SP00084JA

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55.1 [55.100] / 37

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - Power points

48149953 12/06/2018

55.1 [55.100] / 38

Electrical systems - Harnesses and connectors

SOIL18SP00085JA

48149953 12/06/2018

55.1 [55.100] / 39

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - Axle/Mixer/Flow divider adjust

48149953 12/06/2018

55.1 [55.100] / 40

Electrical systems - Harnesses and connectors

SOIL18SP00087JA

48149953 12/06/2018

55.1 [55.100] / 41

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - HVAC

48149953 12/06/2018

55.1 [55.100] / 42

Electrical systems - Harnesses and connectors

SOIL18SP00088JA

48149953 12/06/2018

55.1 [55.100] / 43

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - Wiper/Seat/Pressurizer

48149953 12/06/2018

55.1 [55.100] / 44

Electrical systems - Harnesses and connectors

SOIL18SP00089JA

48149953 12/06/2018

55.1 [55.100] / 45

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - Cab lights

48149953 12/06/2018

55.1 [55.100] / 46

Electrical systems - Harnesses and connectors

SOIL18SP00090JA

48149953 12/06/2018

55.1 [55.100] / 47

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - Rexroth control

48149953 12/06/2018

55.1 [55.100] / 48

Electrical systems - Harnesses and connectors

SOIL18SP00091JA

48149953 12/06/2018

55.1 [55.100] / 49

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - Lights relays

48149953 12/06/2018

55.1 [55.100] / 50

Electrical systems - Harnesses and connectors

SOIL18SP00092JA

48149953 12/06/2018

55.1 [55.100] / 51

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - Icu 2

48149953 12/06/2018

55.1 [55.100] / 52

Electrical systems - Harnesses and connectors

SOIL18SP00093JA

48149953 12/06/2018

55.1 [55.100] / 53

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - FNR/Lock control interface

48149953 12/06/2018

55.1 [55.100] / 54

Electrical systems - Harnesses and connectors

SOIL18SP00095JA

48149953 12/06/2018

55.1 [55.100] / 55

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - Turn signals/Signal unit

48149953 12/06/2018

55.1 [55.100] / 56

Electrical systems - Harnesses and connectors

SOIL18SP00096JA

48149953 12/06/2018

55.1 [55.100] / 57

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - Console wiring harness junctions

48149953 12/06/2018

55.1 [55.100] / 58

Electrical systems - Harnesses and connectors

SOIL18SP00097JA

48149953 12/06/2018

55.1 [55.100] / 59

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - Radio

48149953 12/06/2018

55.1 [55.100] / 60

Electrical systems - Harnesses and connectors

SOIL18SP00098JA

48149953 12/06/2018

55.1 [55.100] / 61

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - Boom Section 1 - 4

48149953 12/06/2018

55.1 [55.100] / 62

Electrical systems - Harnesses and connectors

SOIL18SP00099JA

48149953 12/06/2018

55.1 [55.100] / 63

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - Boom section 5 - 7/Range select

48149953 12/06/2018

55.1 [55.100] / 64

Electrical systems - Harnesses and connectors

SOIL18SP00100JA

48149953 12/06/2018

55.1 [55.100] / 65

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - Product pressure switches/Mixture

48149953 12/06/2018

55.1 [55.100] / 66

Electrical systems - Harnesses and connectors

SOIL18SP00101JA

48149953 12/06/2018

55.1 [55.100] / 67

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - Product/Supply modules

48149953 12/06/2018

55.1 [55.100] / 68

Electrical systems - Harnesses and connectors

SOIL18SP00102JA

48149953 12/06/2018

55.1 [55.100] / 69

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - Hydraulic frame fittings

48149953 12/06/2018

55.1 [55.100] / 70

Electrical systems - Harnesses and connectors

SOIL18SP00103JA

48149953 12/06/2018

55.1 [55.100] / 71

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - Main supply switch/Ball valve relay

48149953 12/06/2018

55.1 [55.100] / 72

Electrical systems - Harnesses and connectors

SOIL18SP00104JA

48149953 12/06/2018

55.1 [55.100] / 73

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - LH boom controls

48149953 12/06/2018

55.1 [55.100] / 74

Electrical systems - Harnesses and connectors

SOIL18SP00105JA

48149953 12/06/2018

55.1 [55.100] / 75

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - RH boom controls

48149953 12/06/2018

55.1 [55.100] / 76

Electrical systems - Harnesses and connectors

SOIL18SP00106JA

48149953 12/06/2018

55.1 [55.100] / 77

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - Height/Fold controls

48149953 12/06/2018

55.1 [55.100] / 78

Electrical systems - Harnesses and connectors

SOIL18SP00107JA

48149953 12/06/2018

55.1 [55.100] / 79

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - Controller interface

48149953 12/06/2018

55.1 [55.100] / 80

Electrical systems - Harnesses and connectors

SOIL18SP00108JA

48149953 12/06/2018

55.1 [55.100] / 81

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - One-touch control module

48149953 12/06/2018

55.1 [55.100] / 82

Electrical systems - Harnesses and connectors

SOIL18SP00109JA

48149953 12/06/2018

55.1 [55.100] / 83

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - Application of CAN network bus 1

48149953 12/06/2018

55.1 [55.100] / 84

Electrical systems - Harnesses and connectors

SOIL18SP00110JA

48149953 12/06/2018

55.1 [55.100] / 85

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - Application of CAN network bus 1

48149953 12/06/2018

55.1 [55.100] / 86

Electrical systems - Harnesses and connectors

SOIL18SP00111JA

48149953 12/06/2018

55.1 [55.100] / 87

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - Reserve

48149953 12/06/2018

55.1 [55.100] / 88

Electrical systems - Harnesses and connectors

SOIL18SP00112JA

48149953 12/06/2018

55.1 [55.100] / 89

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - Veh CAN/Service input

48149953 12/06/2018

55.1 [55.100] / 90

Electrical systems - Harnesses and connectors

SOIL18SP00113JA

48149953 12/06/2018

55.1 [55.100] / 91

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - Product CAN network bus Chassis/Control supply/ACC input

48149953 12/06/2018

55.1 [55.100] / 92

Electrical systems - Harnesses and connectors

SOIL18SP00114JA

48149953 12/06/2018

55.1 [55.100] / 93

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - Traction, Rotation limit, Bypass, axle, Backup alarm

48149953 12/06/2018

55.1 [55.100] / 94

Electrical systems - Harnesses and connectors

SOIL18SP00115JA

48149953 12/06/2018

55.1 [55.100] / 95

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - Junctions of the frame wiring harness and ground cable of the cleaning system

48149953 12/06/2018

55.1 [55.100] / 96

Electrical systems - Harnesses and connectors

SOIL18SP00116JA

48149953 12/06/2018

55.1 [55.100] / 97

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - Main cab bulkhead - Inside of cab

48149953 12/06/2018

55.1 [55.100] / 98

Electrical systems - Harnesses and connectors

SOIL18SP00117JA

48149953 12/06/2018

55.1 [55.100] / 99

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - Main cab bulkhead - Outside of cab

48149953 12/06/2018

55.1 [55.100] / 100

Electrical systems - Harnesses and connectors

SOIL18SP00118JA

48149953 12/06/2018

55.1 [55.100] / 101

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - Engine chassis interface

48149953 12/06/2018

55.1 [55.100] / 102

Electrical systems - Harnesses and connectors

SOIL18SP00119JA

48149953 12/06/2018

55.1 [55.100] / 103

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - Hood lights

48149953 12/06/2018

55.1 [55.100] / 104

Electrical systems - Harnesses and connectors

SOIL18SP00120JA

48149953 12/06/2018

55.1 [55.100] / 105

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - Light extension

48149953 12/06/2018

55.1 [55.100] / 106

Electrical systems - Harnesses and connectors

SOIL18SP00121JA

48149953 12/06/2018

55.1 [55.100] / 107

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - Hydraulic sensors, Radar, Charge PSI

48149953 12/06/2018

55.1 [55.100] / 108

Electrical systems - Harnesses and connectors

SOIL18SP00122JA

48149953 12/06/2018

55.1 [55.100] / 109

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - LTS marker, Fuel sender, WIF sensor

48149953 12/06/2018

55.1 [55.100] / 110

Electrical systems - Harnesses and connectors

SOIL18SP00123JA

48149953 12/06/2018

55.1 [55.100] / 111

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - Washer, Mirror, Midship wklt

48149953 12/06/2018

55.1 [55.100] / 112

Electrical systems - Harnesses and connectors

SOIL18SP00124JA

48149953 12/06/2018

55.1 [55.100] / 113

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - Propulsion valves

48149953 12/06/2018

55.1 [55.100] / 114

Electrical systems - Harnesses and connectors

SOIL18SP00125JA

48149953 12/06/2018

55.1 [55.100] / 115

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - Remote control module

48149953 12/06/2018

55.1 [55.100] / 116

Electrical systems - Harnesses and connectors

SOIL18SP00126JA

48149953 12/06/2018

55.1 [55.100] / 117

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - Tier 3 engine interface

48149953 12/06/2018

55.1 [55.100] / 118

Electrical systems - Harnesses and connectors

SOIL18SP00127JA

48149953 12/06/2018

55.1 [55.100] / 119

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - Tier 3 engine ECM

48149953 12/06/2018

55.1 [55.100] / 120

Electrical systems - Harnesses and connectors

SOIL18SP00128JA

48149953 12/06/2018

55.1 [55.100] / 121

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - Reserve

48149953 12/06/2018

55.1 [55.100] / 122

Electrical systems - Harnesses and connectors

SOIL18SP00129JA

48149953 12/06/2018

55.1 [55.100] / 123

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - Road/Cab interface switch

48149953 12/06/2018

55.1 [55.100] / 124

Electrical systems - Harnesses and connectors

SOIL18SP00130JA

48149953 12/06/2018

55.1 [55.100] / 125

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - NAV controller

48149953 12/06/2018

55.1 [55.100] / 126

Electrical systems - Harnesses and connectors

SOIL18SP00131JA

48149953 12/06/2018

55.1 [55.100] / 127

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - GPS receiver/AG CAN network bus (EST)

48149953 12/06/2018

55.1 [55.100] / 128

Electrical systems - Harnesses and connectors

SOIL18SP00132JA

48149953 12/06/2018

55.1 [55.100] / 129

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - Steering control

48149953 12/06/2018

55.1 [55.100] / 130

Electrical systems - Harnesses and connectors

SOIL18SP00133JA

48149953 12/06/2018

55.1 [55.100] / 131

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - GPS antenna

48149953 12/06/2018

55.1 [55.100] / 132

Electrical systems - Harnesses and connectors

SOIL18SP00134JA

48149953 12/06/2018

55.1 [55.100] / 133

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - LH boom - Section 9

48149953 12/06/2018

55.1 [55.100] / 134

Electrical systems - Harnesses and connectors

SOIL18SP00135JA

48149953 12/06/2018

55.1 [55.100] / 135

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - RH boom - Section 9

48149953 12/06/2018

55.1 [55.100] / 136

Electrical systems - Harnesses and connectors

SOIL18SP00136JA

48149953 12/06/2018

55.1 [55.100] / 137

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - Direct injection 1

48149953 12/06/2018

55.1 [55.100] / 138

Electrical systems - Harnesses and connectors

SOIL18SP00137JA

48149953 12/06/2018

55.1 [55.100] / 139

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - Direct injection 2

48149953 12/06/2018

55.1 [55.100] / 140

Electrical systems - Harnesses and connectors

SOIL18SP00138JA

48149953 12/06/2018

55.1 [55.100] / 141

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - Auto leveling 1

48149953 12/06/2018

55.1 [55.100] / 142

Electrical systems - Harnesses and connectors

SOIL18SP00139JA

48149953 12/06/2018

55.1 [55.100] / 143

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - Auto leveling 2

48149953 12/06/2018

55.1 [55.100] / 144

Electrical systems - Harnesses and connectors

SOIL18SP00140JA

48149953 12/06/2018

55.1 [55.100] / 145

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - AutoFold 1

48149953 12/06/2018

55.1 [55.100] / 146

Electrical systems - Harnesses and connectors

SOIL18SP00141JA

48149953 12/06/2018

55.1 [55.100] / 147

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - AutoFold 2

48149953 12/06/2018

55.1 [55.100] / 148

Electrical systems - Harnesses and connectors

SOIL18SP00142JA

48149953 12/06/2018

55.1 [55.100] / 149

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - SH073 - Autofold 3

48149953 12/06/2018

55.1 [55.100] / 150

Electrical systems - Harnesses and connectors

SOIL18SP00143JA

48149953 12/06/2018

55.1 [55.100] / 151

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - Sprayer boom

48149953 12/06/2018

55.1 [55.100] / 152

Electrical systems - Harnesses and connectors

SOIL18SP00144JA

48149953 12/06/2018

55.1 [55.100] / 153

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - A-pillar Viper

48149953 12/06/2018

55.1 [55.100] / 154

Electrical systems - Harnesses and connectors

SOIL18SP00145JA

48149953 12/06/2018

55.1 [55.100] / 155

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - SCS5000 A-pillar

48149953 12/06/2018

55.1 [55.100] / 156

Electrical systems - Harnesses and connectors

SOIL18SP00146JA

48149953 12/06/2018

55.1 [55.100] / 157

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - A-pillar AFS

48149953 12/06/2018

55.1 [55.100] / 158

Electrical systems - Harnesses and connectors

SOIL18SP00147JA

48149953 12/06/2018

55.1 [55.100] / 159

Electrical systems - Harnesses and connectors

Wiring harnesses - Wiring schema - Block diagram

48149953 12/06/2018

55.1 [55.100] / 160

Electrical systems - Harnesses and connectors

SOIL18SP00148JA

48149953 12/06/2018

55.1 [55.100] / 161

Electrical systems - Harnesses and connectors

48149953 12/06/2018

55.1 [55.100] / 162

Index Electrical systems - 55 Harnesses and connectors - 100 Wiring harnesses - Wiring schema - Application of CAN network bus 1 . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Wiring schema - Console wiring harness junctions . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Wiring schema - Main supply switch/Ball valve relay . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Wiring schema - Direct injection 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

140

Wiring harnesses - Wiring schema - LH boom controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Wiring schema - Service lights/Headlights switch . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Wiring schema - Application of CAN network bus 1 . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Wiring schema - GPS receiver/AG CAN network bus (EST) . . . . . . . . . . . . . . . .

128

Wiring harnesses - Wiring schema - Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Wiring schema - Batteries / Distribution / Start-up . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Wiring schema - Light extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

106

Wiring harnesses - Wiring schema - SH073 - Autofold 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

150

Wiring harnesses - Wiring schema - Steering control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

130

Wiring harnesses - Wiring schema - Tier 3 engine interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

118

Wiring harnesses - Wiring schema - Main cab bulkhead - Inside of cab . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Wiring schema - A-pillar AFS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

158

Wiring harnesses - Wiring schema - A-pillar Viper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

154

Wiring harnesses - Wiring schema - Auto leveling 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

142

Wiring harnesses - Wiring schema - Auto leveling 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

144

Wiring harnesses - Wiring schema - AutoFold 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

146

Wiring harnesses - Wiring schema - AutoFold 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

148

Wiring harnesses - Wiring schema - Axle/Mixer/Flow divider adjust . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Wiring schema - Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

160

Wiring harnesses - Wiring schema - Boom Section 1 - 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Wiring schema - Boom section 5 - 7/Range select . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Wiring schema - Cab lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Wiring schema - Cleaning system ground cable . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Wiring schema - Controller interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Wiring schema - Direct injection 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

138

Wiring harnesses - Wiring schema - Electrical schematic legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Wiring schema - Engine chassis interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

102

Wiring harnesses - Wiring schema - FNR/Lock control interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Wiring schema - GPS antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

132

Wiring harnesses - Wiring schema - HVAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

48149953 12/06/2018

55.1 [55.100] / 163

Wiring harnesses - Wiring schema - Height/Fold controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Wiring schema - Hood lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

104

Wiring harnesses - Wiring schema - Hydraulic frame fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Wiring schema - Hydraulic sensors, Radar, Charge PSI . . . . . . . . . . . . . . . . . . . .

108

Wiring harnesses - Wiring schema - Icu 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Wiring schema - Ignition switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Wiring schema - Index - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Wiring schema - Junctions of the frame wiring harness and ground cable of the cleaning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Wiring schema - LH boom - Section 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

134

Wiring harnesses - Wiring schema - LTS marker, Fuel sender, WIF sensor . . . . . . . . . . . . . . . . . . . .

110

Wiring harnesses - Wiring schema - Lights relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Wiring schema - Main cab bulkhead - Outside of cab . . . . . . . . . . . . . . . . . . . . . .

100

Wiring harnesses - Wiring schema - NAV controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

126

Wiring harnesses - Wiring schema - Neutral/Reverse/TPS/Cab pressure . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Wiring schema - One-touch control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Wiring schema - Optional codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Wiring schema - Parking brake/Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Wiring schema - Power points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Wiring schema - Product CAN network bus - Chassis/Control supply/ACC input

Wiring harnesses - Wiring schema - Product pressure switches/Mixture . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Wiring schema - Product/Supply modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Wiring schema - Propulsion valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

114

Wiring harnesses - Wiring schema - RH boom - Section 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

136

Wiring harnesses - Wiring schema - RH boom controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Wiring schema - Remote control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

116

Wiring harnesses - Wiring schema - Reserve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

122

Wiring harnesses - Wiring schema - Rexroth control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Wiring schema - Road/Cab interface switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

124

Wiring harnesses - Wiring schema - SCS5000 A-pillar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

156

Wiring harnesses - Wiring schema - Sprayer boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

152

Wiring harnesses - Wiring schema - Switched fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Wiring schema - Switched fuses 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Wiring schema - Switched fuses 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Wiring schema - Switched fuses 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Wiring schema - Tier 3 engine ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

120

Wiring harnesses - Wiring schema - Traction, Rotation limit, Bypass, axle, Backup alarm . . . . . . . .

Wiring harnesses - Wiring schema - Turn signals/Signal unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Wiring schema - Unswitched fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Wiring schema - Veh CAN/Service input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Wiring schema - Washer, Mirror, Midship wklt . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

112

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Wiring harnesses - Wiring schema - Wiper/Seat/Pressurizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Wiring schema - Wklts fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Wiring schema - Cab ground cable / Roof ground cable . . . . . . . . . . . . . . . . . . . .

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Electrical systems - 55 Hydrostatic drive control system - 019

SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Electrical systems - 55 Hydrostatic drive control system - 019

SERVICE Hydrostatic drive control system Calibrate - Drive controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Calibrate - Propel handle rotary position sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Calibrate - Drive controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Electrical systems - Hydrostatic drive control system

Hydrostatic drive control system - Calibrate - Drive controller NOTE: If the power train control module is replaced, the new module must be calibrated. 1. Turn the ignition switch to the OFF position. 2. Place the park brake switch into the OFF position. 3. Place the speed potentiometer (1) into the maximum speed position (full clockwise). 4. Place the hydrostatic control lever into the full forward position; do not force the lever ahead, push the lever lightly. 5. Turn the ignition switch to the ON position with the park brake OFF, do not start the engine. The transmission indicator (2) will steadily be illuminated, then momentarily flash off. This indicates that the hydrostatic control lever forward calibration has completed and is ready for the next value.

SOIL17SP00561AA

RCPH11BEN319BAM

6. Place the hydrostatic control lever into the neutral position. Leave the lever in neutral for approximately two seconds until the transmission indicator (2) momentarily flashes off. This indicates that the controller is ready for the next value. 7. Place the hydrostatic control lever into the full reverse position; do not force the lever, push the lever lightly. Leave the lever in the full reverse position for approximately two seconds until the transmission indicator (2) momentarily flashes off. This indicates that the controller is ready for the next value. 8. The maximum speed potentiometer calibration occurs next automatically. The transmission indicator (2) will momentarily flash off within a couple seconds indicating the maximum value has been saved. The speed potentiometer (1) is already in the maximum position from step 2. 9. Rotate the speed potentiometer (1) to the minimum speed position (full counter-clockwise). The transmission indicator (2) will again momentarily flash off. This indicates that the minimum value has been saved. 10. Calibration procedure is now complete. The transmission indicator (2) will flash three times in succession indicating that calibration was successful. NOTE: Controller Area Network (CAN) error, eleven flashes will occur while the engine is not running. 11. If the calibration is determined to be unsatisfactory, or three flashes on the transmission indicator (2) are not observed in the previous step, repeat the entire calibration process.

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Electrical systems - Hydrostatic drive control system

Drive controller error codes The following error codes can be displayed by the transmission indicator light. The code numbers are indicated by the transmission indicator flashing at approximately two second intervals, with a space of approximately four seconds between the code sequences. Error message Start latch

Number Cause Effect of flashes The start condition is not met. All of the PWM outputs are One switched off. The fault lamp flashes.

FNR potentiometer

Two

Speed potentiometer

Three

The input command voltage signal wiper or the supply shorted to ground. Wire break The input command voltage signal wiper or the supply shorted to high voltage. Wire break The remote station signal shorted to high voltage or ground. Wire break to the remote station. The input command voltage signal wiper or the supply shorted to high voltage. Wire break The circuit controlling proportional output one is open or a short-circuit has occurred.

Propel enable

Five

Ground speed

Six

Pump forward solenoid

Eight

Pump reverse solenoid

Nine

The circuit controlling proportional output two is open or a short-circuit has occurred.

Motor solenoid

Ten

The circuit controlling proportional output two is open or a short-circuit has occurred.

Outputs ramp to zero. No output possible. The fault lamp flashes. Drive with the pumps only possible. The fault lamp flashes. No drive is possible. The fault lamp flashes.

Remedy

Return the command voltage signal to the neutral position. Check the neutral switch, the remote station switch, and the hydrostatic control lever positions are all in the correct states or positions. Check the command voltage signal. Check the wiring to the command voltage signal. Check the command voltage signal. Check the wiring to the variable speed pot signal. Check the remote station switch and wiring.

Drive with the pump only possible. The fault lamp flashes.

Check the ground speed sensor and wiring.

The PMW output controlling proportional output one is switched off. Proportional output one is blocked. The fault lamp flashes. No drive in the forward direction possible. The PWM output controlling proportional output two is switched off. Proportional output two is blocked. The fault lamp flashes. No drive with the reverse pump possible. The PWM output controlling proportional output two is switched off. Proportional output two is blocked. The fault lamp flashes. Drive with the pumps only, no motors.

Return the command voltage signal to the neutral position. Check the pump forward solenoid and wiring.

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Return the command voltage signal to the neutral position.

Return the command voltage signal to the neutral position. Check the motor solenoid and wiring.

Electrical systems - Hydrostatic drive control system

Error message CAN

Remedy Number Cause Effect of flashes Eleven No CAN bus communication. No engine over-speed Check the CAN wiring and detection. the engine module. The fault lamp flashes. The motor control is disabled. NOTE: CAN error (eleven flashes) will occur at 0 engine RPM.

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Electrical systems - Hydrostatic drive control system

Hydrostatic drive control system - Calibrate - Propel handle rotary position sensor NOTICE: If the propel handle rotary position sensor is replaced, it must be properly adjusted and calibrated. To perform this check, you will need a digital multimeter and a back probe extension wire set (Use appropriate tool). 1. Insert the black lead back probe into terminal C (black) on connector P144 and insert the red lead back probe into terminal B (blue) on connector P144 (2). This connection will show the voltage output of the rotary position sensor (1), while connected to propel control system controller. Set the multimeter to read voltage. 2. Turn the ignition switch to the ON position (engine Off). Make sure that the park brake is disengaged. Power to the propel control system controller is cut-off when the unit is in park. 3. When the propel handle is in neutral position the voltage reading should be 2.20 – 2.30 V. Adjust the sensor position until the voltage reads 2.20 – 2.30 V in neutral. 4. After adjustment the voltages should be: • Full forward voltage (FV) 4.40 – 4.60 V • Neutral voltage (NV) 2.20 – 2.30 V • Full reverse voltage (RV) 0.50 – 0.70 V

RAIL13SP01332FA

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Electrical systems - Hydrostatic drive control system

Hydrostatic drive control system - Calibrate - Drive controller NOTE: If the power train control module (Plus 1 propel module) is replaced, the new module must be calibrated. 1. Begin with the ignition switch in the OFF position. 2. Place the park brake switch into the OFF position. 3. Place the max speed potentiometer (1) into the maximum speed position. 4. Place the hydrostatic control lever (2) into the full forward position. (This puts the FNR potentiometer into full forward position). 5. Place the ignition switch into the RUN position, but do not start the engine. Leave the max speed potentiometer (1) and hydrostatic control lever (2) in position for 5 seconds. 6. Place the hydrostatic control lever (2) into the neutral position for 5 seconds. 7. Place the hydrostatic control lever (2) into the full reverse position for 5 seconds. 8. Place the max speed potentiometer (1) into the minimum speed position for 5 seconds. 9. Place the ignition switch into the OFF position. Move the hydrostatic control lever (2) back to neutral. Cycle ignition switch back to RUN position, but do not start the engine. 10. The power train control module (Plus 1 propel module) calibration is complete.

SOIL17SC01052CA

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Electrical systems - Hydrostatic drive control system

Power train control module error code indicator lamps 1. The power train control module (Plus 1 propel module) is located in the electrical compartment behind the operators seat. 2. There are two LED indicators adjacent to the connectors. The green power LED should be ON when software is running correctly. The red status LED should be OFF. If the red status LED is flashing see the table below for flash codes. Error 1 2

Long 1 1

Short 1 2

Fault Description FNR Fault (out of range) Max speed pot fault (out of range) Pump forward coil fault (open or shorted) Pump reverse coil fault (open or shorted) Motor coil fault (open or shorted) CAN communication fault (loss of engine RPM signal)

NOTE: Error 1, 3 and 4 will result in no propel. Error 2, 5 and 6 will prevent wheel motors from shifting, which will limit speed to 19.3 km/h (12.0 mph) NOTE: Only one flash code can be displayed at a time. If there are multiple flash codes, the first flash code must be resolved to view other flash codes.

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Index Electrical systems - 55 Hydrostatic drive control system - 019 Hydrostatic drive control system - Calibrate - Propel handle rotary position sensor . . . . . . . . . . . . . .

Hydrostatic drive control system - Calibrate - Drive controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Electrical systems - 55 FAULT CODES - DTC

SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Electrical systems - 55 FAULT CODES - DTC

DIAGNOSTIC 3001 - Diagnostic fault check of synchronization for double potentiometer and Low idle switch . . . . . . . 7 3002 - Signal Range Check High for Acceleration Pedal Position Device Driver Sensor 1 . . . . . . . . . . . . 9 3005 - Air filter clog or circuit failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3007 - Engine coolant temperature sensor is higher than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3008 - Engine coolant temperature sensor voltage is lower than expected . . . . . . . . . . . . . . . . . . . . . . . . 14 3014 - Air filter clog or circuit failure present for a long time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 3015 - Fuel temperature sensor voltage is higher than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 3016 - Fuel temperature sensor voltage is lower than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 3019 - Intake manifold pressure sensor voltage is higher than expected . . . . . . . . . . . . . . . . . . . . . . . . . . 21 3024 - ECU internal failure - Ambient pressure sensor voltage is higher than expected . . . . . . . . . . . . . 23 3025 - ECU internal failure - Ambient pressure sensor voltage is lower than expected . . . . . . . . . . . . . . 24 3028 - Oil pressure is too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 3029 - Oil pressure sensor voltage is higher than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 3030 - Oil pressure sensor voltage is lower than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 3034 - Oil temperature sensor voltage is higher than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 3035 - Oil temperature sensor voltage is lower than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 3037 - Intake manifold pressure sensor voltage is lower than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 3051 - Battery Voltage To Engine Controller - Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 3052 - Battery Voltage To Engine Controller - Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 3063 - Short circuit in injector 1 (in firing order) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 3067 - Short circuit in injector 4 (in firing order) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 3071 - Short circuit in injector 2 (in firing order) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 3075 - Short circuit in injector 6 (in firing order) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 3079 - Short circuit in injector 3 (in firing order) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 3083 - Short circuit in injector 5 (in firing order) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 3088 - Crankshaft speed sensor values are not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 3089 - Crankshaft speed sensor pattern is not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 3090 - Camshaft speed sensor values are not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 3091 - Camshaft speed sensor pattern is not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 3093 - Compared camshaft and crankshaft speed sensor values are not plausible . . . . . . . . . . . . . . . . . 64 3096 - CAN A Bus off failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

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3102 - Fuel rail pressure sensor voltage is lower than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 3104 - Fuel pressure relief valve is open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 3105 - Fuel pressure relief valve is forced to open, perform pressure increase . . . . . . . . . . . . . . . . . . . . . 70 3106 - Fuel pressure relief valve reached maximum allowed opening count . . . . . . . . . . . . . . . . . . . . . . . 71 3110 - Rail pressure sensor value is above maximum offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 3111 - Rail pressure sensor value is below minimum offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 3112 - Fuel rail pressure sensor voltage is higher than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 3141 - Fuel pump pressure has exceeded desired pressure limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 3146 - Water in fuel detected or water in fuel circuit failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 3154 - Intake air heater actuator is shorted to battery voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 3155 - Intake air heater actuator is shorted to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 3156 - Grid Heater Relay - No Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 3157 - Engine controller configuration timeout anti-tamper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 3160 - Fan clutch solenoid short circuit to battery failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 3161 - Fan actuator - short circuit to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 3162 - Fan actuator - open load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 3163 - Fan clutch solenoid ECU driver over temperature failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 3164 - Fan speed above maximum threshold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 3165 - Fan speed below minimum threshold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 3166 - Fuel filter heater actuator is shorted to battery voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 3167 - Fuel Filter Heater Relay - Short Circuit To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 3168 - Fuel filter heater relay - open load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 3169 - Fuel filter heater relay - signal not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 3172 - Engine coolant temperature has exceeded the pre-warning threshold . . . . . . . . . . . . . . . . . . . . . 100 3173 - Engine coolant temperature has exceeded the warning threshold . . . . . . . . . . . . . . . . . . . . . . . . 102 3175 - Fan speed could not be measured for a period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 3176 - High pressure pump fuel delivery quantity in over run exceeds a maximum threshold . . . . . . . 106 3177 - Engine over speed condition detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 3179 - CAN communication failure between vehicle controller and ECU - BC2ECU2 message . . . . . 109 3180 - CAN communication error between vehicle controller to ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 3182 - CAN timeout error from cruise control vehicle speed (CCVS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 3183 - CAN communication failure between vehicle controller and ECU controller - TSC1_VR message (Engine brake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 3184 - CAN communication failure between vehicle controller and ECU controller - TSC1_VR message (Engine brake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 3185 - CAN timeout error from transmission - Transmission fluids (TF) message . . . . . . . . . . . . . . . . . 119 3196 - Open load error of injector in cylinder 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 3204 - Open load error of injector in cylinder 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 3210 - Injection bank 1 short circuit failure (all injectors of the same bank can be affected) . . . . . . . . . 127 3218 - Injection bank 2 short circuit failure (all injectors of the same bank can be affected) . . . . . . . . . 128 3230 - ECU internal failure - Injector CY33x component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 3238 - ECU internal failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 3245 - ECU internal failure - Query/response communication errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

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3252 - ECU internal failure - SPI communication error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 3253 - ECU internal failure - Voltage ratio in ADC monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 3255 - ECU internal failure - ADC test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 3263 - CAN C Bus off failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 3265 - Fuel injection requested during overrun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 3283 - ECU internal failure - Sensor 5 volt supply 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 3285 - ECU internal failure - Sensor 5 volt supply 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 3293 - Fuel pressure has exceeded maximum positive deviation limits . . . . . . . . . . . . . . . . . . . . . . . . . . 142 3301 - Fuel rail pressure has exceeded maximum negative deviation limits . . . . . . . . . . . . . . . . . . . . . . 143 3305 - Fuel rail pressure has dropped below the minimum limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 3309 - Fuel rail pressure has exceeded maximum limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 3334 - CAN communication failure between vehicle controller and ECU controller - TSC1_PE message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 3338 - CAN communication failure between vehicle controller and ECU controller - TSC1_VE message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 3361 - There was an error during Write/Read EEPROM operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 3362 - ECU internal failure - Fuel calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 3368 - Torque limitation caused by performance limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 3370 - Strong torque limitation from engine protection active . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 3371 - Strong torque limitation from injection system active . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 3425 - Under boost failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 3443 - Torque limitation due to excessive coolant temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 3444 - Torque limitation due to excessive exhaust gas temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 3445 - Torque limitation due to excessive fuel temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 3446 - Torque limitation due to excessive intake air temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 3447 - Torque limitation due to excessive oil temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 3448 - Torque limitation due to turbocharger protection after start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 3449 - ECU internal failure - Calculated engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 3458 - Crankcase pressure too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 3459 - Oil temperature too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 3460 - Oil temperature too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 3461 - ECU internal failure - Timeout in the shut off path test error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 3462 - ECU internal failure - Overvoltage monitoring error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 3475 - CAN timeout error from coolant water pump actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171 3501 - ECU internal failure - Software resets in DSM 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 3502 - ECU internal failure - Software resets in DSM 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 3508 - Torque limitation active . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176 3517 - Ambient temperature sensor voltage is higher than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 3518 - Ambient temperature sensor voltage is lower than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 3525 - Downstream NOx sensor internal failure (Open Circuit Error) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 3526 - Downstream NOx sensor internal failure (Short Circuit Error) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182 3528 - Downstream NOx sensor values are not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183 3529 - Downstream NOx sensor internal failure (Heater Open Circuit Error) . . . . . . . . . . . . . . . . . . . . . . 184

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3530 - Downstream NOx sensor internal failure (Heater Short Circuit Error) . . . . . . . . . . . . . . . . . . . . . . 185 3531 - Downstream NOx sensor internal failure (Heater Performance Plausibility Error) . . . . . . . . . . . 186 3533 - CAN timeout error from downstream NOx sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188 3549 - Intake air humidity sensor voltage is higher than expected for too long . . . . . . . . . . . . . . . . . . . . 190 3557 - Intake air humidity sensor voltage is higher than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192 3581 - Torque limitation is active . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193 3616 - Torque limitation due to turbo charger protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194 3623 - Downstream NOx sensor lambda signal deviation - NOx sensor possible removal detected . . 195 3624 - Crankcase pressure sensor voltage is higher than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 3625 - Crankcase pressure sensor voltage is lower than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198 3626 - Crankcase pressure has exceeded tolerance limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 3628 - Crankcase pressure too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 3638 - Torque limitation caused by engine brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202 3647 - Over boost failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203 3652 - CAN A Bus off passive failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 3680 - Engine speed limitation via fuel injection cut off is active . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207 3686 - DOC upstream temperature sensor signal drift at cold start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208 3688 - Water in fuel sensor or sensor circuit failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210 3699 - ECU EEPROM memory failure - EEPData1 block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212 3700 - Intake air humidity sensor value is not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213 3703 - The minimum rail pressure value necessary to allow fuel injection has not been reached . . . . 214 3738 - ECU internal failure - ROM error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 3739 - ECU internal failure - Loss of synchronization to MM from CPU . . . . . . . . . . . . . . . . . . . . . . . . . . 216 3740 - ECU internal failure - ECU shutdown test failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217 3741 - ECU internal failure - Wrong set response time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218 3742 - ECU internal failure - SPI errors during MoCSOP execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219 3743 - ECU internal failure - Undervoltage monitoring error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 3745 - ECU internal failure - WDA is not working correctly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221 3746 - ECU internal failure - Alarm task period error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222 3747 - ECU internal failure - Positive test failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223 3749 - ECU internal failure - Accelerator pedal position sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224 3750 - ECU internal failure - Fuel injection energizing time not plausible . . . . . . . . . . . . . . . . . . . . . . . . . 225 3751 - ECU internal failure - Fuel injection energizing phase is not plausible . . . . . . . . . . . . . . . . . . . . . 226 3753 - ECU internal failure - Injection quality correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227 3754 - ECU internal failure - Rail pressure plausibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228 3755 - ECU internal failure - Torque request comparison . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229 3756 - ECU internal failure - Post injection quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 3757 - ECU internal failure - Post injection shut off failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231 3758 - Post injection efficiency failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232 3759 - ECU internal failure - Torque request due to fuel pressure exceeds maximum torque limit . . . 233 3760 - ECU internal failure - Torque request due to air control exceeds maximum torque limit . . . . . . 234 3761 - ECU internal failure - Torque request exceeds maximum torque limit . . . . . . . . . . . . . . . . . . . . . . 235

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3762 - ECU 5 volt supply voltage is higher than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236 3763 - ECU 5 volt supply voltage is lower than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237 3764 - ECU after run power interruption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238 3767 - ECU internal failure - 'WDA active' reported due to errors in query/response communication . 241 3768 - ECU internal failure - 'ABE active' reported due to undervoltage detection . . . . . . . . . . . . . . . . . 242 3769 - ECU internal failure - 'ABE active' report due to overvoltage detection . . . . . . . . . . . . . . . . . . . . . 243 3770 - ECU internal failure - 'WDA/ABE active' reported . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244 3799 - Fuel pressure relief valve is forced open, perform pressure shock . . . . . . . . . . . . . . . . . . . . . . . . 245 3805 - Maximum rail pressure exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246 3808 - High pressure pump fuel delivery quantity at low idle is too high . . . . . . . . . . . . . . . . . . . . . . . . . . 247 3811 - ECU internal failure - Sensor 5 volt supply 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248 3814 - ECU temperature sensor error detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 3838 - Upstream oxidation catalyst temperature sensor voltage is lower than expected . . . . . . . . . . . . 251 3870 - CAN communication failure between vehicle controller and ECU - BC2ECU1 message . . . . . 253 3877 - Supply UB1 short to battery failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255 3878 - Supply UB2 short to battery failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257 3879 - Supply UB3 short to battery failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259 3881 - Supply UB1 short to ground failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261 3882 - Supply UB2 short to ground failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263 3883 - Supply UB3 short to ground failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264 3903 - Fuel temperature is too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266 3905 - Intake air heater ECU driver has an over temperature error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268 3911 - Fuel metering unit is shorted to battery voltage at the high side . . . . . . . . . . . . . . . . . . . . . . . . . . . 270 3912 - Fuel metering unit is shorted to ground at the high side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272 3916 - Fuel pressure relief valve has reached maximum allowed open time . . . . . . . . . . . . . . . . . . . . . . 274 3936 - ECU internal: Error sensor supplies voltage tracker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276 3961 - CAN communication failure - External torque/speed checksum and counter . . . . . . . . . . . . . . . 277 3962 - Crankcase pressure too high for too long . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279 3963 - Crankcase pressure too high and oil pressure too low - Fuel in oil suspected . . . . . . . . . . . . . . 280 3968 - After run relay high side driver circuit open failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281 3969 - After run relay high side ECU driver circuit over temperature failure . . . . . . . . . . . . . . . . . . . . . . . 283 3970 - After run relay high side driver circuit short to battery failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285 3977 - Prefilter fuel pressure sensor voltage is higher than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287 3978 - Prefilter fuel pressure sensor voltage is lower than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289 3985 - Exhaust gas pressure sensor voltage is higher than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291 3986 - Exhaust gas pressure sensor voltage is lower than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293

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Electrical systems - FAULT CODES

3001 - Diagnostic fault check of synchronization for double potentiometer and Low idle switch Context: The Engine Control Unit (ECU) A-9000 monitors the low idle switch and accelerator pedal position sensor B-9111 to determine synchronization status. The switch and potentiometer are two separate devices mechanically coupled and contained within the sensor module. The analog position sensor signal is compared to the status of the low idle switch position. If the analog position signal is less than 0.591 V and the low idle switch is actuated or the analog position signal is greater than 0.958 V and the low idle switch is not actuated, this fault will occur. Cause: The low idle switch and accelerator pedal position sensor B-9111 position signal and low idle switch signal to the ECU A-9000 do not agree. Possible failure modes: 1. Faulty low idle switch and accelerator pedal position sensor B-9111 position signal or low idle switch circuit wiring, grounded. 2. Faulty low idle switch and accelerator pedal position sensor B-9111 position signal or low idle switch circuit wiring, shorted to a high source. 3. Faulty low idle switch and accelerator pedal position sensor B-9111, failed internally. 4. Fault ECU A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 4. 2. Check the low idle switch and accelerator pedal position sensor B-9111 position signal circuit wiring for a short to ground or a voltage source condition. Disconnect the vehicle (VE) harness from the low idle switch and accelerator pedal position sensor B-9111 at connector X-9100. With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle (VE) harness from: From X-9100 pin 3 X-9100 pin 6

To chassis ground chassis ground

Value there should be no continuity. there should be no continuity.

Then with the key switch in the ON position, use a multimeter to check for voltage on the vehicle (VE) harness from: From X-9100 pin 3 X-9100 pin 6

To chassis ground chassis ground

Value there should be no voltage. there should be no voltage.

A. If there is no continuity or voltage, leave connector X-9100 disconnected and continue with Step 3. B. If there is continuity or voltage, there is a short to ground or a voltage source condition in the vehicle (VE) harness. Use the appropriate vehicle service manual and electrical schematics to locate and repair the grounded or shorted voltage source condition. 3. Check the low idle switch and accelerator pedal position sensor B-9111.

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Electrical systems - FAULT CODES

Use a multimeter to measure resistance on the low idle switch and accelerator pedal position sensor B-9111 from: From

Value there should be measurable resistance. X-9100 pin 3 X-9100 pin 5 there should be measurable resistance. X-9100 pin 4 X-9100 pin 5 there should be measurable resistance. NOTE: The measured value in the first two checks when added together should equal the measured value of the third check. X-9100 pin 3

X-9100 pin 4

Then, while operating the accelerator pedal, use the multimeter to measure resistance on the low idle switch and accelerator pedal position sensor B-9111 from: From

Value there should be a varying measurable resistance. X-9100 pin 3 X-9100 pin 5 there should be a varying measurable resistance. NOTE: Both measurements should vary in linearly increasing or decreasing fashion throughout the travel of the accelerator pedal. X-9100 pin 3

X-9100 pin 4

Then, while operating the accelerator pedal, use the multimeter to check for continuity on the low idle switch and accelerator pedal position sensor B-9111 from: From

Value there should be a change from no continuity to continuity (switching action). NOTE: Early in the travel of the accelerator pedal, typically 14 â&#x20AC;&#x201C; 16% of full travel, the low idle switch should change states. . X-9100 pin 1

X-9100 pin 6

A. If the test results are all acceptable, check the ECU A-9000 for the appropriate software and re-flash, if necessary. B. If the test results are not all acceptable, the low idle switch and accelerator pedal position sensor B-9111 has failed internally. Replace the unit. 4. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3002 - Signal Range Check High for Acceleration Pedal Position Device Driver Sensor 1 Context: The Engine Control Unit (ECU) A-9000 provides sensor power and ground reference used by the low idle switch and accelerator pedal position sensor B-9100 and monitors both the switch and potentiometer position. If the low idle switch and accelerator pedal position sensor B-9100 position sensor signal is greater than 5.20 V, this fault will occur. Cause: The low idle switch and accelerator pedal position sensor B-9100 position signal to the ECU A-9000 is greater than 5.20 V. Possible failure modes: 1. Faulty low idle switch and accelerator pedal position sensor B-9100 position signal circuit wiring, shorted to a high source. 2. Fault ECU A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 3. 2. Check the low idle switch and accelerator pedal position sensor B-9100 position signal circuit wiring for a short to voltage source condition. Disconnect the vehicle (VE) harness from the low idle switch and accelerator pedal position sensor B-9100 at connector X-9100. With the key switch in the ON position, use a multimeter to check for voltage on the vehicle (VE) harness from: From X-9100 pin 1

To chassis ground

Value there should be no voltage.

A. If there is no voltage present, check the ECU A-9000 for the appropriate software and re-flash, if necessary. B. If there is voltage, there is a short to a voltage source condition in the vehicle (VE) harness between connector X-9100 pin 1 and connector X-9001 pin 79, wire VE-145. Locate and repair the damaged conductors. 3. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3005 - Air filter clog or circuit failure Context: The Electronic Control Unit (ECU) A-9000 monitors the air filter clogging switch. If engine speed is greater than 1400 RPM after 10.00 min of engine running time and an air filter clog or circuit failure is detected, this fault will occur. Cause: An air filter clog or circuit failure has been detected. Possible failure modes: 1. Faulty air filter, clogged. 2. Faulty air filter clogging switch S-9101 wiring or switch. 3. Faulty A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 6. 2. Inspect the engine air filter and air intake system for a clogged or obstructed condition. A. If the filter or air intake system is clogged or obstructed, repair or replace the air filter as necessary. B. If the air filter or air intake system is not clogged or obstructed, continue with step 3. 3. Check the S-9101 circuit for a short circuit condition. Disconnect connector X-9001. Disconnect connector X-9109. The key must be at the OFF position. Use a multimeter to perform the following continuity check: From X-9001 pin 37

To X-9001 pin 27

Value ere should be no continuity.

A. If there is continuity, there is a short circuit condition in the S-9101 circuit. Locate and repair shorted conductor. B. If there no continuity, leave the connectors disconnected and continue with Step 4. 4. Check the S-9101 circuit for a short to key battery power condition. The must be in the ON position. Use a multimeter to perform the following voltage check: From X-9001 pin 37 X-9001 pin 27

To Chassis GND Chassis GND

Value There should be no voltage.. There should be no voltage..

A. If there is voltage, there is a short circuit to key battery power in the S-9101 circuit. Locate and repair shorted conductor. B. If there is no voltage present, continue with step 5.

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5. Replace the S-9101. Use the EST to verify that the status of this fault, DTC 4B84 â&#x20AC;&#x201C; Air filter clog or circuit failure. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 6. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3007 - Engine coolant temperature sensor is higher than expected Context: The Electronic Control Unit (ECU) A-9000 monitors the engine coolant temperature B-9003 circuit for a voltage higher than expected condition. If the A-9000 detects a voltage greater than 4.93 V in the B-9003signal circuit, this fault will occur. Cause: The A-9000 has detected a voltage greater than 4.93 V in the B-9003 signal circuit. Possible failure modes: 1. Faulty B-9003, wiring. 2. Faulty, B-9003, internal failure.. 3. Faulty A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 6. 2. Check the B-9003 for an open circuit condition. Disconnect connector X-9002. Disconnect connector X-9006. The key must be at the OFF position. Use a multimeter to perform the following continuity check: From X-9001 pin 39

To X-9006 pin 1

Value ere should be continuity.

A. If there is no continuity, there is an open circuit condition in the B-9003 signal circuit, wire VE-014. Locate and repair broken conductor. B. If there is continuity, leave both connectors disconnected and continue to Step 3. 3. Check the B-9003 signal circuit for a short circuit condition. The key must be at the OFF position. Use a multimeter to perform the following continuity check: From X-9001 pin 39

To All pins in connector X-9001

Value ere should be no continuity.

A. If there is continuity, there is a short circuit condition in the B-9003 signal circuit, wire EN-014. Locate and repair shorted conductor. B. If there no continuity, leave both connectors disconnected and continue to Step 4. 4. Check the B-9003 signal circuit for a short key battery power condition. The must be in the ON position. Use a multimeter to perform the following voltage check: 48149953 12/06/2018

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From X-9001 pin 39

To Chassis GND

Value There should be no voltage..

A. If there is voltage, there is a short to key battery power condition in the B-9003 signal circuit, wire EN-014. Locate and repair shorted conductor. B. If there no continuity, continue with step 5. 5. Replace the B-9003. Use the EST to verify that the status of this fault, DTC 1113 â&#x20AC;&#x201C; Engine coolant temperature sensor voltage is higher than expected. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 6. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3008 - Engine coolant temperature sensor voltage is lower than expected Context: The Engine Control Unit (ECU) A-9000 monitors the analog input value of the Coolant temperature sensor B-9003 at the engine plug connector X-9002 pin 39. The Coolant temperature sensor B-9003 is a Negative Temperature Coefficient (NTC) thermistor with a resistive range of 332 – 10.149K Ω at -10 – 80 °C (14.0 – 176 °F), conversely. If the Coolant temperature sensor B-9003 input signal circuit is less than 0.188 V, this fault will occur. Cause: The ECU A-9000 is sensing an analog input signal less than 0.188 V in the Coolant temperature sensor B-9003 signal circuit. Possible failure modes: 1. Faulty Coolant temperature sensor B-9003, shorted internally. 2. Faulty Coolant temperature sensor B-9003 signal circuit, shorted to ground. 3. Faulty ECU A-9000, ECU software. Solution: 1. Verify this error code is still present and in an active state. Use the Electronic Service Tool (EST) to check the fault status. A. If the fault is still present and active, continue with step 2. B. If the fault is no longer present or is in an inactive state, the fault may be intermittent and not currently active. Continue with step 5. 2. Verify the condition of the Coolant temperature sensor B-9003. Measure the sensor resistance. Disconnect the engine harness from the Coolant temperature sensor B-9003 at connector X-9006. Use a multimeter to perform the following test on the component: From X-9006 pin 1

To X-9006 pin 2

Value There should be between 332 – 10.149K Ω dependant upon coolant temperature.

A. If the measured resistance is minimal or zero, the Coolant temperature sensor B-9003 has failed, internally. Replace the sensor. B. If the measured resistance is within the specified range, leave the Coolant temperature sensor B-9003 connector X-9006 disconnected and continue with Step 3. 3. Check for a short to ground condition in the Coolant temperature sensor B-9003 signal circuit. Use a multimeter to perform the following check on the engine harness (EN) side: To X-9006 pin 1

From Chassis GND

Value Should no be continuity

A. If there is continuity, leave the Coolant temperature sensor B-9003 connector X-9006 disconnected and continue with Step 4. B. If there is no continuity, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 4. Carefully disconnect the engine harness from the ECU A-9000 at connector X-9002. Use a multimeter to check for continuity from the engine harness side of connector X-9002 pin 39 to chassis ground. ere should be no continuity.

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A. If there is continuity, there is a short to ground condition in the engine harness between the ECU A-9000 engine plug connector X-9002 pin 39 and the Coolant temperature sensor B-9003 connector X-9006 pin 1, wire EN-014. Locate and repair the grounded conductor. B. If there is no continuity, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 5. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3014 - Air filter clog or circuit failure present for a long time Context: The Electronic Control Unit (ECU) A-9000 monitors the air filter clogging switch. Monitoring is performed in two levels. The first level warning is detected if the A-9000 detects an air filter clogging or circuit failure condition. A second level warning is detected if no action is taken after the first level warning. If engine speed is greater than 1400 RPM after 10.00 min of engine running time and a second warning is detected, this fault will occur. Cause: An air filter clog or circuit failure has been detected for longer than 30.00 min. Possible failure modes: 1. Faulty air filter, clogged. 2. Faulty air filter clogging switch S-9101 wiring or switch. 3. Faulty A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 7. 2. Check for the following related faults: DTC 4B84 â&#x20AC;&#x201C; Air filter clog or circuit failure A. If the faults is active, troubleshoot it first and then return to this fault, DTC 4C84 â&#x20AC;&#x201C; Air filter clog or circuit failure present for a long time. B. Is the fault is not active, continue with step 3. 3. Inspect the engine air filter and air intake system for a clogged or obstructed condition. A. If the filter or air intake system is clogged or obstructed, repair or replace the air filter as necessary. B. If the air filter or air intake system is not clogged or obstructed, continue with step 4. 4. Check the S-9101 circuit for a short circuit condition. Disconnect connector X-9001. Disconnect connector X-9109. The key must be at the OFF position. Use a multimeter to perform the following continuity check: From X-9001 pin 37

To X-9001 pin 27

Value ere should be no continuity.

A. If there is continuity, there is a short circuit condition in the S-9101 circuit. Locate and repair shorted conductor. B. If there no continuity, leave the connectors disconnected and continue with Step 5. 5. Check the S-9101 circuit for a short to key battery power condition. The must be in the ON position.

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Use a multimeter to perform the following voltage check: From X-9001 pin 37 X-9001 pin 27

To Chassis GND Chassis GND

Value There should be no voltage.. There should be no voltage..

A. If there is voltage, there is a short circuit to key battery power in the S-9101 circuit. Locate and repair shorted conductor. B. If there is no voltage present, continue with step 6. 6. Replace the S-9101. Use the EST to verify that the status of this fault, DTC 4B84 â&#x20AC;&#x201C; Air filter clog or circuit failure. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 7. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3015 - Fuel temperature sensor voltage is higher than expected Context: The Electronic Control Unit (ECU) A-9000 monitors the fuel temperature sensor B-9002 signal circuit voltage. If the A-9000 determines that there is voltage higher than expected condition in the B-9002 signal circuit, this fault will occur. Cause: The A-9000 has detected a value greater than 4.93 V in the B-9002 signal circuit. Possible failure modes: 1. Faulty B-9002 signal circuit, short to high source condition. 2. Faulty, B-9002, internal failure.. 3. Faulty A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 5. 2. Check the B-9002 signal circuit for a short to high source condition. Disconnect connector X-9005. Disconnect connector X-9002 from the A-9000. The key must be at the OFF position. Use a multimeter to perform the following continuity check: From X-9002 pin 12

To All pins in connector X-9002

Value ere should be no continuity.

A. If there is continuity, there is a short circuit condition in the B-9002 signal circuit, wire EN-012. Locate and repair shorted conductor. B. If there no continuity, leave the connectors disconnected and continue with Step 3. 3. Check the B-9002 for a short to key power condition. The must be in the ON position. Use a multimeter to perform the following voltage check: From X-9002 pin 12

To Chassis GND

Value There should be no voltage..

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B. If the fault has been not resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 5. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3016 - Fuel temperature sensor voltage is lower than expected Context: The Electronic Control Unit (ECU) A-9000 monitors the fuel temperature sensor B-9002 signal circuit voltage. If the A-9000 determines that there is voltage lower than expected condition in the B-9002 signal circuit, this fault will occur. Cause: The A-9000 has detected a value less than 188 mV in the B-9002 signal circuit. Possible failure modes: 1. Faulty B-9002 signal circuit, short to ground condition. 2. Faulty A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 4. 2. Check the B-9002 signal circuit for a short to ground condition. Disconnect connector X-9005. Disconnect connector X-9002 from the A-9000. The key must be at the OFF position. Use a multimeter to perform the following continuity check: From X-9002 pin 12 X-9002 pin 12

To Chassis GND All other pins

Value ere should be no continuity. ere should be no continuity.

A. If there is continuity, there is a short to ground condition in the B-9002 signal circuit, wire EN-012. Locate and repair shorted conductor. B. If there no continuity, continue with step 3. 3. Replace the B-9002. Use the EST to verify that the status of this fault, DTC 2D15 â&#x20AC;&#x201C; Fuel temperature sensor voltage is lower than expected. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 4. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3019 - Intake manifold pressure sensor voltage is higher than expected NOTE: Because this fault causes inducement, it is necessary to perform the Engine Restart Counter Reset / Unlock Inducement configuration with the Electronic Service Tool (EST) before you return the machine to service. Context: The Engine Control Unit (ECU) A-9000 monitors the intake manifold pressure sensor B-9001 pressure signal circuit. If the ECU A-9000 determines that the voltage in the pressure signal circuit is higher than expected, this fault will occur. Cause: The ECU A-9000 has detected a voltage greater than 4.91 V for a period greater than 0.5 s in the intake manifold pressure sensor B-9001 pressure signal circuit. Possible failure modes: 1. Faulty intake manifold pressure sensor B-9001, internal failure. 2. Faulty intake manifold pressure sensor B-9001 pressure signal circuit, open or short to high source condition. 3. Fault ECU A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 5. 2. Check the intake manifold pressure sensor B-9001 pressure signal circuit for an open circuit condition. Disconnect connector X-9003. Disconnect the ECU A-9000 connector X-9002 From X-9002 pin 86

To X-9003 pin 4

Value ere should be continuity.

A. If there is continuity, leave both connectors disconnected and continue to Step 3. B. If there is no continuity, there is an open circuit condition in the intake manifold pressure sensor B-9001 pressure signal circuit, wire EN-006. Locate and repair broken conductor. 3. Check the intake manifold pressure sensor B-9001 pressure signal circuit for a short to high source condition. The key must be at the OFF position. Use a multimeter to perform the following continuity check: From X-9002 pin 86 X-9002 pin 86

To X-9002 pin 7 All other pins

Value ere should be no continuity. ere should be no continuity.

A. If there is continuity, there is a short to high source condition in the intake manifold pressure sensor B-9001 pressure signal circuit, wire ENâ&#x20AC;&#x201C;006. Locate and repair shorted conductor. B. If there no continuity, continue with step 4. 4. Replace the intake manifold pressure sensor B-9001.

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Use the EST to verify if DTC 1D64 â&#x20AC;&#x201C; Intake manifold pressure sensor voltage is higher than expected has been resolved. A. If the fault has been resolved, B. If the fault has been not resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 5. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3024 - ECU internal failure - Ambient pressure sensor voltage is higher than expected Context: The Engine Control Unit A-9000 monitors ambient pressure by the ambient pressure sensor which is internal to the ECU A-9000. If the ECU A-9000 detects a voltage greater than 4.88 V for a period greater than 0.8 s, this fault will occur. If this fault occurs, the ECU A-9000 will be frozen at the last valid ambient pressure value for a preliminary failure and a replacement ambient pressure of 0.8 bar (11.6 psi) if the failure is validated. As this fault can occur from abnormal altitude, verify that the machine is not being operated at extreme altitude before diagnosing this fault. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, escalate an ASIST concern.

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3025 - ECU internal failure - Ambient pressure sensor voltage is lower than expected Context: The Engine Control Unit (ECU) A-9000 monitors ambient pressure by the ambient pressure sensor which is internal to the ECU A-9000. If the ECU A-9000 detects a voltage less than 0.190 V for a period greater than 0.8 s, this fault will occur. If this fault occurs, the ECU A-9000 will be frozen at the last valid ambient pressure value for a preliminary failure and a replacement ambient pressure of 0.8 bar (11.6 psi) if the failure is validated. As this fault can occur from higher than normal altitude, verify that the machine is not being operated at extreme altitude before diagnosing this fault. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, escalate an ASIST concern.

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Electrical systems - FAULT CODES

3028 - Oil pressure is too low Context: The Electronic Control Unit (ECU) A-9000 monitors for a low engine oil pressure condition. If the A-9000 determines that oil pressure is too low, this fault will occur. Cause: The A-9000 has detected a low engine oil pressure condition. Possible failure modes: 1. Faulty oil pressure sensor B-9000. 2. Faulty engine oil level. 3. Faulty engine oil, fuel contamination. 4. Faulty oil pressure control valve. 5. Faulty oil suction line, damaged or leaking. 6. Faulty oil pump. 7. Faulty main bearings, improper clearance or usage. 8. Faulty A-9000, software.

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3029 - Oil pressure sensor voltage is higher than expected Context: The Electronic Control Unit (ECU) A-9000 monitors the oil pressure sensor B-9000 signal circuit. If the A-9000 determines that the voltage in the pressure signal circuit is higher than expected, this fault will occur. Cause: The A-9000 has detected a value greater than 4.93 V for a period greater than 500 ms in the B-9000 pressure signal circuit. Possible failure modes: 1. Faulty, B-9000, internal failure.. 2. Faulty B-9000 pressure signal circuit, shorted to a high source or open circuit condition. 3. Faulty A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 5. 2. Check the B-9000 pressure signal circuit for an open circuit condition. Disconnect connector X-9004. Disconnect connector X-9002 from the A-9000 The key must be at the OFF position. Use a multimeter to perform the following continuity check: From X-9002 pin 35

To X-9004 pin 4

Value ere should be continuity.

A. If there is continuity, leave both connectors disconnected and continue to Step 3. B. If there is no continuity, there is an open circuit condition in the B-9000 pressure signal circuit, wire EN-010. Locate and repair broken conductor. 3. Check the B-9000 signal circuit for a short to high source condition. The key must be at the OFF position. Use a multimeter to perform the following continuity check: From X-9002 pin 35 X-9002 pin 35

To X-9002 pin 31 All other pins

Value ere should be no continuity. ere should be no continuity.

A. If there is continuity, there is a short to high source condition in the B-9000 pressure signal circuit, wire ENâ&#x20AC;&#x201C;010. Locate and repair shorted conductor. B. If there no continuity, continue with step 4. 4. Replace the B-9000. Use the EST to verify if DTC 18D3 â&#x20AC;&#x201C; Oil pressure sensor voltage is higher than expected has been resolved. 48149953 12/06/2018

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A. If it has been resolved, then return the machine to service. B. If it has not been resolved, check the A-9000 for the appropriate software and re-flash, if necessary. 5. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3030 - Oil pressure sensor voltage is lower than expected Context: The Electronic Control Unit (ECU) A-9000 monitors the oil pressure sensor B-9000 signal circuit. If the A-9000 determines that the voltage in the pressure signal circuit is lower than expected, this fault will occur. Cause: The A-9000 has detected a voltage less than 200 mV for a period greater than 500 ms in the B-9000 pressure signal circuit. Possible failure modes: 1. Faulty, B-9000, internal failure.. 2. Faulty B-9000 pressure signal circuit, short to ground condition. 3. Faulty A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 4. 2. Check the B-9000 pressure signal circuit for a short to ground condition. Disconnect connector X-9004. Disconnect connector X-9002 from the A-9000. The key must be at the OFF position. Use a multimeter to perform the following continuity check: From X-9002 pin 35 X-9002 pin 35

To Chassis GND All other pins

Value ere should be no continuity. ere should be no continuity.

A. If there is continuity, there is a short to ground in the B-9000 pressure signal circuit, wire ENâ&#x20AC;&#x201C;010. Locate and repair shorted conductor. B. If there no continuity, continue with step 3. 3. Replace the B-9000. Use the EST to verify if DTC 29D3 â&#x20AC;&#x201C; Oil pressure sensor voltage is lower than expected has been resolved. A. If it has been resolved, then return the machine to service. B. If it has not been resolved, check the A-9000 for the appropriate software and re-flash, if necessary. 4. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

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B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3034 - Oil temperature sensor voltage is higher than expected Context: The Electronic Control Unit (ECU) A-9000 monitors the oil temperature sensor B-9000 signal circuit. If the A-9000 determines that the voltage in the temperature signal circuit is higher than expected, this fault will occur. Cause: The A-9000 has detected a voltage greater than 4.93 V for a period greater than 500 ms in the B-9000 temperature signal circuit. Possible failure modes: 1. Faulty, B-9000, internal failure.. 2. Faulty B-9000 temperature signal circuit, short to high source or open circuit condition. 3. Faulty A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with 2boom. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 5boom. 2. Check the B-9000 temperature signal circuit for an open circuit condition. Disconnect connector X-9004. Disconnect connector X-9002 from the A-9000 The key must be at the OFF position. Use a multimeter to perform the following continuity check: From X-9002 pin 13

To X-9004 pin 2

Value ere should be continuity.

A. If there is continuity, leave both connectors disconnected and continue to Step 3boom. B. If there is no continuity, there is an open circuit condition in the B-9000 temperature signal circuit, wire EN-009. Locate and repair broken conductor. 3. Check the B-9000 signal circuit for a short to high source condition. The key must be at the OFF position. Use a multimeter to perform the following continuity check: From X-9002 pin 13 X-9002 pin 13

To X-9002 pin 31 All other pins

Value ere should be no continuity. ere should be no continuity.

A. If there is continuity, there is a short to high source condition in the B-9000 temperature signal circuit, wire ENâ&#x20AC;&#x201C;009. Locate and repair shorted conductor. B. If there no continuity, continue with step 4boom. 4. Replace the B-9000. Use the EST to verify if DTC 11E3 â&#x20AC;&#x201C; Oil temperature sensor voltage is higher than expected has been resolved. 48149953 12/06/2018

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3035 - Oil temperature sensor voltage is lower than expected Context: The Electronic Control Unit (ECU) A-9000 monitors the oil temperature sensor B-9000 signal circuit. If the A-9000 determines that the voltage in the temperature signal circuit voltage is lower than expected, this fault will occur. Cause: The A-9000 has detected a voltage less than 235 mV for a period greater than 500 ms in the B-9000 temperature signal circuit. Possible failure modes: 1. Faulty, B-9000, internal failure.. 2. Faulty B-9000 temperature signal circuit, short to ground condition. 3. Faulty A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 4. 2. Check the B-9000 temperature signal circuit for a short to ground condition. Disconnect connector X-9004. Disconnect connector X-9002 from the A-9000. The key must be at the OFF position. Use a multimeter to perform the following continuity check: From X-9002 pin 13 X-9002 pin 13 X-9002 pin 13

To Chassis GND X-9002 pin 6 All other pins

Value ere should be no continuity. ere should be no continuity. ere should be no continuity.

A. If there is continuity, there is a short to ground in the B-9000 temperature signal circuit, wire EN-009. Locate and repair shorted conductor. B. If there no continuity, continue with step 3. 3. Replace the B-9000. Use the EST to verify if DTC 22E3 â&#x20AC;&#x201C; Oil temperature sensor voltage is lower than expected has been resolved. A. If it has been resolved, then return the machine to service. B. If it has not been resolved, check the A-9000 for the appropriate software and re-flash, if necessary. 4. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

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B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3037 - Intake manifold pressure sensor voltage is lower than expected NOTE: Because this fault causes inducement, it is necessary to perform the Engine Restart Counter Reset / Unlock Inducement configuration with the Electronic Service Tool (EST) before you return the machine to service. Context: The Electronic Control Unit (ECU) A-9000 monitors the intake manifold pressure sensor B-9001 signal circuit. If the ECU A-9000 determines that the voltage in the pressure signal circuit is lower than expected, this fault will occur. Cause: The ECU A-9000 has detected a voltage less than 0.203 V for a period greater than 0.5 s in the intake manifold pressure sensor B-9001 pressure signal circuit. Possible failure modes: 1. Faulty intake manifold pressure sensor B-9001, internal failure. 2. Faulty intake manifold pressure sensor B-9001 pressure signal circuit, short to ground condition. 3. Fault ECU A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 4. 2. Check the intake manifold pressure sensor B-9001 pressure signal circuit for a short to ground condition. Disconnect connector X-9003. Disconnect the ECU A-9000 connector X-9002. The key must be at the OFF position. Use a multimeter to perform the following continuity check: From X-9002 pin 86 X-9002 pin 86

To Chassis GND All other pins

Value ere should be no continuity. ere should be no continuity.

A. If there is continuity, there is a short to ground in the intake manifold pressure sensor B-9001 pressure signal circuit, wire ENâ&#x20AC;&#x201C;006. Locate and repair shorted conductor. B. If there no continuity, continue with step 3. 3. Replace the intake manifold pressure sensor B-9001. Use the EST to verify if DTC 2E64 â&#x20AC;&#x201C; Intake manifold pressure sensor voltage is lower than expected has been resolved. A. If it has been resolved, B. If it has not been resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 4. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display.

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A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3051 - Battery Voltage To Engine Controller - Voltage Too High NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. Cause: Possible failure modes: 1. External power supply connected 2. Faulty charging system 3. Faulty engine controller Solution: 1. Before proceeding clear the error code with the approved diagnostic equipment. Run the machine under normal conditions and retest. A. If the error code is not indicated, check that the system is operating correctly. B. If the error code is indicated, continue to step 2. 2. Check the battery power supply has not been connected to an external power supply. A. If an external power supply is connected to the machine, disconnect and test the system for normal operation. B. If an external power supply is not connected to the machine, continue to step 3. 3. Check the battery voltage on the instrument cluster. Start the engine and run at 2000 RPM. A. If the voltage displayed is not between 12 â&#x20AC;&#x201C; 15 V, continue to test for a fault in the charging system. B. If the battery voltage is okay, download the correct level of software. If the fault re-ocurrs, remove and replace the engine controller.

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3052 - Battery Voltage To Engine Controller - Voltage Too Low NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. Cause: This code may be induced during cold starting. Possible failure modes: 1. Battery faulty 2. Faulty charging system 3. Faulty connector 4. Faulty wiring harness 5. Faulty engine controller Solution: 1. Before proceeding clear the error code with the approved diagnostic equipment. Run the machine under normal conditions and retest. A. If the error code is not indicated, check that the system is operating correctly. B. If the error code is indicated, continue to step 2. 2. Check the battery condition and terminal connections. A. If the battery or terminals are faulty, repair or replace as required. B. If the battery and terminals are okay, continue to step 3. 3. Check the battery voltage on the instrument cluster. Start the engine and run at 2000 RPM. A. If the voltage displayed is not between 12 â&#x20AC;&#x201C; 15 V, continue to test for a fault in the charging system. B. If the battery voltage is okay, continue to step 4. 4. Check the engine controller connector. Ensure the connector is connected, not damaged, the pins are in the correct position and that the fit is tight. A. If the connector is not okay, repair or replace as required. B. If the connector are okay, continue to step 5. 5. Check the engine controller battery power 30 A fuse. Ensure the fuse is not blown and that the fit is tight. A. If the fuse is not okay, repair or replace as required. B. The fuse is okay, continue to step 6. 6. Check all power supplies and grounds to the engine controller. A. If a fault is indicated, repair or replace the harness as required. B. If no faults are indicated, download the correct level of software. If the fault re-ocurrs, remove and replace the engine controller.

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3063 - Short circuit in injector 1 (in firing order) Context: Hardware errors in the injectors and their respective Engine Control Unit (ECU) A-9000 power stages are investigated within the ECU A-9000. The ECU A-9000 diagnostic procedure uses pattern detection to identify specific errors. When an expected combination of errors is detected, the associated fault occurs. Cause: During cylinder 1 injector Y-9001 evaluation, the pattern for short circuit was detected. Possible failure modes: 1. Faulty cylinder 1 injector Y-9001 solenoid windings, shorted or grounded. 2. Faulty electrical wiring, short high side to low side or ground (damaged wiring harness). 3. Fault ECU A-9000, software. Solution: 1.

Verify this error code is still present and in an active state. Use the Easy Engine software provided on the Electronic Service Tool (EST) to check the fault status and to perform the cylinder cut-out test. A. If the fault is still present and active, continue with step 2. B. If the fault is no longer present or is in an inactive state, the fault may be intermittent and not currently active. Continue with step 10.

Check the integrity of the cylinder 1 injector Y-9001 control circuit. Disconnect the engine harness from the ECU A-9000 at the engine plug connector X-9002 . Use a multimeter to measure the resistance on the EN harness side: From X-9002 pin 49

To X-9002 pin 73

Value There should be greater than 0.1 Ω

A. If there is greater than 0.1 Ω. leave the engine plug connector X-9002 disconnected and continue with Step 3. B. If there is less than 0.1 Ω, continue with step 6. NOTE: The measured amount of injector coil resistance is a very small value, typically between 0.2 – 0.5 Ω. 3.

Check the cylinder 1 injector Y-9001 high side control circuit for a short to ground condition. Use a multimeter to check for continuity on the EN harness side: From X-9002 pin 49

To chassis ground

Value Should no be continuity

A. If there is continuity, continue with step 4. B. If there no continuity, continue with step 8. 4.

Determine location of the short to ground condition. Disconnect the engine cylinder harness from the injector valve cover at connector X-9184-6CYL. Use a multimeter to check for continuity, on the injector (valve) cover side: From X-9184-6CYL pin 4

To chassis ground

Value Should no be continuity

A. If there is continuity to chassis ground, leave connector X-9184-6CYL disconnected and continue with step 5. 48149953 12/06/2018

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B. If there is no continuity, there is a short to ground condition in the engine harness between the valve cover connector X-9184-6CYL pin 4 and the engine plug connector X-9002 pin 49 , wire EN-017-6CYL. Locate and repair the grounded conductor. 5.

Determine location of the short to ground condition. Remove the injector (valve) cover and disconnect the injector harness from Cylinder 1 injector at connector X-9188-6CYL. Use a multimeter to check for continuity on the injector: From X-9188-6CYL pin 1

To chassis ground

Value Should no be continuity

A. If there is continuity, Cylinder 1 injector Y-9001 solenoid coil has failed, replace the injector. B. If there is no continuity, there is a short to ground condition in Cylinder 1 injector circuit, between connector X-9188-6CYL pin 1 and connector X-9184-6CYL pin 4 , wire EN-576-6CYL. Locate and repair the grounded conductor. 6.

Disconnect the engine cylinder harness from the injector valve cover at connector X-9184-6CYL. Use a multimeter to measure the resistance on the injector cover side of the valve cover: From X-9184-6CYL pin 4

To X-9184-6CYL pin 3

Value There should be greater than 0.1 Ω

A. If the resistance is greater than 0.1 Ω, there is a short circuit condition in the engine injector harness between the valve cover connector X-9184-6CYL and the engine plug connector X-9002, wires EN-017-6CYL and EN-018-6CYL. Locate and repair the short circuit. B. If the resistance is less than 0.1 Ω, continue with step 7. 7.

Remove the injector (valve) cover and disconnect the injector harness from Cylinder 5 injector at connector X-9188-6CYL . Use a multimeter to check for continuity on the injector: From X-9188-6CYL pin 1

To X-9188-6CYL pin 2

Value There should be greater than 0.1 Ω

A. If there is greater than 0.1 Ω, there is a short circuit condition in the injector harness, between connector X-9184-6CYL and connectors X-9188-6CYL pin 1 and X-9188-6CYL pin 2, wires EN-576-6CYL and EN-5776CYL. Locate and repair shorted conductors. B. If the resistance is less than 0.1 Ω, the Cylinder 1 injector Y-9001 solenoid coil has failed. Replace the injector. 8.

Check the ECU A-9000 supply voltage. Disconnect the vehicle interface harness (VE) from the ECU A-9000 at the vehicle plug connector X-9001. Turn the Key switch S-9103 to the ON position. Use a multimeter to check for voltage on the vehicle interface (VE) harness side of the vehicle plug: From X-9001 X-9001 X-9001 X-9001 X-9001

pin pin pin pin pin

1 25 26 49 73

To chassis chassis chassis chassis chassis

ground ground ground ground ground

Value There should be 12.0 V There should be 12.0 V There should be 12.0 V There should be 12.0 V There should be 12.0 V

A. If the 12.0 V is present for all five checks, leave the vehicle plug connector X-9001 disconnected and continue with Step 9.

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B. If the 12.0 V is not present for one or more of the checks, use the appropriate vehicle electrical schematics to locate and repair the failure. 9.

Check the ECU A-9000 ground circuits. Place the Key switch S-9103 in the OFF position. Use a multimeter to check for continuity on the vehicle interface (VE) harness side of the vehicle plug: From X-9001 X-9001 X-9001 X-9001 X-9001

pin pin pin pin pin

3 5 28 52 75

To chassis chassis chassis chassis chassis

ground ground ground ground ground

Value ere should be continuity. ere should be continuity. ere should be continuity. ere should be continuity. ere should be continuity.

A. If there is continuity on all five checks, check the ECU A-9000 for the appropriate software and re-flash, if necessary. B. If there is no continuity for one or more of the checks, use the appropriate vehicle electrical schematics to locate and repair the failure. 10. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3067 - Short circuit in injector 4 (in firing order) Context: Hardware errors in the injectors and their respective Engine Control Unit (ECU) A-9000 power stages are investigated within the ECU A-9000. The ECU A-9000 diagnostic procedure uses pattern detection to identify specific errors. When an expected combination of errors is detected, the associated fault occurs. Cause: During cylinder 4 injector Y-9004 evaluation, the pattern for short circuit was detected. Possible failure modes: 1. Faulty cylinder 4 injector Y-9004 solenoid windings, shorted or grounded. 2. Faulty electrical wiring, short high side to low side or ground (damaged wiring harness). 3. Fault ECU A-9000, software. Solution: 1.

Check the integrity of the cylinder 4 injector Y-9004 control circuit. Disconnect the engine harness from the ECU A-9000 at the engine plug connector X-9002 . Use a multimeter to measure the resistance on the EN harness side: From X-9002 pin 27

To X-9002 pin 3

Value There should be greater than 0.1 Ω

Check the cylinder 4 injector Y-9004 high side control circuit for a short to ground condition. Use a multimeter to check for continuity on the EN harness side: From X-9002 pin 27

To chassis ground

Value Should no be continuity

A. If there is continuity, continue with step 4. B. If there no continuity, continue with step 8. 4.

Determine location of the short to ground condition. Disconnect the engine cylinder harness from the injector valve cover at connector X-9185-6CYL. Use a multimeter to check for continuity, on the injector (valve) cover side: From X-9185-6CYL pin 2

To chassis ground

Value Should no be continuity

A. If there is continuity to chassis ground, leave connector X-9185-6CYL disconnected and continue with step 5. 48149953 12/06/2018

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B. If there is no continuity, there is a short to ground condition in the engine harness between the valve cover connector X-9185-6CYL pin 2 and the engine plug connector X-9002 pin 27, wire EN-024-6CYL. Locate and repair the grounded conductor. 5.

Determine location of the short to ground condition. Remove the injector (valve) cover and disconnect the injector harness from Cylinder 4 injector at connector X-9191-6CYL. Use a multimeter to check for continuity on the injector: From X-9191-6CYL pin 1

To chassis ground

Value Should no be continuity

A. If there is continuity, Cylinder 4 injector Y-9004 solenoid coil has failed, replace the injector. B. If there is no continuity, there is a short to ground condition in cylinder 4 injector circuit, between connector X-9185-6CYL pin 2 and connector X-9191-6CYL pin 1, wire EN-582-6CYL. Locate and repair the grounded conductor. 6.

Disconnect the engine cylinder harness from the injector valve cover at connector X-9185-6CYL. Use a multimeter to measure the resistance on the injector cover side of the valve cover: From X-9185-6CYL pin 2

To X-9185-6CYL pin 1

Value There should be greater than 0.1 Ω

A. If the resistance is greater than 0.1 Ω, there is a short circuit condition in the engine injector harness between the valve cover connector X-9185-6CYL and the engine plug connector X-9002, wires EN-023-6CYL and EN-024-6CYL. Locate and repair the short circuit. B. If the resistance is less than 0.1 Ω, continue with step 7. 7.

Remove the injector (valve) cover and disconnect the injector harness from Cylinder 4 injector at connector X-9192-6CYL. Use a multimeter to check for continuity on the injector: From X-9192-6CYL pin 1

To X-9192-6CYL pin 2

Value There should be greater than 0.1 Ω

A. If there is greater than 0.1 Ω, there is a short circuit condition in the injector harness, between connector X-9185-6CYL and connectors X-9192-6CYL pin 1 and X-9192-6CYL pin 2, wires EN-582-6CYL and EN-5836CYL. Locate and repair shorted conductors. B. If the resistance is less than 0.1 Ω, the Cylinder 4 injector Y-9004 solenoid coil has failed. Replace the injector. 8.

pin pin pin pin pin

1 25 26 49 73

To chassis chassis chassis chassis chassis

ground ground ground ground ground

Value There should be 12.0 V There should be 12.0 V There should be 12.0 V There should be 12.0 V There should be 12.0 V

A. If the 12.0 V is present for all five checks, leave the vehicle plug connector X-9001 disconnected and continue with Step 9.

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B. If the 12.0 V is not present for one or more of the checks, use the appropriate vehicle electrical schematics to locate and repair the failure. 9.

pin pin pin pin pin

3 5 28 52 75

To chassis chassis chassis chassis chassis

ground ground ground ground ground

Value ere should be continuity. ere should be continuity. ere should be continuity. ere should be continuity. ere should be continuity.

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3071 - Short circuit in injector 2 (in firing order) Context: Hardware errors in the injectors and their respective Engine Control Unit (ECU) A-9000 power stages are investigated within the ECU A-9000. The ECU A-9000 diagnostic procedure uses pattern detection to identify specific errors. When an expected combination of errors is detected, the associated fault occurs. Cause: During cylinder 2 injector Y-9002 evaluation, the pattern for short circuit was detected. Possible failure modes: 1. Faulty cylinder 2 injector Y-9002 solenoid windings, shorted or grounded. 2. Faulty electrical wiring, short high side to low side or ground (damaged wiring harness). 3. Fault ECU A-9000, software. Solution: 1.

Check the integrity of the cylinder 2 injector Y-9002 control circuit. Disconnect the engine harness from the ECU A-9000 at the engine plug connector X-9002 . Use a multimeter to measure the resistance on the EN harness side: From X-9002 pin 51

To X-9002 pin 73

Value There should be greater than 0.1 Ω

Check the cylinder 2 injector Y-9002 high side control circuit for a short to ground condition. Use a multimeter to check for continuity on the EN harness side: From X-9002 pin 51

To chassis ground

Value Should no be continuity

A. If there is continuity, continue with step 4. B. If there no continuity, continue with step 8. 4.

To chassis ground

Value Should no be continuity

A. If there is continuity to chassis ground, leave connector X-9184-6CYL disconnected and continue with step 5. 48149953 12/06/2018

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B. If there is no continuity, there is a short to ground condition in the engine harness between the valve cover connector X-9184-6CYL pin 1 and the engine plug connector X-9002 pin 51, wire EN-019-6CYL. Locate and repair the grounded conductor. 5.

Determine location of the short to ground condition. Remove the injector (valve) cover and disconnect the injector harness from Cylinder 2 injector at connector . X-9189-6CYL Use a multimeter to check for continuity on the injector: From X-9189-6CYL pin 2

To chassis ground

Value Should no be continuity

A. If there is continuity, cylinder 2 injector Y-9002 solenoid coil has failed, replace the injector. B. If there is no continuity, there is a short to ground condition in cylinder 2 injector circuit, between connector X-9189-6CYL pin 2 and connector X-9184-6CYL pin 1, wire EN-579-6CYL. Locate and repair the grounded conductor. 6.

To X-9184-6CYL pin 2

Value There should be greater than 0.1 Ω

A. If the resistance is greater than 0.1 Ω, there is a short circuit condition in the engine injector harness between the valve cover connector X-9184-6CYL and the engine plug connector X-9002 , wires EN-019-6CYL and EN-020-6CYL. Locate and repair the short circuit. B. If the resistance is less than 0.1 Ω, continue with step 7. 7.

Remove the injector (valve) cover and disconnect the injector harness from Cylinder 2 injector at connector X-9189-6CYL. Use a multimeter to check for continuity on the injector: From X-9189-6CYL pin 1

To X-9189-6CYL pin 2

Value There should be greater than 0.1 Ω

A. If there is greater than 0.1 Ω, there is a short circuit condition in the injector harness, between connector X-9184-6CYL and connectors X-9189-6CYL pin 1 and X-9189-6CYL pin 2, wires EN-578-6CYL and EN-5796CYL. Locate and repair shorted conductors. B. If the resistance is less than 0.1 Ω, the cylinder 2 injector Y-9002 solenoid coil has failed. Replace the injector. 8.

pin pin pin pin pin

1 25 26 49 73

To chassis chassis chassis chassis chassis

ground ground ground ground ground

Value There should be 12.0 V There should be 12.0 V There should be 12.0 V There should be 12.0 V There should be 12.0 V

A. If the 12.0 V is present for all five checks, leave the vehicle plug connector X-9001 disconnected and continue with Step 9.

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B. If the 12.0 V is not present for one or more of the checks, use the appropriate vehicle electrical schematics to locate and repair the failure. 9.

pin pin pin pin pin

3 5 28 52 75

To chassis chassis chassis chassis chassis

ground ground ground ground ground

Value ere should be continuity. ere should be continuity. ere should be continuity. ere should be continuity. ere should be continuity.

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3075 - Short circuit in injector 6 (in firing order) Context: Hardware errors in the injectors and their respective Engine Control Unit (ECU) A-9000 power stages are investigated within the ECU A-9000. The ECU A-9000 diagnostic procedure uses pattern detection to identify specific errors. When an expected combination of errors is detected, the associated fault occurs. Cause: During cylinder 6 injector Y-9006 evaluation, the pattern for short circuit was detected. Possible failure modes: 1. Faulty cylinder 6 injector Y-9006 solenoid windings, shorted or grounded. 2. Faulty electrical wiring, short high side to low side or ground (damaged wiring harness). 3. Fault ECU A-9000, software. Solution: 1.

Check the integrity of the cylinder 6 injector Y-9006 control circuit. Disconnect the engine harness from the ECU A-9000 at the engine plug connector X-9002 . Use a multimeter to measure the resistance on the EN harness side: From X-9002 pin 26

To X-9002 pin 2

Value There should be greater than 0.1 Ω

Check the cylinder 6 injector Y-9006 high side control circuit for a short to ground condition. Use a multimeter to check for continuity on the EN harness side: From X-9002 pin 26

To chassis ground

Value Should no be continuity

A. If there is continuity, continue with step 4. B. If there no continuity, continue with step 8. 4.

Determine location of the short to ground condition. Disconnect the engine cylinder harness from the injector valve cover at connector X-9187-6CYL. Use a multimeter to check for continuity, on the injector (valve) cover side: From X-9187-6CYL pin 2

To chassis ground

Value Should no be continuity

A. If there is continuity to chassis ground, leave connector X-9187-6CYL disconnected and continue with step 5. 48149953 12/06/2018

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B. If there is no continuity, there is a short to ground condition in the engine harness between the valve cover connector X-9187-6CYL pin 2 and the engine plug connector X-9002 pin 26, wire EN-028-6CYL. Locate and repair the grounded conductor. 5.

Determine location of the short to ground condition. Remove the injector (valve) cover and disconnect the injector harness from cylinder 6 injector at connector X-9193-6CYL. Use a multimeter to check for continuity on the injector: From X-9193-6CYL pin 1

To chassis ground

Value Should no be continuity

A. If there is continuity, cylinder 6 injector Y-9006 solenoid coil has failed, replace the injector. B. If there is no continuity, there is a short to ground condition in cylinder 6 injector circuit, between connector X-9193-6CYL pin 1 and connector X-9187-6CYL pin 2, wire EN-586-6CYL. Locate and repair the grounded conductor. 6.

Disconnect the engine cylinder harness from the injector valve cover at connector X-9187-6CYL. Use a multimeter to measure the resistance on the injector cover side of the valve cover: From X-9187-6CYL pin 2

To X-9187-6CYL pin 1

Value There should be greater than 0.1 Ω

A. If the resistance is greater than 0.1 Ω, there is a short circuit condition in the engine injector harness between the valve cover connector X-9187-6CYL and the engine plug connector X-9002, wires EN-027-6CYL and EN-028-6CYL. Locate and repair the short circuit. B. If the resistance is less than 0.1 Ω, continue with step 7. 7.

Remove the injector (valve) cover and disconnect the injector harness from cylinder 6 injector at connector X-9193-6CYL. Use a multimeter to check for continuity on the injector: From X-9193-6CYL pin 1

To X-9193-6CYL pin 2

Value There should be greater than 0.1 Ω

A. If there is greater than 0.1 Ω, there is a short circuit condition in the injector harness, between connector X-9187-6CYL and connectors X-9193-6CYL pin 1 and X-9193-6CYL pin 2 , wires EN-586-6CYL and EN-5876CYL. Locate and repair shorted conductors. B. If the resistance is less than 0.1 Ω, the cylinder 6 injector Y-9006 solenoid coil has failed. Replace the injector. 8.

pin pin pin pin pin

1 25 26 49 73

To chassis chassis chassis chassis chassis

ground ground ground ground ground

Value There should be 12.0 V There should be 12.0 V There should be 12.0 V There should be 12.0 V There should be 12.0 V

A. If the 12.0 V is present for all five checks, leave the vehicle plug connector X-9001 disconnected and continue with Step 9.

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B. If the 12.0 V is not present for one or more of the checks, use the appropriate vehicle electrical schematics to locate and repair the failure. 9.

pin pin pin pin pin

3 5 28 52 75

To chassis chassis chassis chassis chassis

ground ground ground ground ground

Value ere should be continuity. ere should be continuity. ere should be continuity. ere should be continuity. ere should be continuity.

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3079 - Short circuit in injector 3 (in firing order) Context: Hardware errors in the injectors and their respective Engine Control Unit (ECU) A-9000 power stages are investigated within the ECU A-9000. The ECU A-9000 diagnostic procedure uses pattern detection to identify specific errors. When an expected combination of errors is detected, the associated fault occurs. Cause: During cylinder 3 injector Y-9003 evaluation, the pattern for short circuit was detected. Possible failure modes: 1. Faulty cylinder 3 injector Y-9003 solenoid windings, shorted or grounded. 2. Faulty electrical wiring, short high side to low side or ground (damaged wiring harness). 3. Fault ECU A-9000, software. Solution: 1.

Check the integrity of the cylinder 3 injector Y-9003 control circuit. Disconnect the engine harness from the ECU A-9000 at the engine plug connector X-9002 . Use a multimeter to measure the resistance on the EN harness side: From X-9002 pin 50

To X-9002 pin 74

Value There should be greater than 0.1 Ω

Check the cylinder 3 injector Y-9003 high side control circuit for a short to ground condition. Use a multimeter to check for continuity on the EN harness side: From X-9002 pin 50

To chassis ground

Value Should no be continuity

A. If there is continuity, continue with step 4. B. If there no continuity, continue with step 8. 4.

To chassis ground

Value Should no be continuity

A. If there is continuity to chassis ground, leave connector X-9185-6CYL disconnected and continue with step 5. 48149953 12/06/2018

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B. If there is no continuity, there is a short to ground condition in the engine harness between the valve cover connector X-9185-6CYL pin 4 and the engine plug connector X-9002 pin 50, wire EN-021-6CYL. Locate and repair the grounded conductor. 5.

Determine location of the short to ground condition. Remove the injector (valve) cover and disconnect the injector harness from Cylinder 3 injector at connector X-9190-6CYL. Use a multimeter to check for continuity on the injector: From X-9190-6CYL pin 1

To chassis ground

Value Should no be continuity

A. If there is continuity, Cylinder 3 injector Y-9003 solenoid coil has failed, replace the injector. B. If there is no continuity, there is a short to ground condition in cylinder 3 injector circuit, between connector X-9190-6CYL pin 1 and connector X-9185-6CYL pin 4, wire EN-580-6CYL. Locate and repair the grounded conductor. 6.

To X-9185-6CYL pin 3

Value There should be greater than 0.1 Ω

A. If the resistance is greater than 0.1 Ω, there is a short circuit condition in the engine injector harness between the valve cover connector X-9185-6CYL and the engine plug connector X-9002 , wires EN-021-6CYL and EN-022-6CYL. Locate and repair the short circuit. B. If the resistance is less than 0.1 Ω, continue with step 7. 7.

Remove the injector (valve) cover and disconnect the injector harness from Cylinder 3 injector at connector X-9190-6CYL. Use a multimeter to check for continuity on the injector: From X-9190-6CYL pin 1

To X-9190-6CYL pin 2

Value There should be greater than 0.1 Ω

A. If there is greater than 0.1 Ω, there is a short circuit condition in the injector harness, between connector X-9185-6CYL and connectors X-9190-6CYL pin 1 and X-9190-6CYL pin 2, wires EN-580-6CYL and EN-5816CYL. Locate and repair shorted conductors. B. If the resistance is less than 0.1 Ω, the Cylinder 3 injector Y-9003 solenoid coil has failed. Replace the injector. 8.

pin pin pin pin pin

1 25 26 49 73

To chassis chassis chassis chassis chassis

ground ground ground ground ground

Value There should be 12.0 V There should be 12.0 V There should be 12.0 V There should be 12.0 V There should be 12.0 V

A. If the 12.0 V is present for all five checks, leave the vehicle plug connector X-9001 disconnected and continue with Step 9.

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B. If the 12.0 V is not present for one or more of the checks, use the appropriate vehicle electrical schematics to locate and repair the failure. 9.

pin pin pin pin pin

3 5 28 52 75

To chassis chassis chassis chassis chassis

ground ground ground ground ground

Value ere should be continuity. ere should be continuity. ere should be continuity. ere should be continuity. ere should be continuity.

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3083 - Short circuit in injector 5 (in firing order) Context: Hardware errors in the injectors and their respective Engine Control Unit (ECU) A-9000 power stages are investigated within the ECU A-9000. The ECU A-9000 diagnostic procedure uses pattern detection to identify specific errors. When an expected combination of errors is detected, the associated fault occurs. Cause: During cylinder 5 injector Y-9005 evaluation, the pattern for short circuit was detected. Possible failure modes: 1. Faulty cylinder 5 injector Y-9005 solenoid windings, shorted or grounded. 2. Faulty electrical wiring, short high side to low side or ground (damaged wiring harness). 3. Fault ECU A-9000, software. Solution: 1.

Check the integrity of the cylinder 5 injector Y-9005 control circuit. Disconnect the engine harness from the ECU A-9000 at the engine plug connector X-9002 . Use a multimeter to measure the resistance on the EN harness side: From X-9002 pin 25

To X-9002 pin 1

Value There should be greater than 0.1 Ω

Check the cylinder 5 injector Y-9005 high side control circuit for a short to ground condition. Use a multimeter to check for continuity on the EN harness side: From X-9002 pin 25

To chassis ground

Value Should no be continuity

A. If there is continuity, continue with step 4. B. If there no continuity, continue with step 8. 4.

To chassis ground

Value Should no be continuity

A. If there is continuity to chassis ground, leave connector X-9187-6CYL disconnected and continue with step 5. 48149953 12/06/2018

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B. If there is no continuity, there is a short to ground condition in the engine harness between the valve cover connector X-9187-6CYL pin 3 and the engine plug connector X-9002 pin 25 , wire EN-026-6CYL. Locate and repair the grounded conductor. 5.

Determine location of the short to ground condition. Remove the injector (valve) cover and disconnect the injector harness from Cylinder 5 injector at connector X-9192-6CYL . Use a multimeter to check for continuity on the injector: From X-9192-6CYL pin 1

To chassis ground

Value Should no be continuity

A. If there is continuity, cylinder 5 injector Y-9005 solenoid coil has failed, replace the injector. B. If there is no continuity, there is a short to ground condition in Cylinder 5 injector circuit, between connector X-9192-6CYL pin 2 and connector X-9187-6CYL pin 3, wire EN-585-6CYL. Locate and repair the grounded conductor. 6.

To X-9187-6CYL pin 4

Value There should be greater than 0.1 Ω

A. If the resistance is greater than 0.1 Ω, there is a short circuit condition in the engine injector harness between the valve cover connector X-9187-6CYL and the engine plug connector X-9002, wires EN-026-6CYL and EN-025-6CYL. Locate and repair the short circuit. B. If the resistance is less than 0.1 Ω, continue with step 7. 7.

Remove the injector (valve) cover and disconnect the injector harness from Cylinder 5 injector at connector X-9192-6CYL . Use a multimeter to check for continuity on the injector: From X-9192-6CYL pin 1

To X-9192-6CYL pin 2

Value There should be greater than 0.1 Ω

A. If there is greater than 0.1 Ω, there is a short circuit condition in the injector harness, between connector X-9187-6CYL and connectors X-9192-6CYL pin 1 and X-9192-6CYL pin 2, wires EN-584-6CYL and EN-5856CYL. Locate and repair shorted conductors. B. If the resistance is less than 0.1 Ω, the cylinder 5 injector Y-9005 solenoid coil has failed. Replace the injector. 8.

pin pin pin pin pin

1 25 26 49 73

To chassis chassis chassis chassis chassis

ground ground ground ground ground

Value There should be 12.0 V There should be 12.0 V There should be 12.0 V There should be 12.0 V There should be 12.0 V

A. If the 12.0 V is present for all five checks, leave the vehicle plug connector X-9001 disconnected and continue with Step 9.

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B. If the 12.0 V is not present for one or more of the checks, use the appropriate vehicle electrical schematics to locate and repair the failure. 9.

pin pin pin pin pin

3 5 28 52 75

To chassis chassis chassis chassis chassis

ground ground ground ground ground

Value ere should be continuity. ere should be continuity. ere should be continuity. ere should be continuity. ere should be continuity.

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3088 - Crankshaft speed sensor values are not plausible Context: The Electronic Control Unit (ECU) A-9000 is responsible for evaluating the signals received from the camshaft and crankshaft speed sensors. Angle and speed determination, signal plausibility and quality are all evaluated. If A-9000 tests the plausibility of the camshaft speed sensor signal and determines it is plausible, and the A-9000 determines that crankshaft speed signal is not detected for at least two camshaft revolutions, this fault will occur. Cause: The A-9000 has not detected a crankshaft speed signal for at least two camshaft revolutions. Possible failure modes: 1. Faulty phonic or tone wheel timing. 2. Faulty crankshaft speed sensor B-9007. 3. Faulty crankshaft speed sensor B-9007, wiring or electrical disturbances due to damaged isolation of wiring harness or special electrical features. 4. Faulty A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 7. 2. Check the B-9007 signal circuit for an open circuit condition. Disconnect connector X-9002. Disconnect connector X-9021. The key must be at the OFF position. Use a multimeter to perform the following continuity check while shaking the harness to promote an intermittent connection: From X-9002 pin 65

To X-9021 pin 2

Value ere should be continuity.

A. If there is no continuity when shaking the harness or without shaking the harness there is an open circuit condition in the B-9007 signal circuit, wire EN-040. Locate and repair broken conductor. B. If there is continuity, leave both connectors disconnected and continue to Step 3. 3. Check the B-9007 signal circuit for a short circuit condition. The key must be at the OFF position. Use a multimeter to perform the following continuity check: From X-9002 pin 65 X-9002 pin 65

To X-9002 pin 66 All other pins

Value ere should be no continuity. ere should be no continuity.

A. If there is continuity, there is a short circuit condition in the B-9007 signal circuit, wire EN-040. Locate and repair shorted conductor.

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B. If there no continuity, leave both connectors disconnected and continue to Step 4. 4. Check the B-9007 signal circuit for a short circuit condition. The must be in the ON position. Use a multimeter to perform the following voltage check: From X-9002 pin 65

To Chassis GND

Value There should be no voltage..

A. If there is voltage, there is short circuit condition in the B-9007 signal circuit, wire EN-040. Locate and repair shorted conductor. B. If there is no voltage present, continue with step 5. 5. Check the B-9007 wiring for any electrical interferences in the wiring. Check if the correct camshaft sensor is installed and is properly secured, the sensor should not be loose or moving. Check phonic wheel timing on cursor engines and tone wheel timing on NEF engines. Refer to the appropriate service manual for specifications. A. If there is any electrical interference, an incorrect sensor is installed or any modification to the sensor/harness, or the sensor is not mounted correctly, repair as necessary. B. If there are no issues found, continue with step 5. 6. Replace the B-9007. Use the EST to verify that the status of this fault, DTC 4412 â&#x20AC;&#x201C; Crankshaft speed sensor pattern is not plausible. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 7. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3089 - Crankshaft speed sensor pattern is not plausible Context: The Electronic Control Unit (ECU) A-9000 is responsible for evaluating the signals received from the camshaft and crankshaft speed sensors. Angle and speed determination, signal plausibility and quality are all evaluated. If A-9000 determines that more than eighty crankshaft signal plausibility errors have occurred, this fault will occur. Cause: The A-9000 has detected a crankshaft signal implausibility more than eighty times. Possible failure modes: 1. Faulty phonic or tone wheel timing. 2. Faulty crankshaft speed sensor B-9007. 3. Faulty crankshaft speed sensor B-9007, wiring or electrical disturbances due to damaged isolation of wiring harness or special electrical features. 4. Faulty A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 7. 2. Check the B-9007 signal circuit for an open circuit condition. Disconnect connector X-9002. Disconnect connector X-9021. The key must be at the OFF position. Use a multimeter to perform the following continuity check while shaking the harness to promote an intermittent connection: From X-9002 pin 65

To X-9021 pin 2

Value ere should be continuity.

To X-9002 pin 66 All other pins

Value ere should be no continuity. ere should be no continuity.

A. If there is continuity, there is a short circuit condition in the B-9007 signal circuit, wire EN-040. Locate and repair shorted conductor. B. If there no continuity, leave both connectors disconnected and continue to Step 4. 48149953 12/06/2018

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4. Check the B-9007 signal circuit for a short circuit condition. The must be in the ON position. Use a multimeter to perform the following voltage check: From X-9002 pin 65

To Chassis GND

Value There should be no voltage..

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3090 - Camshaft speed sensor values are not plausible Context: The Electronic Control Unit (ECU) A-9000 is responsible for evaluating the signals received from the camshaft and crankshaft speed sensors. Angle and speed determination, signal plausibility and quality are all evaluated. If the A-9000 determines that the camshaft speed signal shows no errors but no camshaft edge signal has been detected at least four times, this fault will occur. Different monitoring strategies are used by the A-9000 during engine start and normal engine running. If the problem is detected at engine start, a redundant synchronization of the angular system is performed using only the crankshaft increment signal and test injections to determine engine phase. If this procedure fails, the injection is aborted and the system waits for a restart. Cause: The A-9000 has monitored a loss in camshaft speed signal at least four times. Possible failure modes: 1. Faulty camshaft speed sensor B-9008, mounting or internal failure. 2. Faulty camshaft speed sensor B-9008, wiring. 3. Faulty phonic wheel timing (Cursor) or tone wheel timing (NEF). Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 7. 2. Check the B-9008 signal circuit for an open circuit condition. Disconnect connector X-9002. Disconnect connector X-9022. The key must be at the OFF position. Use a multimeter to perform the following continuity check while shaking the harness to promote an intermittent connection: From X-9002 pin 68 X-9002 pin 67

To X-9022 pin 2 X-9022 pin 1

Value ere should be continuity. ere should be continuity.

A. If there is no continuity when shaking the harness or without shaking the harness there is an open circuit condition in the B-9008 wiring.Locate and repair broken conductor. B. If there is continuity, leave both connectors disconnected and continue to Step 3. 3. Check the B-9008 signal circuit for a short circuit condition. The key must be at the OFF position. Use a multimeter to perform the following continuity check: From X-9002 pin 68 X-9002 pin 68 X-9002 pin 67

To X-9002 pin 67 All other pins All other pins

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Value ere should be no continuity. ere should be no continuity. ere should be no continuity.

Electrical systems - FAULT CODES

A. If there is continuity, there is a short circuit condition in the B-9008 wiring. Locate and repair shorted conductor. B. If there no continuity, leave both connectors disconnected and continue to Step 4. 4. Check the B-9008 signal circuit for a short circuit condition. The must be in the ON position. Use a multimeter to perform the following voltage check: From X-9002 pin 68 X-9002 pin 67

To Chassis GND Chassis GND

Value There should be no voltage.. There should be no voltage..

A. If there is voltage, there is short circuit condition in the B-9008 wiring.Locate and repair shorted conductor. B. If there is no voltage present, continue with step 5. 5. Check the B-9008 wiring for any electrical interferences in the wiring. Check if the correct camshaft sensor is installed and is properly secured, the sensor should not be loose or moving. Check phonic wheel timing on cursor engines and tone wheel timing on NEF engines. Refer to the appropriate service manual for specifications. A. If there is any electrical interference, the sensor is not mounted correctly, or timing is incorrect, repair as necessary. B. If there are no issues found, continue with step 5 6. Replace the B-9008. Use the EST to verify that the status of this fault, DTC 4212 â&#x20AC;&#x201C; Camshaft speed sensor values are not plausible. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 7. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3091 - Camshaft speed sensor pattern is not plausible Context: The Electronic Control Unit (ECU) A-9000 is responsible for evaluating the signals received from the camshaft and crankshaft speed sensors. Angle and speed determination, signal plausibility and quality are all evaluated. If the A-9000 determines that the camshaft signal does not match the correct pattern (edge distance, level) or not all expected camshaft edges are detected during engine revolution more than six times, this fault will occur. Different monitoring strategies are used by the A-9000 during engine start and normal engine running. If the problem is detected at engine start, a redundant synchronization of the angular system is performed using only the crankshaft increment signal and test injections to determine engine phase. If this procedure fails, the injection is aborted and the system waits for a restart. Cause: The A-9000 has detected a camshaft signal implausibility more than six times. Possible failure modes: 1. Faulty phonic or tone wheel timing. (Cursor engines) 2. Faulty phonic or tone wheel timing. (NEF engines) 3. Faulty camshaft speed sensor B-9008. 4. Faulty camshaft speed sensor B-9008, wiring or electrical disturbances due to damaged isolation of wiring harness or special electrical features. 5. Faulty A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 7. 2. Check the B-9008 signal circuit for an open circuit condition. Disconnect connector X-9002. Disconnect connector X-9022. The key must be at the OFF position. Use a multimeter to perform the following continuity check while shaking the harness to promote an intermittent connection: From X-9002 pin 68

To X-9022 pin 2

Value ere should be continuity.

A. If there is no continuity when shaking the harness or without shaking the harness there is an open circuit condition in the B-9008 signal circuit, wire EN-042. Locate and repair broken conductor. B. If there is continuity, leave both connectors disconnected and continue to Step 3. 3. Check the B-9008 signal circuit for a short circuit condition. The key must be at the OFF position. Use a multimeter to perform the following continuity check:

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From X-9002 pin 68 X-9002 pin 68

To X-9002 pin 67 All other pins

Value ere should be no continuity. ere should be no continuity.

A. If there is continuity, there is a short circuit condition in the B-9008 signal circuit, wire EN-042. Locate and repair shorted conductor. B. If there no continuity, leave both connectors disconnected and continue to Step 4. 4. Check the B-9008 signal circuit for a short circuit condition. The must be in the ON position. Use a multimeter to perform the following voltage check: From X-9002 pin 68

To Chassis GND

Value There should be no voltage..

A. If there is voltage, there is short circuit condition in the B-9008 signal circuit, wire EN-042. Locate and repair shorted conductor. B. If there is no voltage present, continue with step 5. 5. Check the B-9008 wiring for any electrical interferences in the wiring. Check if the correct camshaft sensor is installed and is properly secured, the sensor should not be loose or moving. Check phonic wheel timing on cursor engines and tone wheel timing on NEF engines. Refer to the appropriate service manual for specifications. A. If there is any electrical interference, an incorrect sensor is installed or any modification to the sensor/harness, or the sensor is not mounted correctly, repair as necessary. B. If there are no issues found, continue with step 5 6. Replace the B-9008. Use the EST to verify that the status of this fault, DTC 4112 â&#x20AC;&#x201C; Camshaft speed sensor pattern is not plausible. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 7. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3093 - Compared camshaft and crankshaft speed sensor values are not plausible Context: The Engine Control Unit (ECU) A-9000 monitors the camshaft position sensor and crankshaft position sensor for angle and speed determination, signal plausibility and quality. If the A-9000 determines that the compared values between the two sensors are implausible, this fault will occur. Possible failure modes: 1. Faulty camshaft positioning. 2. Faulty camshaft position wheel positioning. 3. Faulty camshaft position sensor positioning. 4. Faulty crankshaft signal wheel positioning. 5. Faulty A-9000, software.

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3096 - CAN A Bus off failure Context: The Engine Control Unit (ECU) A-9000 is capable of connecting to and communicating on three separate Controller Area Networks (CAN). Proper configuration and monitoring of the three twisted pair configured networks is also a function of the ECU A-9000. CAN Node A Bus is the main vehicle interface bus. The ECU A-9000 provides a CAN termination resistor for the CAN Node A Bus, internal to the ECU A-9000. If the ECU A-9000 senses that CAN Node A Bus is not functioning properly, this fault will occur. Cause: ECU A-9000 has sensed a “Bus Off” state to be present at the CAN Node A. Possible failure modes: 1. Faulty supply voltage or ground, missing. 2. Faulty CAN circuit wiring, open circuit, short to ground, or short circuit. 3. Faulty ECU A-9000, termination resistor or software. Solution: 1. Verify fault is present and in active state. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step2. B. If the fault is no longer present or is in an inactive state, the fault may be intermittent and not currently active. Continue with step 6. 2. Check for other vehicle CAN faults. Use the EST to determine if vehicle CAN faults exist. A. If other vehicle CAN faults do exist, resolve the vehicle CAN faults, then check to see that DTC 951B – CAN A Bus off failure is also resolved. B. If other vehicle CAN faults do not exist, continue with step 3. 3. Check the ECU A-9000 supply voltage. Disconnect the vehicle (VE) harness from the ECU A-9000 at connector X-9001. With the keyswitch in the on position, use a multimeter to check for voltage on the vehicle (VE) harness side: From X-9001 X-9001 X-9001 X-9001 X-9001

pin pin pin pin pin

1 25 26 49 73

To chassis chassis chassis chassis chassis

ground ground ground ground ground

Value There should be 12.0 V . There should be 12.0 V . There should be 12.0 V . There should be 12.0 V . There should be 12.0 V .

A. If the voltage is present on all of the checks, leave connector X-9001 disconnected and continue with Step 4. B. If the voltage is not present for one or more of the checks, see the appropriate vehicle service manual and electrical schematics to locate and restore supply power to the ECU A-9000. 4. Check the ECU A-9000 grounding. With the keyswitch in the off position, use a multimeter to check for continuity on the vehicle (VE) harness side: From X-9001 pin 3 X-9001 pin 5

To chassis ground chassis ground 48149953 12/06/2018

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Value ere should be continuity. ere should be continuity.

Electrical systems - FAULT CODES

From X-9001 pin 28 X-9001 pin 52 X-9001 pin 75

To chassis ground chassis ground chassis ground

Value ere should be continuity. ere should be continuity. ere should be continuity.

A. If there is continuity on all of the checks, leave connector X-9001 disconnected and continue with Step 5. B. If there is no continuity for one or more of the checks, see the appropriate vehicle service manual and electrical schematics to locate and restore the grounding circuit to the ECU A-9000. 5. Determine the condition of the ECU A-9000 CAN circuit. With the ignition switch in the OFF position, use a multimeter to measure the resistance of the CAN connection on the vehicle (VE) harness side: From X-9001 pin 46 X-9001 pin 46 X-9001 pin 47

To X-9001 pin 47 chassis ground chassis ground

Value There should be 120 ÎŠ . Should no be continuity Should no be continuity

Use a multimeter to measure the resistance of the CAN termination resistor, internal to the ECU A-9000: From X-9001 pin 46

To X-9001 pin 47

Value There should be 120 ÎŠ .

A. If the measured resistances are correct and neither conductor is grounded, check the ECU A-9000 for the appropriate software and re-flash, if necessary. B. If the measured resistances are not correct or one or both of the conductors is grounded, refer to the appropriate vehicle service manual and electrical schematics to locate and restore the termination resistance to the CAN circuit. 6. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3102 - Fuel rail pressure sensor voltage is lower than expected Context: The Engine Control Unit (ECU) A-9000 monitors the fuel rail pressure sensor B-9004 signal circuit. If the ECU A-9000 determines that the voltage in the rail pressure sensor B-9004 signal circuit is lower than expected, this fault will occur. Cause: The ECU A-9000 has detected a value less than 0.189 V for period greater than 0.2 s. Possible failure modes: 1. Faulty rail pressure sensor B-9004, internal failure. 2. Faulty rail pressure sensor B-9004 signal circuit, short to ground condition. 3. Fault ECU A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 4. 2. Check the rail pressure sensor B-9004 signal circuit for a short to ground condition. Disconnect connector X-9026-4CYL. Disconnect the ECU A-9000 connector X-9002. The key must be at the OFF position. Use a multimeter to perform the following continuity check: From X-9002 pin 36 X-9002 pin 36 X-9002 pin 36

To Chassis GND X-9002 pin 60 All other pins

Value ere should be no continuity. ere should be no continuity. ere should be no continuity.

A. If there is continuity, there is a short to ground condition in the B-9004 signal circuit, wire EN-002. Locate and repair shorted conductor. B. If there no continuity, continue with step 3. 3. Replace the rail pressure sensor B-9004. Use the EST to verify the status of DTC 2525 â&#x20AC;&#x201C; Fuel rail pressure sensor voltage is lower than expected. A. If this fault is resolved, then return the machine to service. B. If this fault is not resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 4. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

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B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3104 - Fuel pressure relief valve is open Context: A mechanical Pressure Relief Valve (PRV), integral to the fuel rail, will open in the event excessive rail pressure occurs. The Engine Control Unit (ECU) A-9000 senses and counts the radical reductions in rail pressure. If a valve opening is detected, this fault will occur. Cause: The ECU A-9000 has detected that the PRV is open. Possible failure modes: 1. The A-9000 has commanded the PRV open by a pressure shock. 2. Faulty fuel injectors. 3. Faulty high pressure pump. 4. Faulty fuel metering unit Y-9000, wiring or internal failure. 5. Faulty PRV. 6. Faulty rail pressure sensor B-9004, implausible signal. 7. Faulty A-9000, software. Solution: 1. Other possible fuel system faults that may occur or may have caused this fault: DTC F245 – Fuel pressure relief valve is forced to open, perform pressure increase DTC F345 – Fuel pressure relief valve is forced to open, perform pressure shock DTC F445 – Fuel pressure relief valve is open DTC 5255 – Fuel metering unit has an open load error DTC 4155 – Fuel metering unit intermittent electrical connection failure DTC 8355 – Fuel metering unit has an over-temperature error DTC 3C65 – High pressure pump fuel delivery quantity at low idle is too high DTC 3B65 – High pressure pump fuel delivery quantity in over run exceeds a maximum threshold DTC 2265 – Fuel rail pressure has exceeded maximum positive deviation limits DTC 1D85 – Maximum rail pressure exceeded DTC 1425 – Fuel rail pressure sensor voltage is higher than expected DTC 15E5 – Prefilter fuel pressure sensor voltage is higher than expected

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3105 - Fuel pressure relief valve is forced to open, perform pressure increase Context: To determine mechanical wear out or to send the system into limp home mode, the Electronic Control Unit (ECU) A-9000 can force the fuel pressure relief valve open. This action consists of two steps, waiting for the rail pressure to build up and then performing the pressure shock. If the A-9000 commands this operation, this fault will occur. Once a rail pressure sensor Y-9007 failure is detected or maximum rail pressure is exceeded, the system will go into a limp home mode. If this fault occurs, other fuel related system faults can occur due to the increase in fuel pressure. Solution: 1. Other possible fuel system faults that may occur or may have caused this fault: DTC F345 – Fuel pressure relief valve is forced to open, perform pressure shock DTC F445 – Fuel pressure relief valve is open DTC 5255 – Fuel metering unit has an open load error DTC 4155 – Fuel metering unit intermittent electrical connection failure DTC 8355 – Fuel metering unit has an over-temperature error DTC 3C65 – High pressure pump fuel delivery quantity at low idle is too high DTC 3B65 – High pressure pump fuel delivery quantity in over run exceeds a maximum threshold DTC 2265 – Fuel rail pressure has exceeded maximum positive deviation limits DTC 1D85 – Maximum rail pressure exceeded DTC 1425 – Fuel rail pressure sensor voltage is higher than expected DTC 15E5 – Prefilter fuel pressure sensor voltage is higher than expected

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3106 - Fuel pressure relief valve reached maximum allowed opening count Context: A mechanical Pressure Relief Valve (PRV), integral to the fuel rail, will open in the event excessive rail pressure occurs. The Engine Control Unit (ECU) A-9000 senses and counts the sudden reductions in rail pressure due to an opening of the PRV. If the count of 50 is exceeded, this fault will occur. Cause: The PRV opening counter, internal to the A-9000, has exceeded 50. Possible failure modes: 1. Faulty PRV, check tightness and opening pressure. 2. Faulty fuel metering unit Y-9000, wiring. 3. Faulty fuel metering unit Y-9000, internal failure. Solution: 1. Check the status of the following related faults: DTC 4465 – Fuel pump pressure has exceeded desired pressure limits DTC 1865 – Fuel rail pressure has exceeded maximum limit DTC 5255 – Fuel metering unit has an open load error DTC 4155 – Fuel metering unit intermittent electrical connection failure DTC 2265 – Fuel rail pressure has exceeded maximum positive deviation limits DTC 1565 – Fuel rail pressure has exceeded maximum negative deviation limits A. If any of the related faults are active, diagnose them first and then return to this fault, DTC 1145 – Fuel pressure relief valve reached maximum allowed opening count. B. If none of the related faults are active, continue with step 2. 2. Replace the PRV. Use the Electronic Service Tool (EST) to perform the PRV counter reset. A. Return the machine to service condition. B. If the fault is still active, check the ECU A-9000 for the appropriate software and re-flash, if necessary.

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3110 - Rail pressure sensor value is above maximum offset Context: The Electronic Control Unit (ECU) A-9000 monitors fuel rail pressure against offset drift at engine stand still after a waiting period. This allows rail pressure to drop to ambient pressure, which is approximately 1.00 bar. If the A-9000 determines that the rail pressure sensor B-9004 is above maximum offset, this fault will occur. Cause: The A-9000 has determined that the rail pressure sensor B-9004 is above maximum offset. Possible failure modes: 1. Faulty B-9004, wiring. 2. Faulty, B-9004, internal failure.. (possibly due to overpressure) 3. Faulty A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 5. 2. Check for the following related faults: DTC 1425 – Fuel rail pressure sensor voltage is higher than expected DTC 4125 – Rail pressure sensor value is intermittent A. If any of the related faults are active, diagnose them first and then return to this fault, DTC 1225 – Rail pressure sensor value is above maximum offset. B. If none of the related faults are active, continue with step 3. 3. Check that the B-9004 is properly mounted and secured. A. If the sensor is loose or incorrectly mounted, repair as necessary. B. If the B-9004 is properly mounted and secured, continue with step 4. 4. Replace the B-9004. Use the EST to verify that the status of this fault, DTC 1225 – Rail pressure sensor value is above maximum offset. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, check the ECU A-9000 for the appropriate software and re-flash, as necessary. 5. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation. 48149953 12/06/2018

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3111 - Rail pressure sensor value is below minimum offset Context: The Electronic Control Unit (ECU) A-9000 monitors fuel rail pressure against offset drift at engine stand still after a waiting period. This allows rail pressure to drop to ambient pressure, which is approximately 1.00 bar. If the A-9000 determines that the rail pressure sensor B-9004 is below minimum offset, this fault will occur. Cause: The A-9000 has determined that the rail pressure sensor B-9004 is below minimum offset. Possible failure modes: 1. Faulty B-9004, wiring. 2. Faulty, B-9004, internal failure.. (possibly due to overpressure) 3. Faulty A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 5. 2. Check for the following related faults: DTC 2525 – Fuel rail pressure sensor voltage is lower than expected DTC 4125 – Rail pressure sensor value is intermittent A. If any of the related faults are active, diagnose them first and then return to this fault, DTC 2325 – Rail pressure sensor value is below minimum offset. B. If none of the related faults are active, continue with step 3. 3. Check that the B-9004 is properly mounted and secured. A. If the sensor is loose or incorrectly mounted, repair as necessary. B. If the B-9004 is properly mounted and secured, continue with step 4. 4. Replace the B-9004. Use the EST to verify that the status of this fault, DTC 2325 – Rail pressure sensor value is below minimum offset. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, check the ECU A-9000 for the appropriate software and re-flash, as necessary. 5. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation. 48149953 12/06/2018

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3112 - Fuel rail pressure sensor voltage is higher than expected Context: The Engine Control Unit (ECU) A-9000 monitors the fuel rail pressure sensor B-9004 signal circuit. If the ECU A-9000 determines that the voltage in the rail pressure sensor B-9004 signal circuit is higher than expected, this fault will occur. Cause: The ECU A-9000 has detected a value greater than 4.9 V for period greater than 0.2 s. Possible failure modes: 1. Faulty rail pressure sensor B-9004 reference voltage, excessive. 2. Faulty rail pressure sensor B-9004, internal failure. 3. Faulty rail pressure sensor B-9004 signal circuit, short to high source or open circuit condition. 4. Fault ECU A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 7. 2. Check for the following related faults: DTC E42D â&#x20AC;&#x201C; ECU internal failure - Sensor 5 volt supply 3 A. If the faults is active, resolve fault DTC E42D â&#x20AC;&#x201C; ECU internal failure - Sensor 5 volt supply 3. Then determine if fault, DTC 1425 â&#x20AC;&#x201C; Fuel rail pressure sensor voltage is higher than expected is also resolved. B. Is the fault is not active, continue with step 3. 3. Check the rail pressure sensor B-9004 signal circuit for an open circuit condition. Disconnect connector X-9026. Disconnect the ECU A-9000 connector X-9002. The key must be at the OFF position. Use a multimeter to perform the following continuity check: From X-9002 pin 36

To X-9026-4CYL pin 2

Value ere should be continuity.

A. If there is continuity, leave the connectors disconnected and continue with Step 4. B. If there is no continuity, there is an open circuit condition in the rail pressure sensor B-9004 signal circuit, wire EN-002. Locate and repair broken conductor. 4. Check the rail pressure sensor B-9004 signal circuit for a short to high source condition. The key must be at the OFF position. Use a multimeter to perform the following continuity check:

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From X-9002 pin 36 X-9002 pin 36

To X-9002 pin 11 All other pins

Value ere should be no continuity. ere should be no continuity.

A. If there is continuity, there is a short to high source condition in the rail pressure sensor B-9004 signal circuit, wire EN-002. Locate and repair shorted conductor. B. If there no continuity, leave the connectors disconnected and continue with Step 5. 5. Check the rail pressure sensor B-9004 signal circuit for a short to key power condition. The must be in the ON position. Use a multimeter to perform the following voltage check: From X-9002 pin 36

To Chassis GND

Value There should be no voltage..

A. If there is voltage, there is a short to key power condition in the rail pressure sensor B-9004 signal circuit, wire EN-002. Locate and repair shorted conductor. B. If there is no voltage present, continue with step 6. 6. Replace the rail pressure sensor B-9004. Use the EST to verify the status of DTC 1425 â&#x20AC;&#x201C; Fuel rail pressure sensor voltage is higher than expected. A. If this fault is resolved, then return the machine to service. B. If this fault is not resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 7. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3141 - Fuel pump pressure has exceeded desired pressure limits Context: The fuel metering unit Y-9000 controls the desired fuel flow to the fuel rail. The unit is adjusted by feed back control from the Electronic Control Unit (ECU). If actual fuel pressure exceeds requested fuel pressure, leakage will be assumed and this fault will occur. Cause: Actual fuel pressure has exceeded requested fuel pressure by 100.0 bar (1450.0 psi). Possible failure modes: 1. Operating in higher than normal ambient pressure conditions. 2. Faulty fuel injectors, internal leakage or blockage. 3. Faulty fuel pressure sensor B-9004, wiring or internal failure. 4. Faulty fuel metering unit Y-9000, wiring or internal failure. 5. Faulty high pressure pump, feeding efficiency low. 6. Faulty charge gear pump, pressure too high. 7. Faulty A-9000, software. Solution: 1. Use the EST to check for the following related faults that may have caused this fault to occur. If any of the listed faults are active, diagnose them first and then return to this fault, DTC 4465 – Fuel pump pressure has exceeded desired pressure limits. DTC 6655 – Fuel metering unit is shorted to battery voltage at the low side DTC 7555 – Fuel metering unit is shorted to ground at the high side DTC 8355 – Fuel metering unit has an over-temperature error DTC 5255 – Fuel metering unit has an open load error DTC 4155 – Fuel metering unit intermittent electrical connection failure DTC 1425 – Fuel rail pressure sensor voltage is higher than expected DTC 3C65 – High pressure pump fuel delivery quantity at low idle is too high DTC 3B65 – High pressure pump fuel delivery quantity in over run exceeds a maximum threshold DTC 1565 – Fuel rail pressure has exceeded maximum negative deviation limits DTC 2265 – Fuel rail pressure has exceeded maximum positive deviation limits

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3146 - Water in fuel detected or water in fuel circuit failure NOTE: This fault code is for the Water in Fuel switch with black connector housing. Context: The Engine Control Unit (ECU) A-9000 monitors the voltage output from the water in fuel switch S-9102 to determine if water is present in the fuel supply. If water is detected in the fuel, warnings will be displayed to alert the operator of potential engine damage if operation continues. High voltage signal from the water in fuel switch S-9102 indicates water present. Cause: This fault code is displayed to warn the operator that the Engine Control Unit (ECU) A-9000 has detected excess water in the fuel system or a fault in the water in fuel switch circuit. Possible failure modes: 1. Excess water in the fuel supply. 2. Faulty water in fuel switch S-9102, wiring or internal (mechanical and/or electrical) failure. 3. Fault ECU A-9000, software. Solution: 1. Verify this error code is still present and in an active state. Use the Easy Engine software provided on the Electronic Service Tool (EST) to check the fault status. A. If the fault is still present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, Continue with step 7. 2. Check fuel for water contamination. A. If there is water contamination, continue with step 3. B. If there is no water contamination, Continue with step 4. 3. Verify proper water in fuel switch S-9102 operation. Purge fuel supply system, replace fuel filter(s) and refill with fuel that is free of water contamination. Start and run the engine for 5 minutes. Check for code to return to active status. A. If code returns in an active status, replace water in fuel switch S-9102. B. If code remains inactive, then return the machine to service. 4. Check for open, short and grounded circuit conditions in the water in fuel switch S-9102 circuit. Disconnect the water in fuel switch S-9102 at connector X-9125. Disconnect the vehicle (VE) harness from the ECU A-9000 at connector X-9001. With the key switch in the OFF position, use a multimeter to perform the following tests, on the vehicle (VE) harness: From X-9125 pin 1 X-9125 pin 2 X-9125 pin 3

To X-9001 pin 13 X-9001 pin 43 X-9118 pin 4

Value ere should be continuity. ere should be continuity. ere should be continuity.

Then use the multimeter to perform the following tests, on the vehicle (VE) harness:

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From X-9125 pin 1 X-9125 pin 1 X-9125 pin 2

To X-9125 pin 2 X-9125 pin 3 X-9125 pin 3

Value Should no be continuity Should no be continuity Should no be continuity

Then use the multimeter to perform the following tests, on the vehicle (VE) harness: From X-9125 pin 1 X-9125 pin 2 X-9125 pin 3

To Ground Ground Ground

Value Should no be continuity Should no be continuity Should no be continuity

A. If the results are not as expected for any of the wiring tests listed above, there is an open, short or grounded circuit condition in the wiring. Use the appropriate vehicle service manual and schematics to diagnose and repair the wiring. B. If the results are as expected in all of the wiring tests listed above, the wiring is ok. Leave connectors X-9001 and X-9125 disconnected and continue with Step 5. 5. Check for key switch voltage supply to water in fuel switch S-9102. With the key switch in an ON position, use a multimeter to perform the following test, on the vehicle (VE) harness side: From X-9125 pin 3 X-9125 pin 1

To Ground Ground

Value There should be key switch voltage. There should be no key switch voltage.

A. If there is key switch voltage present in the first check and not present in the second check, continue with step 6. B. If key switch voltage is not present in the first check or present in the second check, use the appropriate vehicle service manual and schematics to diagnose and repair the wiring. 6. Replace the water in fuel switch S-9102, then check to see if this fault has been resolved. A. If this fault is resolved, then return the machine to service. B. If this fault is not resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 7. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3154 - Intake air heater actuator is shorted to battery voltage Context: The Engine Control Unit (ECU) A-9000 monitors the intake air heater relay K-9101 control circuit for a short to high source condition. If a short to high source condition is detected, this fault will occur. Cause: The A-9000 has detected a short to high source condition in the K-9101 control circuit. Possible failure modes: 1. Faulty K-9101, coil. 2. Faulty K-9101, short to high source. 3. Faulty A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 4. 2. Check the K-9101 coil for an internal failure. Remove the K-9101. Use a multimeter to test the K-9101 coil. From X-9116 PIN 1

To X-9116 PIN 2

Value There should be between 70 â&#x20AC;&#x201C; 130 ÎŠ.

A. If the value is within the specified range, leave the K-9101 removed and continue with step 3. B. If the value is not within the specified range, the K-9101 has failed internally. Replace the K-9101. 3. Check the K-9101 control circuit for a short to high source condition. Disconnect connector X-9001. The key must be at the OFF position. Use a multimeter to perform the following continuity check: From X-9001 pin 83 X-9001 pin 83

To X-9001 pin 74 All other pins

Value ere should be no continuity. ere should be no continuity.

A. If there is continuity, there is a short to high source condition in the K-9101 control circuit, wire VE-202. See the appropriate service manual to locate and repair the shorted conductor. B. If there no continuity, check the A-9000 for the appropriate software and re-flash, if necessary. 4. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display.

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3155 - Intake air heater actuator is shorted to ground Context: The Engine Control Unit (ECU) A-9000 monitors the intake air heater relay K-9101 control circuit for a short to ground condition. If a short to ground condition is detected, this fault will occur. Cause: The ECU A-9000 has detected a short to ground condition in the intake air heater relay K-9101 control circuit. Possible failure modes: 1. Faulty intake air heater relay K-9101, internal failure. 2. Faulty intake air heater relay K-9101 control circuit, short to ground condition. 3. Fault ECU A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 4. 2. Check the intake air heater relay K-9101 for an internal failure. Remove the intake air heater relay K-9101 from its socket. Use a multimeter to perform the following resistance check, on the relay: From X-9116 pin 1

To X-9116 pin 2

Value There should be between 70 â&#x20AC;&#x201C; 130 ÎŠ.

A. If the value is within the specified range, leave the intake air heater relay K-9101 disconnected and continue to Step 3. B. If the value is not within the specified range, the intake air heater relay K-9101 has failed internally. Replace the intake air heater relay K-9101. 3. Check the intake air heater relay K-9101 control circuit for a short to ground condition. Disconnect the ECU A-9000 connector X-9001. The key must be at the OFF position. Use a multimeter to perform the following continuity check: From X-9001 pin 83 X-9001 pin 83

To Chassis GND All other pins

Value ere should be no continuity. ere should be no continuity.

A. If there is continuity, there is a short to ground condition in the intake air heater relay K-9101 control circuit, wire VE-202. See the appropriate service manual to locate and repair the shorted conductor. B. If there no continuity, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 4. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display.

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3156 - Grid Heater Relay - No Load NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. Cause: Possible failure modes: 1. Faulty connector 2. Faulty grid heater relay 3. Faulty wiring harness 4. Faulty engine controller Solution: 1. Before proceeding clear the error code with the approved diagnostic equipment. Run the machine under normal conditions and retest. A. If the error code is not active, check that the system is operating correctly. B. If the error code is active, continue to step 2. 2. Check the engine controller connector and the grid heater relay connector. Ensure the connectors are connected, not damaged , the pins are in the correct position and that the fit is tight. A. If the connectors are not okay, repair or replace as required. B. If the connectors are okay, continue to step 3. 3. Check the grid heater relay. Remove the grid heater relay and check the operation of the relay. A. If the relay does not operate correctly, replace the grid heater relay. B. If the relay is okay, continue to step 4. 4. Check for 12 V. Turn the key switch on. Measure the voltage between grid heater connector pin 2 and ground. Expected voltage is 12 V. A. If approximately 12 V is not present, repair or replace the harness as required. B. If approximately 12 V is present, continue to step 5. 5. Check for an open circuit. Disconnect the engine controller connector. Check between engine controller connector pin 12 and connector grid heater relay pin 1. A. If an open circuit is found, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re-ocurrs, remove and replace the engine controller.

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3157 - Engine controller configuration timeout anti-tamper NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. NOTE: The message to 'register the dataset, if it has been changed', will occasionally appear on the EST after downloading software. If the procedure to register the dataset has been completed, the machine needs to run for five minutes to complete the registration process between machine modules. Cause: Engine controller configuration took longer than 4 min or the engine control unit (ECU) was not detected on the CAN bus.

Possible failure modes: 1. ECU configuration timed out. 2. ECU not detected on the CAN bus. Solution: 1. Verify the configuration process was started within the 4 minute time out period. Erase fault and proceed with configuration. Download the correct engine data set using the electronic service tool (EST) easy engine download tool. After download, register the engine data set for use with the EST configuration screen “Engine data registration.” A. If fault code 3157 – Engine controller configuration timeout anti-tamper not indicated, check that the system is operating correctly. B. If fault code 3157 – Engine controller configuration timeout anti-tamperis still present, continue to Step 2. 2. Check for other CAN bus related error codes being displayed. A. If other fault codes are displayed, continue to these tests. B. If no other error code is displayed, then continue to step 3. 3. Check all power supplies and grounds to the engine controller at connector. A. If a fault is indicated, repair or replace the harness as required. B. If no faults are indicated, download the correct level of software to the ECM. If the fault is still present, download the correct level of software to the instrument cluster.

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3160 - Fan clutch solenoid short circuit to battery failure Context: The Electronic Control Unit (ECU) A-9000 monitors the fan clutch solenoid Y-9104 for a short circuit to battery condition. If the A-9000 detects a short to battery condition in the Y-9104 wiring, fault will occur. Cause: The A-9000 has detected a short to battery condition in the Y-9104 wiring. Possible failure modes: 1. Faulty Y-9104, wiring or internal failure. 2. Faulty A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 6. 2. Check the Y-9104 for an internal failure. Disconnect connector X-9103. Use a multimeter to perform the following resistance check: From Y-9104 PIN 3

To Y-9104 PIN 4

Value There should approximately 6 â&#x20AC;&#x201C; 12 ÎŠ

A. If the specified value is measured, leave connector disconnected and continue with step 3. B. If the specified value is not measured, the Y-9104 has failed internally. Replace the Y-9104. 3. Check the Y-9104 wiring for a short to battery condition. Disconnect connector X-9001. Use a multimeter to perform the following continuity check: From X-9001 pin 87 X-9001 pin 87

To X-9001 pin 74 All pins in connector X-9001

Value ere should be no continuity. ere should be no continuity.

A. If there is continuity, there is a short circuit condition in the Y-9104 circuit, wire VE-115. Locate and repair broken conductor. B. If there is continuity, leave the connectors disconnected and continue with Step 4. 4. Check the Y-9104 wiring for short to key battery power condition. The must be in the ON position. Use a multimeter to perform the following voltage check: From X-9001 pin 87

To Chassis GND

Value There should be no voltage..

A. If there is voltage, there is a short to key battery power condition in the Y-9104 circuit, wire VE-115. Locate and repair shorted conductor. 48149953 12/06/2018

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B. If there is no voltage present, continue with step 5. 5. Replace the Y-9104. Use the EST to verify that the status of this fault, DTC 5533 â&#x20AC;&#x201C; Fan clutch solenoid open load failure. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 6. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3161 - Fan actuator - short circuit to ground NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. Cause: Possible failure modes: 1. Faulty connector 2. Faulty electronic fan 3. Faulty wiring harness 4. Faulty engine controller Solution: 1. Before proceeding clear the error code with the approved diagnostic equipment. Run the machine under normal conditions and retest. A. If the error code is not active, check that the system is operating correctly. B. If the error code is active, continue to step 2 2. Check the engine controller connector and the electronic fan connector . Ensure the connectors are connected, not damaged , the pins are in the correct position and that the fit is tight. A. If the connectors are okay, repair or replace as required. B. If the connectors are okay, continue to step 3. 3. Check the electronic fan. A. Disconnect electronic fan connector. Measure the resistance between the component side of connector, pins 3 and 4. If the resistance indicated is not approximately 7.0 ÎŠ remove and replace the electronic fan. B. If the resistance indicated is approximately 7.0 ÎŠ continue to step 4. 4. Check for a short to ground.. Disconnect the engine control unit connector. Check between the power supply wire and ground A. If a short circuit to ground is indicated, repair or replace the wiring harness as required. B. If the harness is okay, remove and replace the electronic fan.

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3162 - Fan actuator - open load NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. Cause: Possible failure modes: 1. Faulty connector 2. Faulty electronic fan 3. Faulty wiring harness 4. Faulty engine controller Solution: 1. Before proceeding clear the error code with the approved diagnostic equipment. Run the machine under normal conditions and retest. A. If the error code is not active, check that the system is operating correctly. B. If the error code is active, continue to step 2 2. Check the engine controller connector and the electronic fan connector . Ensure the connectors are connected, not damaged , the pins are in the correct position and that the fit is tight. A. If the connectors are okay, repair or replace as required. B. If the connectors are okay, continue to step 3. 3. Check the electronic fan. A. Disconnect electronic fan connector. Measure the resistance between the component side of connector, pins 3 and 4. If the resistance indicated is not approximately 7.0 ÎŠ remove and replace the electronic fan. B. If the resistance indicated is approximately 7.0 ÎŠ continue to step 4. 4. Check for an open circuit. Disconnect the engine control unit connector. Check between the engine control unit and the electronic fan connector. Check schematic for connector pin numbers. A. If an open circuit is indicated, repair or replace the harness as required.. B. If the harness is okay, remove and replace the electronic fan.

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3163 - Fan clutch solenoid ECU driver over temperature failure Context: The Electronic Control Unit (ECU) A-9000 monitors the fan clutch solenoid Y-9104 for an over temperature/current condition. If the A-9000 detects an over temperature/current condition in the Y-9104 wiring, fault will occur. Cause: The A-9000 has detected an over temperature/current condition in the Y-9104 wiring. Possible failure modes: 1. Faulty Y-9104, wiring or internal failure. 2. Faulty A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 6. 2. 3Check the Y-9104 for an internal failure. Disconnect connector X-9103. Use a multimeter to perform the following resistance check: From Y-9104 PIN 3

To Y-9104 PIN 4

Value There should approximately 6 â&#x20AC;&#x201C; 12 ÎŠ.

To X-9001 pin 74 All pins in connector X-9001 All pins in connector X-9001

Value ere should be no continuity. ere should be no continuity. ere should be no continuity.

A. If there is continuity, there is a short circuit condition in the Y-9104 wiring. Locate and repair broken conductor. B. If there is continuity, leave the connectors disconnected and continue with Step 4. 4. Check the Y-9104 wiring for short to key battery power condition. The must be in the ON position. Use a multimeter to perform the following voltage check: From X-9001 pin 87 X-9001 pin 74

To Chassis GND Chassis GND

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Value There should be no voltage.. There should be no voltage..

Electrical systems - FAULT CODES

A. If there is voltage, there is a short to key battery power condition in the Y-9104 wiring. Locate and repair shorted conductor. B. If there is no voltage present, continue with step 5. 5. Replace the Y-9104. Use the EST to verify that the status of this fault, DTC 5533 â&#x20AC;&#x201C; Fan clutch solenoid open load failure. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 6. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3164 - Fan speed above maximum threshold Context: The Electronic Control Unit (ECU) A-9000 monitors the fan speed sensor B-9103 for fan speed. Fan speed is measured using time interval between pulses. If the A-9000 determines that fan speed is above the maximum threshold based on engine speed, this fault will occur. Cause: The A-9000 has determined that fan speed is above the maximum threshold. Possible failure modes: 1. Faulty cooling fan operation. 2. Faulty vistronic fan clutch solenoid Y-9104, wiring or internal failure. 3. Faulty B-9103, wiring or internal failure. 4. Faulty A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 7. 2. Use the EST to check for the following related faults: DTC 6733 – Fan clutch solenoid short circuit to battery failure DTC 8633 – Fan clutch solenoid ECU driver over temperature failure A. If any of the related faults are active, diagnose them first and then return to this fault, DTC 1A33 – Fan speed above maximum threshold. B. If none of the related faults are active, continue with step 3. 3. Check the fan clutch for proper operation. The engine must be running. Unplug fan connector X-9103. The fan should go to full lock up. A. If the fan goes into lock up, leave connector disconnected and continue with step 4. B. If the fan does not lock up, the fan clutch assembly has failed. Replace the fan clutch Y-9103. 4. Check the fan clutch for proper operation. Disconnect connector X-9103. The engine must be running. Use a jumper wire to provide voltage to the Y-9103. From +Batt Battery -

To X-9103 pin 4 X-9103 pin 3

The fan should operate at minimum speed. This may take up to 60.00 s.

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A. If the fan does not operate, the fan clutch assembly has failed. Replace the Y-9103. B. If the fan operates, leave connector disconnected and continue with step 5. 5. Check the B-9103 wiring for a short circuit condition. Disconnect connector X-9001. The key must be in the OFF position for continuity and ON position for voltage. Use a multimeter to perform the following wiring checks: From X-9001 pin 64 X-9001 pin 64 X-9001 pin 64

To X-9001 pin 67 All pins in connector X-9001 Chassis GND

Value ere should be no continuity. ere should be no continuity. There should be no voltage..

A. If the specified values are not measured, there is a short circuit condition in the B-9103 wiring. Locate and repair shorted conductor. B. If the specified values are measured, continue with step 6. 6. Replace the B-9103. Use the EST to verify that the fault has been resolved. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 7. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3165 - Fan speed below minimum threshold Context: The Electronic Control Unit (ECU) A-9000 monitors the fan speed sensor B-9103 for fan speed. Fan speed is measured using time interval between pulses. If the A-9000 determines that fan speed is below the minimum threshold based on engine speed, this fault will occur. Cause: The A-9000 has determined that fan speed is below the minimum threshold. Possible failure modes: 1. Faulty cooling fan operation, blocked or inoperative. 2. Faulty vistronic fan clutch solenoid Y-9104, wiring or internal failure. 3. Faulty B-9103, wiring or internal failure. 4. Faulty A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 7. 2. Use the EST to check for the following related faults: DTC 5533 â&#x20AC;&#x201C; Fan clutch solenoid open load failure A. If the listed fault is active, diagnose them first and then return to this fault, DTC 1A33 â&#x20AC;&#x201C; Fan speed above maximum threshold. B. If the listed fault is not active, continue with step 3. 3. Check the fan clutch for proper operation. The engine must be running. Unplug fan connector X-9103. The fan should go to full lock up. A. If the fan goes into lock up, leave connector disconnected and continue with step 4. B. If the fan does not lock up, the fan clutch assembly has failed. Replace the fan clutch Y-9103. 4. Check the fan clutch for proper operation. Disconnect connector X-9103. The engine must be running. Use a jumper wire to provide voltage to the Y-9103. From +Batt Battery -

To X-9103 pin 4 X-9103 pin 3

The fan should operate at minimum speed. This may take up to 60.00 s. A. If the fan does not operate, the fan clutch assembly has failed. Replace the Y-9103.

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B. If the fan operates, leave connector disconnected and continue with step 5. 5. Check the B-9103 wiring for a short circuit condition. Disconnect connector X-9001. Disconnect connector X-9103. The key must be at the OFF position. Use a multimeter to perform the following continuity check: From X-9001 pin 64 X-9001 pin 64 X-9001 pin 64

To X-9001 pin 65 All pins in connector X-9001 Chassis GND

Value ere should be no continuity. ere should be no continuity. ere should be no continuity.

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3166 - Fuel filter heater actuator is shorted to battery voltage Context: The Electronic Control Unit (ECU) A-9000 monitors the fuel filter heater relay K-9100 signal circuit for a short to battery condition. If the A-9000 detects a short to battery condition for a period greater than 200 ms, this fault will occur. Cause: The A-9000 has detected a short to battery condition in the fuel filter heater relay circuit for a period greater than 200 ms. Possible failure modes: 1. Faulty K-9100, coil. 2. Faulty K-9100 signal circuit, short to battery condition. 3. Faulty A-9000, software. Solution: 1. Verify that the fault code is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 4. 2. Check the K-9100 coil for an internal failure. Remove the K-9100. Use a multimeter to perform the following resistance test: From K-9100 PIN 85

To K-9100 PIN 86

Value The coil resistance should be between 70.0 – 130.0 Ω (70.0 – 130.0 Ω).

A. If the value is within the specified range, leave the K-9100 disconnected and continue to Step 3. B. If the value is not within the specified value, the K-9100 has failed internally. Replace the K-9100. 3. Check the K-9100 signal circuit for a short to battery condition. Disconnect connector X-9001 from the A-9000. Turn the key to the ON position. Use a multimeter to perform the following voltage test: From X-9001 pin 61 X-9001 pin 61

To Chassis GND All other pins

Value There should be no voltage.. There should be no voltage..

A. If there is voltage, there is a short to battery condition in the K-9100 signal circuit, wire VE-121. Locate and repair shorted conductor. B. If there is no voltage present, check the A-9000 for the appropriate software and re-flash, if necessary. 4. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display.

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3167 - Fuel Filter Heater Relay - Short Circuit To Ground NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. Cause: Possible failure modes: 1. Faulty connector 2. Faulty fuel filter heater 3. Faulty wiring harness 4. Faulty engine controller Solution: 1. Before proceeding clear the error code with the approved diagnostic equipment. Run the machine under normal conditions and retest. A. If the error code is not active, check that the system is operating correctly. B. If the error code is active, continue to step 2 2. Check the engine controller connector and the fuel filter heater connector . Ensure the connectors are connected, not damaged , the pins are in the correct position and that the fit is tight. A. If the connectors are okay, repair or replace as required. B. If the connectors are okay, replace the fuel filter heater.

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3168 - Fuel filter heater relay - open load NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. Cause: Possible failure modes: 1. Faulty connector 2. Faulty fuel filter heater 3. Faulty wiring harness 4. Faulty engine controller Solution: 1. Before proceeding clear the error code with the approved diagnostic equipment. Run the machine under normal conditions and retest. A. If the error code is not active, check that the system is operating correctly. B. If the error code is active, continue to step 2 2. Check the engine controller connector and the fuel filter heater connector . Ensure the connectors are connected, not damaged , the pins are in the correct position and that the fit is tight. A. If the connectors are okay, repair or replace as required. B. If the connectors are okay, replace the fuel filter heater.

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3169 - Fuel filter heater relay - signal not plausible

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3172 - Engine coolant temperature has exceeded the pre-warning threshold Context: The Engine Control Unit (ECU) A-9000 monitors the engine coolant temperature. Two engine temperature thresholds are available to signal high engine temperature. A pre-warning is set if engine temperature coolant exceeds 106.0 °C (222.7 °F) and a warning is set if engine coolant temperature exceeds 110.0 °C (229.9 °F). If the pre-warning threshold is exceeded, this fault will occur. Cause: The engine coolant temperature pre-warning threshold has been exceeded. Possible failure modes: 1. Engine temperature too high. (heavy use or high environmental temperature) 2. Faulty engine cooling system, coolant low, thermostat stuck closed, restricted cooling package etc. 3. Faulty B-9003 wiring or internal failure. 4. Faulty A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 6. 2. Check for the following related faults: DTC 1113 – Engine coolant temperature sensor voltage is higher than expected A. If the faults is active, troubleshoot it first and then return to this fault, DTC F523 – Engine coolant temperature has exceeded the pre-warning threshold. B. Is the fault is not active, continue with step 3. 3. Check the engine cooling system for an over temperature condition. Check the cooling system for leakage, damage or blockage. Check the ambient air temperature using the EST to verify that the machine is not operating in extreme ambient temperatures. A. If any failures are found, repair the cooling system as necessary. B. If no faults are found, continue with step 4. 4. Check the B-9003 wiring. Disconnect connector X-9002. Disconnect connector X-9006. The key must be in the OFF position for continuity checks and the ON position for voltage checks. Use a multimeter to perform the following wiring checks: From X-9001 pin 39 X-9001 pin 39

To X-9006 pin 1 X-9001 pin 59 48149953 12/06/2018

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Value ere should be continuity. ere should be no continuity.

Electrical systems - FAULT CODES

From X-9001 pin 39 X-9001 pin 39 X-9001 pin 39

To Chassis GND All pins in connector Chassis GND

Value ere should be no continuity. ere should be no continuity. There should be no voltage..

A. If the specified values are not measured, there is a short circuit condition in the B-9003 wiring, wire EN-014. Locate and repair shorted conductor. B. If the specified values are measured, continue with step 5. 5. Replace the B-9003. Use the EST to verify that the status of this fault, DTC F523 â&#x20AC;&#x201C; Engine coolant temperature has exceeded the pre-warning threshold. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 6. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3173 - Engine coolant temperature has exceeded the warning threshold Context: The Engine Control Unit (ECU) A-9000 monitors the engine coolant temperature. Two engine temperature thresholds are available to signal high engine temperature. A pre-warning is set if engine temperature coolant exceeds 106.0 °C (222.7 °F) and a warning is set if engine coolant temperature exceeds 110.0 °C (229.9 °F). If the warning threshold is exceeded, this fault will occur. Cause: The engine coolant temperature warning threshold has been exceeded. Possible failure modes: 1. Engine temperature too high. (heavy use or high environmental temperature) 2. Faulty engine cooling system, coolant low, thermostat stuck closed, restricted cooling package etc. 3. Faulty B-9003 wiring or internal failure. 4. Faulty A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 6. 2. Check for the following related faults: DTC 1113 – Engine coolant temperature sensor voltage is higher than expected DTC F523 – Engine coolant temperature has exceeded the pre-warning threshold A. If the faults is active, troubleshoot it first and then return to this fault, DTC F523 – Engine coolant temperature has exceeded the pre-warning threshold. B. Is the fault is not active, continue with step 3. 3. Check the engine cooling system for an over temperature condition. Check the cooling system for leakage, damage or blockage. Check the ambient air temperature using the EST to verify that the machine is not operating in extreme ambient temperatures. A. If any failures are found, repair the cooling system as necessary. B. If no faults are found, continue with step 4. 4. Check the B-9003 wiring. Disconnect connector X-9002. The key must be in the OFF position for continuity checks and the ON position for voltage checks. Use a multimeter to perform the following wiring checks: From X-9001 pin 39 X-9001 pin 39

To X-9006 pin 1 X-9001 pin 59 48149953 12/06/2018

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Value ere should be continuity. ere should be no continuity.

Electrical systems - FAULT CODES

From X-9001 pin 39 X-9001 pin 39 X-9001 pin 39

To Chassis GND All pins in connector Chassis GND

Value ere should be no continuity. ere should be no continuity. There should be no voltage..

A. If the specified values are not measured, there is a short circuit condition in the B-9003 wiring, wire EN-014. Locate and repair shorted conductor. B. If the specified values are measured, continue with step 5. 5. Replace the B-9003. Use the EST to verify that the status of this fault, DTC F623 â&#x20AC;&#x201C; Engine coolant temperature has exceeded the warning threshold. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 6. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3175 - Fan speed could not be measured for a period Context: The Electronic Control Unit (ECU) A-9000 monitors fan speed by the fan speed sensor B-9103. Speed is measured using time interval between pulses. If the A-9000 determines that the times interval is too long or has stopped completely, this fault will occur. Cause: The A-9000 has determined that the fan speed signal could not be measured for an extended period of time. Possible failure modes: 1. Faulty engine cooling fan assembly. 2. Faulty B-9103, wiring. 3. Faulty, B-9103, internal failure.. 4. Faulty A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 5. 2. Check the B-9103 signal circuit wiring. Disconnect connector X-9103. Disconnect connector X-9001. The key must be in the OFF position for continuity and ON position for voltage. Use a multimeter to perform the following wiring checks: From X-9001 X-9001 X-9001 X-9001 X-9001 X-9001

pin pin pin pin pin pin

64 64 64 64 64 64

To Value X-9103 pin 1 ere should be continuity. X-9001 pin 65 ere should be no continuity. X-9001 pin 67 ere should be no continuity. All pins in connector X-9001 ere should be no continuity. ere should be no continuity. Chassis GND Chassis ground (Key ON for voltage) There should be no voltage..

A. If the specified values are not obtained, the is a fault in the B-9103 wiring. Locate and repair the failed conductor. B. If the specified values are obtained, continue with step 3. 3. Inspect the cooling fan for proper operation. A. If the fan is not properly engaging or functioning correctly, repair the fan assembly as necessary. B. If the fan assembly is functioning properly, continue with step 4. 4. Replace the B-9103. Use the EST to verify that the status of this fault, DTC 4933 â&#x20AC;&#x201C; Fan speed signal could not be measured for a period.

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A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 5. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3176 - High pressure pump fuel delivery quantity in over run exceeds a maximum threshold Context: The Electronic Control Unit (ECU) A-9000 controls fuel delivery by the fuel metering unit Y-9000. The A-9000 monitors for high pressure leakage during over run. If high pressure fuel delivery quantity exceeds a maximum threshold in over run and desired fuel pressure can not be reached, leakage in the system is assumed and this fault will occur. Cause: The A-9000 has determined that desired fuel rail pressure is lower than expected in over run. Possible failure modes: 1. Faulty fuel injectors, internal leakage or stuck open. 2. Faulty pressure relief valve, leaking. 3. Faulty fuel metering unit Y-9000. 4. Faulty high pressure pump. 5. Faulty fuel filter, clogged. 6. Faulty low pressure fuel lines, leaking. (air entrance) 7. Faulty low pressure gear pump. 8. Faulty electric lift pump. (if applicable)

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3177 - Engine over speed condition detected Context: The Electronic Control Unit (ECU) A-9000 monitors engine speed in case of an overspeed condition. Engine overspeed can be caused by operating states such as downhill travel. If an engine overspeed condition is detected, this fault will occur. Cause: The A-9000 has detected that engine speed has exceeded 2600 RPM. Possible failure modes: 1. Operating error. (downhill travel) 2. Engine runaway condition. Engine continues to accelerate without any operator input. (fuel or oil leakage into cylinders) 3. Faulty fuel injectors, leakage into cylinders. (Causing engine runaway condition) 4. Faulty camshaft speed sensor B-9008 wiring or internal failure. 5. Faulty crankshaft speed sensor B-9007 wiring or internal failure. 6. Faulty A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 4. 2. Check for the following related faults: DTC 3312 – Compared camshaft and crankshaft speed sensor values are not plausible DTC 4112 – Camshaft speed sensor pattern is not plausible DTC 4212 – Camshaft speed sensor values are not plausible DTC 4412 – Crankshaft speed sensor pattern is not plausible DTC 4512 – Crankshaft speed sensor values are not plausible A. If any of the related faults are active, diagnose them first and then return to this fault, DTC F1A2 – Engine over speed condition detected. B. If none of the related faults are active, continue with step 3. 3. Verify that this fault was not activated by a downhill travel condition or any other operating conditions that may have caused this fault. A. If the fault is no longer active, then return the machine to service. B. If the fault is still active, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 4. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. 48149953 12/06/2018

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B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3179 - CAN communication failure between vehicle controller and ECU - BC2ECU2 message Context: The Engine Control Unit (ECU) A-9000 is capable of connecting to and communicating on three separate Controller Area Networks (CAN). Proper configuration and monitoring of the three twisted pair configured networks is also a function of the ECU A-9000. CAN Node A Bus is the main vehicle interface bus. The ECU A-9000 provides a CAN termination resistor for the CAN Node A Bus, internal to the ECU A-9000. The ECU A-9000 receives and responds to proprietary Body Computer (BC) information. If the ECU A-9000 senses a message timeout, this fault will occur. Cause: ECU A-9000 has sensed a BC message timeout. Possible failure modes: 1. Faulty vehicle system, related CAN fault. 2. Faulty supply voltage or ground, missing. 3. Faulty CAN circuit wiring, open circuit, short to ground, or short circuit. 4. Faulty ECU A-9000, termination resistor or software. Solution: 1. Verify fault is present and in active state. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step2. B. If the fault is no longer present or is in an inactive state, the fault may be intermittent and not currently active. Continue with step 6. 2. Check for related vehicle CAN faults. Use the EST to determine if related vehicle CAN faults exist. A. If related vehicle CAN faults do exist, resolve the vehicle CAN faults, then check to see that DTC 956B â&#x20AC;&#x201C; CAN communication failure between vehicle controller and ECU - BC2ECU2 message is also resolved. B. If related vehicle CAN faults do not exist, continue with step 3. 3. Check the ECU A-9000 supply voltage. Disconnect the vehicle (VE) harness from the ECU A-9000 at connector X-9001. With the keyswitch in the on position, use a multimeter to check for voltage on the vehicle (VE) harness side: From X-9001 X-9001 X-9001 X-9001 X-9001

pin pin pin pin pin

1 25 26 49 73

To chassis chassis chassis chassis chassis

ground ground ground ground ground

Value There should be 12.0 V . There should be 12.0 V . There should be 12.0 V . There should be 12.0 V . There should be 12.0 V .

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From X-9001 X-9001 X-9001 X-9001 X-9001

pin pin pin pin pin

3 5 28 52 75

To chassis chassis chassis chassis chassis

ground ground ground ground ground

Value ere should be continuity. ere should be continuity. ere should be continuity. ere should be continuity. ere should be continuity.

To X-9001 pin 47 chassis ground chassis ground

Value There should be 120 ÎŠ . Should no be continuity Should no be continuity

Use a multimeter to measure the resistance of the CAN termination resistor, internal to the ECU A-9000: From X-9001 pin 46

To X-9001 pin 47

Value There should be 120 ÎŠ .

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3180 - CAN communication error between vehicle controller to ECU Context: The Engine Control Unit (ECU) A-9000 is capable of connecting to and communicating on three separate Controller Area Networks (CAN). Proper configuration and monitoring of the three twisted pair configured networks is also a function of the ECU A-9000. CAN Node A Bus is the main vehicle interface bus. The ECU A-9000 provides a CAN termination resistor for the CAN Node A Bus, internal to the ECU A-9000. The ECU A-9000 receives and responds to proprietary idle speed, intermediate speed and feedback information. If the ECU A-9000 senses a message timeout, this fault will occur. Cause: ECU A-9000 has sensed a proprietary speed message timeout. Possible failure modes: 1. Faulty vehicle system, related CAN fault. 2. Faulty supply voltage or ground, missing. 3. Faulty CAN circuit wiring, open circuit, short to ground, or short circuit. 4. Faulty ECU A-9000, termination resistor or software. Solution: 1. Verify fault is present and in active state. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step2. B. If the fault is no longer present or is in an inactive state, the fault may be intermittent and not currently active. Continue with step 6. 2. Check for related vehicle CAN faults. Use the EST to determine if related vehicle CAN faults exist. A. If related vehicle CAN faults do exist, resolve the vehicle CAN faults, then check to see that DTC 9B7B â&#x20AC;&#x201C; CAN communication error between vehicle controller to ECU is also resolved. B. If related vehicle CAN faults do not exist, continue with step 3. 3. Check the ECU A-9000 supply voltage. Disconnect the vehicle (VE) harness from the ECU A-9000 at connector X-9001. With the keyswitch in the on position, use a multimeter to check for voltage on the vehicle (VE) harness side: From X-9001 X-9001 X-9001 X-9001 X-9001

pin pin pin pin pin

1 25 26 49 73

To chassis chassis chassis chassis chassis

ground ground ground ground ground

Value There should be 12.0 V . There should be 12.0 V . There should be 12.0 V . There should be 12.0 V . There should be 12.0 V .

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From X-9001 X-9001 X-9001 X-9001 X-9001

pin pin pin pin pin

3 5 28 52 75

To chassis chassis chassis chassis chassis

ground ground ground ground ground

Value ere should be continuity. ere should be continuity. ere should be continuity. ere should be continuity. ere should be continuity.

To X-9001 pin 47 chassis ground chassis ground

Value There should be 120 ÎŠ . Should no be continuity Should no be continuity

Use a multimeter to measure the resistance of the CAN termination resistor, internal to the ECU A-9000: From X-9001 pin 46

To X-9001 pin 47

Value There should be 120 ÎŠ .

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3182 - CAN timeout error from cruise control vehicle speed (CCVS) Context: The Engine Control Unit (ECU) A-9000 is capable of connecting to and communicating on three separate Controller Area Networks (CAN). Proper configuration and monitoring of the three twisted pair configured networks is also a function of the ECU A-9000. CAN Node A Bus is the main vehicle interface bus. The ECU A-9000 provides a CAN termination resistor for the CAN Node A Bus, internal to the ECU A-9000. The ECU A-9000 receives and responds to proprietary Cruise Control Vehicle Speed (CCVS) information. If the ECU A-9000 senses a message timeout, this fault will occur. Cause: ECU A-9000 has sensed a CCVS message timeout. Possible failure modes: 1. Faulty vehicle system, related CAN fault. 2. Faulty supply voltage or ground, missing. 3. Faulty CAN circuit wiring, open circuit, short to ground, or short circuit. 4. Faulty ECU A-9000, termination resistor or software. Solution: 1. Verify fault is present and in active state. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step2. B. If the fault is no longer present or is in an inactive state, the fault may be intermittent and not currently active. Continue with step 6. 2. Check for related vehicle CAN faults. Use the EST to determine if related vehicle CAN faults exist. A. If related vehicle CAN faults do exist, resolve the vehicle CAN faults, then check to see that DTC 9741 â&#x20AC;&#x201C; CAN timeout error from cruise control vehicle speed (CCVS) is also resolved. B. If related vehicle CAN faults do not exist, continue with step 3. 3. Check the ECU A-9000 supply voltage. Disconnect the vehicle (VE) harness from the ECU A-9000 at connector X-9001. With the keyswitch in the on position, use a multimeter to check for voltage on the vehicle (VE) harness side: From X-9001 X-9001 X-9001 X-9001 X-9001

pin pin pin pin pin

1 25 26 49 73

To chassis chassis chassis chassis chassis

ground ground ground ground ground

Value There should be 12.0 V . There should be 12.0 V . There should be 12.0 V . There should be 12.0 V . There should be 12.0 V .

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From X-9001 X-9001 X-9001 X-9001 X-9001

pin pin pin pin pin

3 5 28 52 75

To chassis chassis chassis chassis chassis

ground ground ground ground ground

Value ere should be continuity. ere should be continuity. ere should be continuity. ere should be continuity. ere should be continuity.

To X-9001 pin 47 chassis ground chassis ground

Value There should be 120 ÎŠ . Should no be continuity Should no be continuity

Use a multimeter to measure the resistance of the CAN termination resistor, internal to the ECU A-9000: From X-9001 pin 46

To X-9001 pin 47

Value There should be 120 ÎŠ .

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3183 - CAN communication failure between vehicle controller and ECU controller - TSC1_VR message (Engine brake) Context: The Engine Control Unit (ECU) A-9000 is capable of connecting to and communicating on three separate Controller Area Networks (CAN). Proper configuration and monitoring of the three twisted pair configured networks is also a function of the ECU A-9000. CAN Node A Bus is the main vehicle interface bus. The ECU A-9000 provides a CAN termination resistor for the CAN Node A Bus, internal to the ECU A-9000. The ECU A-9000 receives and responds to Vehicle Retarder (VR) information at two different rates (active and passive) dependant upon change request status. If the ECU A-9000 is not sensing the VR message at the active rate, this fault will occur. Cause: The ECU A-9000 is not properly sensing the VR message. Possible failure modes: 1. Faulty vehicle system, related CAN fault. 2. Faulty supply voltage or ground, missing. 3. Faulty CAN circuit wiring, open circuit, short to ground, or short circuit. 4. Faulty ECU A-9000, termination resistor or software. Solution: 1. Verify fault is present and in active state. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step2. B. If the fault is no longer present or is in an inactive state, the fault may be intermittent and not currently active. Continue with step 6. 2. Check for related vehicle CAN faults. Use the EST to determine if vehicle CAN faults exist. A. If related vehicle CAN faults do exist, resolve the vehicle CAN faults, then check to see that DTC 93CB â&#x20AC;&#x201C; CAN communication failure between vehicle controller and ECU controller - TSC1_VR message (Engine brake) is also resolved. B. If related vehicle CAN faults do not exist, continue with step 3. 3. Check the ECU A-9000 supply voltage. Disconnect the vehicle (VE) harness from the ECU A-9000 at connector X-9001. With the keyswitch in the on position, use a multimeter to check for voltage on the vehicle (VE) harness side: From X-9001 X-9001 X-9001 X-9001 X-9001

pin pin pin pin pin

1 25 26 49 73

To chassis chassis chassis chassis chassis

ground ground ground ground ground

Value There should be 12.0 V . There should be 12.0 V . There should be 12.0 V . There should be 12.0 V . There should be 12.0 V .

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With the keyswitch in the off position, use a multimeter to check for continuity on the vehicle (VE) harness side: From X-9001 X-9001 X-9001 X-9001 X-9001

pin pin pin pin pin

3 5 28 52 75

To chassis chassis chassis chassis chassis

ground ground ground ground ground

Value ere should be continuity. ere should be continuity. ere should be continuity. ere should be continuity. ere should be continuity.

To X-9001 pin 47 chassis ground chassis ground

Value There should be 120 ÎŠ . Should no be continuity Should no be continuity

Use a multimeter to measure the resistance of the CAN termination resistor, internal to the ECU A-9000: From X-9001 pin 46

To X-9001 pin 47

Value There should be 120 ÎŠ .

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3184 - CAN communication failure between vehicle controller and ECU controller - TSC1_VR message (Engine brake) Context: The Engine Control Unit (ECU) A-9000 is capable of connecting to and communicating on three separate Controller Area Networks (CAN). Proper configuration and monitoring of the three twisted pair configured networks is also a function of the ECU A-9000. CAN Node A Bus is the main vehicle interface bus. The ECU A-9000 provides a CAN termination resistor for the CAN Node A Bus, internal to the ECU A-9000. The ECU A-9000 receives and responds to Vehicle Retarder (VR) information at two different rates (active and passive) dependant upon change request status. If the ECU A-9000 is not sensing the VR message at the passive rate, this fault will occur. Cause: The ECU A-9000 is not properly sensing the VR message. Possible failure modes: 1. Faulty vehicle system, related CAN fault. 2. Faulty supply voltage or ground, missing. 3. Faulty CAN circuit wiring, open circuit, short to ground, or short circuit. 4. Faulty ECU A-9000, termination resistor or software. Solution: 1. Verify fault is present and in active state. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step2. B. If the fault is no longer present or is in an inactive state, the fault may be intermittent and not currently active. Continue with step 6. 2. Check for related vehicle CAN faults. Use the EST to determine if vehicle CAN faults exist. A. If related vehicle CAN faults do exist, resolve the vehicle CAN faults, then check to see that DTC 94CB â&#x20AC;&#x201C; CAN communication failure between vehicle controller and ECU controller - TSC1_VR message (Engine brake) is also resolved. B. If related vehicle CAN faults do not exist, continue with step 3. 3. Check the ECU A-9000 supply voltage. Disconnect the vehicle (VE) harness from the ECU A-9000 at connector X-9001. With the keyswitch in the on position, use a multimeter to check for voltage on the vehicle (VE) harness side: From X-9001 X-9001 X-9001 X-9001 X-9001

pin pin pin pin pin

1 25 26 49 73

To chassis chassis chassis chassis chassis

ground ground ground ground ground

Value There should be 12.0 V . There should be 12.0 V . There should be 12.0 V . There should be 12.0 V . There should be 12.0 V .

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With the keyswitch in the off position, use a multimeter to check for continuity on the vehicle (VE) harness side: From X-9001 X-9001 X-9001 X-9001 X-9001

pin pin pin pin pin

3 5 28 52 75

To chassis chassis chassis chassis chassis

ground ground ground ground ground

Value ere should be continuity. ere should be continuity. ere should be continuity. ere should be continuity. ere should be continuity.

To X-9001 pin 47 chassis ground chassis ground

Value There should be 120 ÎŠ . Should no be continuity Should no be continuity

Use a multimeter to measure the resistance of the CAN termination resistor, internal to the ECU A-9000: From X-9001 pin 46

To X-9001 pin 47

Value There should be 120 ÎŠ .

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3185 - CAN timeout error from transmission - Transmission fluids (TF) message Context: The Engine Control Unit (ECU) A-9000 is capable of connecting to and communicating on three separate Controller Area Networks (CAN). Proper configuration and monitoring of the three twisted pair configured networks is also a function of the ECU A-9000. CAN Node A Bus is the main vehicle interface bus. The ECU A-9000 provides a CAN termination resistor for the CAN Node A Bus, internal to the ECU A-9000. The ECU A-9000 receives and responds to proprietary Transmission Fluids (TF) information. If the ECU A-9000 senses a message timeout, this fault will occur. Cause: ECU A-9000 has sensed a TF message timeout. Possible failure modes: 1. Faulty vehicle system, related CAN fault. 2. Faulty supply voltage or ground, missing. 3. Faulty CAN circuit wiring, open circuit, short to ground, or short circuit. 4. Faulty ECU A-9000, termination resistor or software. Solution: 1. Verify fault is present and in active state. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step2. B. If the fault is no longer present or is in an inactive state, the fault may be intermittent and not currently active. Continue with step 6. 2. Check for related vehicle CAN faults. Use the EST to determine if related vehicle CAN faults exist. A. If related vehicle CAN faults do exist, resolve the vehicle CAN faults, then check to see that DTC 978B â&#x20AC;&#x201C; CAN timeout error from transmission - Transmission fluids (TF) message is also resolved. B. If related vehicle CAN faults do not exist, continue with step 3. 3. Check the ECU A-9000 supply voltage. Disconnect the vehicle (VE) harness from the ECU A-9000 at connector X-9001. With the keyswitch in the on position, use a multimeter to check for voltage on the vehicle (VE) harness side: From X-9001 X-9001 X-9001 X-9001 X-9001

pin pin pin pin pin

1 25 26 49 73

To chassis chassis chassis chassis chassis

ground ground ground ground ground

Value There should be 12.0 V . There should be 12.0 V . There should be 12.0 V . There should be 12.0 V . There should be 12.0 V .

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From X-9001 X-9001 X-9001 X-9001 X-9001

pin pin pin pin pin

3 5 28 52 75

To chassis chassis chassis chassis chassis

ground ground ground ground ground

Value ere should be continuity. ere should be continuity. ere should be continuity. ere should be continuity. ere should be continuity.

To X-9001 pin 47 chassis ground chassis ground

Value There should be 120 ÎŠ . Should no be continuity Should no be continuity

Use a multimeter to measure the resistance of the CAN termination resistor, internal to the ECU A-9000: From X-9001 pin 46

To X-9001 pin 47

Value There should be 120 ÎŠ .

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3196 - Open load error of injector in cylinder 2 Context: Hardware errors in the injectors and their respective Engine Control Unit (ECU) A-9000 power stages are investigated within the ECU A-9000. The ECU A-9000 diagnostic procedure uses pattern detection to identify specific errors. When an expected combination of errors is detected, the associated fault occurs. Cause: During cylinder 2 injector Y-9002 evaluation, the pattern for an open circuit was detected. Possible failure modes: 1. Faulty cylinder 2 injector Y-9002 solenoid windings, open circuit. 2. Faulty electrical wiring, broken or disconnected conductor, high side or low side (damaged wiring harness). 3. Fault ECU A-9000, software. Solution: 1. Verify this error code is still present and in an active state. Use the Easy Engine software provided on the Electronic Service Tool (EST) to check the fault status and to perform the cylinder cut-out test. A. If the fault is still present and active, continue with step 2. B. If the fault is no longer present or is in an inactive state, the fault may be intermittent and not currently active. Continue with step 9. 2. Check the integrity of the cylinder 2 injector Y-9002 control circuit. Disconnect the engine harness from the ECU A-9000 at the engine plug connector X-9002 . Use a multimeter to measure the resistance on the engine (EN) harness side: From X-9002 pin 51

To X-9002 pin 75

Value There should be between 0.2 – 0.5 Ω.

A. If there is greater than 0.5 Ω. leave the engine plug connector X-9002 disconnected and continue with Step 3. B. If there is between 0.2 – 0.5 Ω , continue with step 7. 3. Determine location of the open circuit condition. Disconnect the engine cylinder harness from the injector valve cover at connector X-9184-6CYL. Use a multimeter to check for continuity on the engine (EN) harness side: From X-9002 pin 51

To X-9184-6CYL pin 1

Value Should becontinuity

A. If there is continuity, leave both the engine plug connector X-9002 and the injector (valve) cover connector X-9184-6CYL disconnected, then continue with Step 4. B. If there is no continuity, there is an open circuit condition in the engine (EN) harness between connector X-9002 pin 51 and connector X-9184-6CYL pin 1 , wire EN-019. Locate and repair broken conductor. 4. Determine location of the open circuit condition. Use a multimeter to check for continuity on the engine (EN) harness side: From X-9184-6CYL pin 2

To X-9002 pin 75 48149953 12/06/2018

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Value Should becontinuity

Electrical systems - FAULT CODES

A. If there is continuity, continue with step 5. B. If there is no continuity, there is an open circuit condition in the engine (EN) harness between the valve cover connector X-9184-6CYL pin 2 and the engine plug connector X-9002 pin 75, wire EN-020. Locate and repair broken conductor. 5. Determine location of the open circuit condition. Remove the injector (valve) cover and disconnect the injector harness from the Cylinder 2 injector at connector X-9189-6CYL. Use a multimeter to check for continuity in the injector harness: From X-9184-6CYL pin 2

To X-9189-6CYL pin 2

Value Should becontinuity

A. If there is continuity, leave the injector harness connector X-9189-6CYL disconnected from cylinder 2 continue with Step 6. B. If there is no continuity, there is an open circuit condition in the injector harness, between connector X-91846CYL pin 1 and connector X-9189-6CYL pin 2, wire EN-579. Locate and repair broken conductor. 6. Determine location of the open circuit condition. Use a multimeter to measure the resistance, on the injector: From X-9189-6CYL pin 1

To X-9189-6CYL pin 2

Value There should be between 0.2 – 0.5 Ω

A. If there is between 0.2 – 0.5 Ω, there is an open circuit condition in the injector harness between connector X-9189-6CYL pin 1 and connector X-9184-6CYL pin 2, wire EN-578. Locate and repair broken conductor. B. If the resistance is greater than 0.5 Ω, the cylinder 2 injector Y-9002 solenoid coil has failed, replace the injector. 7. Check the ECU A-9000 supply voltage. Disconnect the vehicle interface harness (VE) from the ECU A-9000 at the vehicle plug connector X-9001. Turn the Key switch S-9103 to the ON position. Use a multimeter to check for voltage on the vehicle interface (VE) harness side of the vehicle plug: From X-9001 X-9001 X-9001 X-9001 X-9001

pin pin pin pin pin

1 25 26 49 73

To chassis chassis chassis chassis chassis

ground ground ground ground ground

There There There There There

should should should should should

Value be 12.0 V be 12.0 V be 12.0 V be 12.0 V be 12.0 V

A. If the 12.0 V is present for all five checks, leave the vehicle plug connector X-9001 disconnected and continue with Step 8. B. If the 12.0 V is not present for one or more of the checks, use the appropriate vehicle electrical schematics to locate and repair the failure. 8. Check the ECU A-9000 ground circuits. Place the Key switch S-9103 in the OFF position. Use a multimeter to check for continuity on the vehicle interface (VE) harness side of the vehicle plug: From X-9001 pin 3 X-9001 pin 5 X-9001 pin 28

To chassis ground chassis ground chassis ground

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Value ere should be continuity. ere should be continuity. ere should be continuity.

Electrical systems - FAULT CODES

From X-9001 pin 52 X-9001 pin 75

To chassis ground chassis ground

Value ere should be continuity. ere should be continuity.

A. If there is continuity on all five checks, check the ECU A-9000 for the appropriate software and re-flash, if necessary. B. If there is no continuity for one or more of the checks, use the appropriate vehicle electrical schematics to locate and repair the failure. 9. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3204 - Open load error of injector in cylinder 4 Context: Hardware errors in the injectors and their respective Engine Control Unit (ECU) A-9000 power stages are investigated within the ECU A-9000. The ECU A-9000 diagnostic procedure uses pattern detection to identify specific errors. When an expected combination of errors is detected, the associated fault occurs. Cause: During cylinder 4 injector Y-9004 evaluation, the pattern for an open circuit was detected. Possible failure modes: 1. Faulty cylinder 4 injector Y-9004 solenoid windings, open circuit. 2. Faulty electrical wiring, broken or disconnected conductor, high side or low side (damaged wiring harness). 3. Fault ECU A-9000, software. Solution: 1. Verify this error code is still present and in an active state. Use the Easy Engine software provided on the Electronic Service Tool (EST) to check the fault status and to perform the cylinder cut-out test. A. If the fault is still present and active, continue with step 2. B. If the fault is no longer present or is in an inactive state, the fault may be intermittent and not currently active. Continue with step 9. 2. Check the integrity of the cylinder 4 injector Y-9004 control circuit. Disconnect the engine harness from the ECU A-9000 at the engine plug connector X-9002 . Use a multimeter to measure the resistance on the engine (EN) harness side: From X-9002 pin 27

To X-9002 pin 3

Value There should be between 0.2 – 0.5 Ω.

A. If there is greater than 0.5 Ω. leave the engine plug connector X-9002 disconnected and continue with Step 3. B. If there is between 0.2 – 0.5 Ω , continue with step 7. 3. Determine location of the open circuit condition. Disconnect the engine cylinder harness from the injector (valve) cover at connector X-9185-6CYL . Use a multimeter to check for continuity on the engine (EN) harness side: From X-9002 pin 27

To X-9185-6CYL pin 2

Value Should becontinuity

A. If there is continuity, leave both the engine plug connector X-9002 and the injector (valve) cover connector X-9185-6CYL disconnected, then continue with Step 4. B. If there is no continuity, there is an open circuit condition in the engine (EN) harness between connector X-9002 pin 27 and connector X-9185-6CYL pin 2, wire EN-024. Locate and repair broken conductor. 4. Determine location of the open circuit condition. Use a multimeter to check for continuity on the engine (EN) harness side: From X-9185-6CYL pin 1

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Value Should becontinuity

Electrical systems - FAULT CODES

A. If there is continuity, continue with step 5. B. If there is no continuity, there is an open circuit condition in the engine (EN) harness between the valve cover connector X-9185-6CYL pin 1 and the engine plug connector X-9002 pin 3, wire EN-023. Locate and repair broken conductor. 5. Determine location of the open circuit condition. Remove the injector (valve) cover and disconnect the injector harness from the cylinder 4 injector at connector X-9191-6CYL. Use a multimeter to check for continuity in the injector harness: From X-9191-6CYL pin 1

To X-9185-6CYL pin 2

Value Should becontinuity

A. If there is continuity, leave the injector harness connector X-9191-6CYL disconnected from cylinder 4 continue with Step 6. B. If there is no continuity, there is an open circuit condition in the injector harness, between connector X-91916CYL pin 1and connector, X-9185-6CYL pin 2 wire EN-582. Locate and repair broken conductor. 6. Determine location of the open circuit condition. Use a multimeter to measure the resistance, on the injector: From X-9191-6CYL pin 1

To X-9191-6CYL pin 2

Value There should be between 0.2 – 0.5 Ω

A. If there is between 0.2 – 0.5 Ω, there is an open circuit condition in the injector harness between connector X-9191-6CYL pin 2 and connector X-9185-6CYL pin 1, wire EN-583. Locate and repair broken conductor. B. If the resistance is greater than 0.5 Ω, the cylinder 4 injector Y-9004 solenoid coil has failed, replace the injector. 7. Check the ECU A-9000 supply voltage. Disconnect the vehicle interface harness (VE) from the ECU A-9000 at the vehicle plug connector X-9001. Turn the Key switch S-9103 to the ON position. Use a multimeter to check for voltage on the vehicle interface (VE) harness side of the vehicle plug: From X-9001 X-9001 X-9001 X-9001 X-9001

pin pin pin pin pin

1 25 26 49 73

To chassis chassis chassis chassis chassis

ground ground ground ground ground

There There There There There

should should should should should

Value be 12.0 V be 12.0 V be 12.0 V be 12.0 V be 12.0 V

To chassis ground chassis ground chassis ground

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Value ere should be continuity. ere should be continuity. ere should be continuity.

Electrical systems - FAULT CODES

From X-9001 pin 52 X-9001 pin 75

To chassis ground chassis ground

Value ere should be continuity. ere should be continuity.

A. If there is continuity on all five checks, check the ECU A-9000 for the appropriate software and re-flash, if necessary. B. If there is no continuity for one or more of the checks, use the appropriate vehicle electrical schematics to locate and repair the failure. 9. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3210 - Injection bank 1 short circuit failure (all injectors of the same bank can be affected) Context: Hardware errors in the injectors and their respective Engine Control Unit (ECU) A-9000 power stages are investigated within the ECU A-9000. The injector control scheme also groups the individual injector control circuits into banks. The ECU A-9000 diagnostic procedure uses pattern detection to identify specific injector as well as bank errors. When an expected combination of errors is detected, the associated fault occurs. If a short circuit failure condition exists in bank 1, this fault will occur. Cause: The ECU A-9000 has determined that a short circuit condition exists in injector control bank 1. Possible failure modes: 1. Faulty bank 1 injector circuit wiring, shorted. 2. Faulty bank 1 injector solenoid windings, shorted. 3. Fault ECU A-9000, software. Solution: 1. Check for bank 1 injector fault code. Use the Electronic Service Tool (EST) to check for the presence of DTC 6226 – Short circuit in injector 1 or DTC 6426 – Short circuit error of injector in cylinder 3 or DTC 6626 – Short circuit error of injector in cylinder 2. A. If either DTC 6226 – Short circuit in injector 1 or DTC 6426 – Short circuit error of injector in cylinder 3 or DTC 6626 – Short circuit error of injector in cylinder 2 is present, resolve the relevant fault. Then determine if fault, DTC 7116 – Injection bank 1 short circuit failure (all injectors of the same bank can be affected) is also resolved. B. If neither DTC 6226 – Short circuit in injector 1 or DTC 6426 – Short circuit error of injector in cylinder 3 or DTC 6626 – Short circuit error of injector in cylinder 2 is present, check the ECU A-9000 for the appropriate software and re-flash, if necessary.

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3218 - Injection bank 2 short circuit failure (all injectors of the same bank can be affected) Context: Hardware errors in the injectors and their respective Engine Control Unit (ECU) A-9000 power stages are investigated within the ECU A-9000. The injector control scheme also groups the individual injector control circuits into banks. The ECU A-9000 diagnostic procedure uses pattern detection to identify specific injector as well as bank errors. When an expected combination of errors is detected, the associated fault occurs. If a short circuit failure condition exists in bank 2, this fault will occur. Cause: The ECU A-9000 has determined that a short circuit condition exists in injector control bank 2. Possible failure modes: 1. Faulty bank 2 injector circuit wiring, shorted. 2. Faulty bank 2 injector solenoid windings, shorted. 3. Fault ECU A-9000, software. Solution: 1. Check for bank 2 injector fault code. Use the Electronic Service Tool (EST) to check for the presence of DTC 6326 – Short circuit in injector 5 or DTC 6526 – Short circuit error of injector in cylinder 6 or DTC 6726 – Short circuit error of injector in cylinder 4. A. If either DTC 6326 – Short circuit in injector 5 or DTC 6526 – Short circuit error of injector in cylinder 6 or DTC 6726 – Short circuit error of injector in cylinder 4 is present, resolve the relevant fault. Then determine if fault, DTC 7216 – Injection bank 2 short circuit failure (all injectors of the same bank can be affected) is also resolved. B. If neither DTC 6326 – Short circuit in injector 5 or DTC 6526 – Short circuit error of injector in cylinder 6 or DTC 6726 – Short circuit error of injector in cylinder 4 is present, check the ECU A-9000 for the appropriate software and re-flash, if necessary.

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Electrical systems - FAULT CODES

3230 - ECU internal failure - Injector CY33x component Context: The Electronic Control Unit (ECU) A-9000 performs a diagnostic procedure using pattern detections to identify specific A-9000 errors and triggers the appropriate substitute reaction. If the A-9000 determines an expected combination of errors are detected (measured and reference pattern are matching), this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, escalate an ASIST concern.

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Electrical systems - FAULT CODES

3238 - ECU internal failure Context: The Electronic Control Unit (ECU) A-9000 performs a diagnostic test of the sensor supplies by monitoring the communication between the processor and the voltage supply device. If the A-9000 determines that the communication data is incorrect or data transfer was not successful, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, escalate an ASIST concern.

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3245 - ECU internal failure - Query/response communication errors Context: The Engine Control Unit (ECU) A-9000 monitors internal communications with the power stage controllers over Serial Peripheral Interface (SPI) bus. If no response or erroneous response is detected, the ECU A-9000 will reset and monitor again seven times. If the error is still detected, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, escalate an ASIST concern.

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3252 - ECU internal failure - SPI communication error Context: The Elngine Control Unit (ECU) A-9000 tests the correct functioning of the fuel injection path shut off procedure. During this test, each injection path is shortly activated during ECU A-9000 initialization. If a Serial Peripheral Interface (SPI) communication error is detected during this test, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, escalate an ASIST concern.

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Electrical systems - FAULT CODES

3253 - ECU internal failure - Voltage ratio in ADC monitoring Context: The Engine Control Unit (ECU) A-9000 monitors the efficiency of the Analog to Digital Converter (ADC) using a voltage ratio conversion test. The A-9000 will count each time the voltage ratio is out of the desired range. If the count exceeds 15 times, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, escalate an ASIST concern.

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Electrical systems - FAULT CODES

3255 - ECU internal failure - ADC test Context: The Engine Control Unit (ECU) A-9000 monitors the efficiency of the Analog to Digital Converter (ADC). A fixed test input voltage is sent to and converted by the ADC. The test voltage value must be between 4.73 â&#x20AC;&#x201C; 4.83 V. The A-9000 monitors this test and counts each time the value is not recorded in the specified range. If the counter exceeds 15 times, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, escalate an ASIST concern.

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Electrical systems - FAULT CODES

3263 - CAN C Bus off failure NOTE: Because this fault causes inducement, it is necessary to perform the Engine Restart Counter Reset / Unlock Inducement configuration with the Electronic Service Tool (EST) before you return the machine to service. Context: The Engine Control Unit (ECU) A-9000 is capable of connecting to and communicating on three separate Controller Area Networks (CAN). Proper configuration and monitoring of the three twisted pair configured networks is also a function of the ECU A-9000. CAN Node C Bus is the main engine interface bus. The ECU A-9000 provides a CAN termination resistor for the CAN Node C Bus, internal to the ECU A-9000. If the ECU A-9000 senses that CAN Node C Bus is not functioning properly, this fault will occur. Cause: ECU A-9000 has sensed a “Bus Off” state to be present at CAN Node C. Possible failure modes: 1. Faulty supply voltage or ground, missing. 2. Faulty CAN circuit wiring, open circuit, short to ground, or short circuit. 3. Faulty ECU A-9000, termination resistor or software. Solution: 1. Verify fault is present and in active state. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step2. B. If the fault is no longer present or is in an inactive state, the fault may be intermittent and not currently active. Continue with step 6. 2. Check for other vehicle CAN faults. Use the EST to determine if other engine CAN faults exist. A. If other engine CAN faults do exist, resolve the engine CAN faults, then check to see that DTC 971B – CAN C Bus off failure is also resolved. B. If other engine CAN faults do not exist, continue with step 3. 3. Check the ECU A-9000 supply voltage. Disconnect the vehicle (VE) harness from the ECU A-9000 at connector X-9001. With the keyswitch in the on position, use a multimeter to check for voltage on the vehicle (VE) harness side: From X-9001 X-9001 X-9001 X-9001 X-9001

pin pin pin pin pin

1 25 26 49 73

To chassis chassis chassis chassis chassis

ground ground ground ground ground

Value There should be 12.0 V . There should be 12.0 V . There should be 12.0 V . There should be 12.0 V . There should be 12.0 V .

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From X-9001 X-9001 X-9001 X-9001 X-9001

pin pin pin pin pin

3 5 28 52 75

To chassis chassis chassis chassis chassis

ground ground ground ground ground

Value ere should be continuity. ere should be continuity. ere should be continuity. ere should be continuity. ere should be continuity.

A. If there is continuity on all of the checks, continue with step 5. B. If there is no continuity for one or more of the checks, see the appropriate vehicle service manual and electrical schematics to locate and restore the grounding circuit to the ECU A-9000. 5. Determine the condition of the ECU A-9000 CAN C circuit. Disconnect the Engine (EN) harness from the ECU A-9000 at connector X-9002. With the keyswitch in the off position, use a multimeter to measure the resistance of the CAN connection on the engine (EN) harness side: From X-9002 pin 17 X-9002 pin 17 X-9002 pin 18

To X-9002 pin 18 chassis ground chassis ground

Value There should be 120 ÎŠ . Should no be continuity Should no be continuity

Use a multimeter to measure the resistance of the CAN C termination resistor, internal to the ECU A-9000: From X-9002 pin 17

To X-9002 pin 18

Value There should be 120 ÎŠ .

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Electrical systems - FAULT CODES

3265 - Fuel injection requested during overrun Context: The Electronic Control Unit (ECU) A-9000 monitors for requested fuel injection during over run. If injections are requested during over run, this fault will occur. Cause: Fuel injection has been requested during over run. Possible failure modes: 1. Faulty fuel injectors, leakage. 2. Incorrect injection timing. 3. Faulty Pressure Relief Valve (PRV). 4. Faulty A-9000, software.

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Electrical systems - FAULT CODES

3283 - ECU internal failure - Sensor 5 volt supply 2 Context: The Engine Control Unit (ECU) A-9000 provides three independent 5.0 V voltage supplies for sensors. These voltages are monitored by hardware within the ECU A-9000 to make sure they are within a given range. If sensor supply 2 reference voltage is out of range, this fault will occur.

Cause: The ECU A-9000 sensor supply 2 reference voltage is out of range. Possible failure modes: 1. Faulty fuel filter pressure sensor B-9112 or sensor supply wire. 2. Faulty fan speed sensor B-9103 or sensor supply wire. (if equipped) 3. Faulty fuel filter clogging pressure sensor B-9006 or sensor supply wire. 4. Faulty inlet water pump pressure sensor B-9011 or sensor supply wire. 5. Faulty accelerator pedal position sensor B-9011 or sensor supply wire. (if equipped) 6. Faulty exhaust gas absolute pressure sensor B-9005 or sensor supply wire. (if equipped) Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 4. 2. The ECU A-9000 monitors this fault continuously. Disconnect each connector one at a time, use EST to monitor the status of DTC E32D – ECU internal failure - Sensor 5 volt supply 2. - Pre filter pressure sensor B-9112 connector X-9179 - Fan speed sensor B-9103 connector X-9103 - Pre filter clogging pressure sensor B-9006 connector X-9019 - Inlet water pump pressure sensor B-9011 connector X-9027 - Accelerator pedal position sensor B-9011 connector X-9100 (if equipped) - Exhaust gas absolute pressure sensor B-9005 connector X-9018 A. If either DTC E32D – ECU internal failure - Sensor 5 volt supply 2 is eliminated after a connector disconnection, the relevant component has failed. Replace the relevant component. B. If either DTC E32D – ECU internal failure - Sensor 5 volt supply 2 has not been eliminated after connector disconnection, leave all connectors disconnected and continue to Step 3. 3. Check the all of the supply 2 circuits for a short circuit condition. The must be in the ON position. Use a multimeter to perform the following voltage check: From X-9179 pin 1 X-9103 pin 1

To Chassis GND Chassis GND

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Value There should be between 4.5 – 5.5 V. There should be between 4.5 – 5.5 V.

Electrical systems - FAULT CODES

From X-9019 X-9027 X-9100 X-9018

pin pin pin pin

3 1 2 3

To Chassis Chassis Chassis Chassis

GND GND GND GND

Value There should be between 4.5 – 5.5 V. There should be between 4.5 – 5.5 V. There should be between 4.5 – 5.5 V. There should be between 4.5 – 5.5 V.

A. If any of the circuits are not in the specified range, there is a short circuit condition in the relevant circuit. Locate and repair shorted conductor. B. If all of the circuits are within the specified range, check the A-9000 for the appropriate software and re-flash, if necessary. 4. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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Electrical systems - FAULT CODES

3285 - ECU internal failure - Sensor 5 volt supply 3 Context: The Engine Control Unit (ECU) A-9000 provides three independent 5.0 V voltage supplies for sensors. These voltages are monitored by hardware within the A-9000 to make sure they are within a given range. If sensor supply 3 reference voltage is out of range, this fault will occur.

Cause: The A-9000 sensor supply 3 reference voltage is out of range. Possible failure modes: 1. Faulty Intake air humidity and ambient temperature sensor B-9105 or sensor supply wire. 2. Faulty rail pressure sensor B-9004 or sensor supply wire. 3. Faulty secondary cooling system outlet intercooler temperature and pressure sensor B-9012 or sensor supply wire. (if equipped) 4. Faulty A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 4. 2. The A-9000 monitors this fault continuously. Disconnect each connector one at a time, use EST to monitor the status of DTC E42D – ECU internal failure - Sensor 5 volt supply 3. Intake air humidity and ambient temperature sensor B-9105 connector X-9105 Rail pressure sensor B-9004 connector X-9026 Outlet intercooler temperature and pressure sensor B-9012 connector X-9028 A. If either DTC E42D – ECU internal failure - Sensor 5 volt supply 3 is eliminated after a connector disconnection, the relevant component has failed. Replace the relevant component. B. If either DTC E42D – ECU internal failure - Sensor 5 volt supply 3 has not been eliminated after connector disconnection, leave all connectors disconnected and continue to Step 3. 3. Check the all of the supply 3 circuits for a short circuit condition. The must be in the ON position. Use a multimeter to perform the following voltage check: From X-9105 pin 1 X-9026 pin 3 X-9028 pin 3

To Chassis GND Chassis GND Chassis GND

Value There should be between 4.5 – 5.5 V. There should be between 4.5 – 5.5 V. There should be between 4.5 – 5.5 V.

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4. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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Electrical systems - FAULT CODES

3293 - Fuel pressure has exceeded maximum positive deviation limits Context: The Electronic Control Unit (ECU) A-9000 monitors fuel pressure control. Fuel pressure is controlled by the fuel metering unit Y-9000. If the A-9000 determines that rail pressure is lower than expected based on engine speed dependant threshold, fuel rail pressure has exceeded maximum positive deviation limits and this fault will occur. Cause: The A-9000 has determined that measured rail pressure is lower than the commanded pressure according to engine speed dependant threshold. Possible failure modes: 1. Faulty fuel injectors, leaking. 2. Faulty Pressure Relief Valve (PRV), leaking. 3. Faulty fuel metering unit Y-9000. 4. Faulty high pressure pump. 5. Faulty fuel filter, clogged. 6. Faulty low pressure fuel lines, air entrance, clogged or damaged. 7. Faulty electric fuel pump. (if equipped) 8. Faulty low pressure gear pump.

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Electrical systems - FAULT CODES

3301 - Fuel rail pressure has exceeded maximum negative deviation limits Context: The Electronic Control Unit (ECU) A-9000 monitors fuel pressure control. Fuel pressure is controlled by the fuel metering unit Y-9000. If the A-9000 determines that desired fuel pressure has been exceeded although the Y-9000 is fully closed, fuel rail pressure has exceeded maximum deviation limits and this fault will occur. Cause: The A-9000 has determined that desired fuel pressure has been reached despite the Y-9000 being closed. Possible failure modes: 1. Faulty, Y-9007, internal failure.. 2. Faulty Y-9007, wiring. 3. Faulty gear pump pressure. 4. Faulty low pressure fuel lines from high pressure pump to tank, clogged or damaged. Solution: 1. Check for the following related faults: DTC 5255 – Fuel metering unit has an open load error DTC 4155 – Fuel metering unit intermittent electrical connection failure DTC 8355 – Fuel metering unit has an over-temperature error A. If any of the related faults are active, diagnose them first and then return to this fault, DTC 1565 – Fuel rail pressure has exceeded maximum negative deviation limits. B. If none of the related faults are active, continue with step 2. 2. Check the low pressure fuel lines from high pressure pump to tank for damage or clogging. Also check for proper gear pump pressure. A. If the lines show damage or signs of clogging, there may be blockage that is not allowing excess fuel to be returned to the fuel tank. If gear pump pressure is excessive, a fuel rail pressure maximum negative deviation condition may be present. Repair the fuel system as necessary. B. If the lines are free of damage, clogging and the gear pump pressure is within the specified range, check the ECU A-9000 for the appropriate software and re-flash, if necessary.

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Electrical systems - FAULT CODES

3305 - Fuel rail pressure has dropped below the minimum limit Context: The Electronic Control Unit (ECU) A-9000 monitors the fuel rail pressure sensor B-9004 for the appropriate fuel pressure. If the ECU A-9000 determines that fuel pressure is less than the necessary pressure needed to perform fuel injection, this fault will occur. Cause: The ECU A-9000 has detected a fuel pressure less than 200.0 bar (2900.0 psi). Possible failure modes: 1. Faulty injectors, internal leakage or stuck open. 2. Faulty fuel metering unit Y-9000, wiring or internal failure. 3. Faulty high pressure pump. 4. Faulty fuel filter, clogged. 5. Faulty Pressure Relief Valve (PRV), leaking or stuck open. 6. Faulty electric lift pump. (if equipped) 7. Faulty gear pump pressure, too low. 8. Faulty A-9000, software.

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Electrical systems - FAULT CODES

3309 - Fuel rail pressure has exceeded maximum limit Context: The Electronic Control Unit (ECU) A-9000 monitors the fuel rail pressure sensor B-9004 for proper fuel pressure. If the ECU A-9000 determines that fuel pressure is greater than 2000 bar (29000 psi), this fault will occur. Cause: The ECU A-9000 has detected a fuel pressure greater than 2000 bar (29000 psi) for a period greater than 1 s. Possible failure modes: 1. Faulty Y-9000 wiring, open circuit condition. 2. Faulty, Y-9000, internal failure.. 3. Faulty fuel return line, damaged or clogged. 4. Faulty A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 5. 2. Check for the following possible related fault: DTC 5255 – Fuel metering unit has an open load error A. If the faults is active, troubleshoot it first and then return to this fault, DTC 1865 – Fuel rail pressure has exceeded maximum limit. B. Is the fault is not active, continue with step 3. 3. Check the Y-9000 for an internal failure. Disconnect connector X-9007. Use a multimeter to perform the following resistance check: From X-9007 pin 1

To X-9007 pin 2

Value There should be between 2.8 – 3.2 Ω.

A. If the value is within the specified range, continue with step 4. B. If the value is not within the specified range, the Y-9007 has failed internally. Replace the Y-9007. 4. Inspect the high pressure pump fuel return line for damage or blockage. A. If there is damage or blockage, repair the fuel line as necessary. B. If the fuel lines do not have any blockage or damage, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 5. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. 48149953 12/06/2018

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B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3334 - CAN communication failure between vehicle controller and ECU controller - TSC1_PE message Context: The Engine Control Unit (ECU) A-9000 is capable of connecting to and communicating on three separate Controller Area Networks (CAN). Proper configuration and monitoring of the three twisted pair configured networks is also a function of the ECU A-9000. CAN Node A Bus is the main vehicle interface bus. The ECU A-9000 provides a CAN termination resistor for the CAN Node A Bus, internal to the ECU A-9000. The ECU A-9000 receives and responds to Power take-off to Engine controller (PE) information at two different rates (active and passive) dependant upon change request status. If the ECU A-9000 is not sensing the PE message at the passive rate, this fault will occur. Cause: The ECU A-9000 is not properly sensing the PE message. Possible failure modes: 1. Faulty vehicle system, related CAN fault. 2. Faulty supply voltage or ground, missing. 3. Faulty CAN circuit wiring, open circuit, short to ground, or short circuit. 4. Faulty ECU A-9000, termination resistor or software. Solution: 1. Verify fault is present and in active state. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step2. B. If the fault is no longer present or is in an inactive state, the fault may be intermittent and not currently active. Continue with step 6. 2. Check for related vehicle CAN faults. Use the EST to determine if vehicle CAN faults exist. A. If related vehicle CAN faults do exist, resolve the vehicle CAN faults, then check to see that DTC 99BB â&#x20AC;&#x201C; CAN communication failure between vehicle controller and ECU controller - TSC1_PE message is also resolved. B. If related vehicle CAN faults do not exist, continue with step 3. 3. Check the ECU A-9000 supply voltage. Disconnect the vehicle (VE) harness from the ECU A-9000 at connector X-9001. With the keyswitch in the on position, use a multimeter to check for voltage on the vehicle (VE) harness side: From X-9001 X-9001 X-9001 X-9001 X-9001

pin pin pin pin pin

1 25 26 49 73

To chassis chassis chassis chassis chassis

ground ground ground ground ground

Value There should be 12.0 V . There should be 12.0 V . There should be 12.0 V . There should be 12.0 V . There should be 12.0 V .

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With the keyswitch in the off position, use a multimeter to check for continuity on the vehicle (VE) harness side: From X-9001 X-9001 X-9001 X-9001 X-9001

pin pin pin pin pin

3 5 28 52 75

To chassis chassis chassis chassis chassis

ground ground ground ground ground

Value ere should be continuity. ere should be continuity. ere should be continuity. ere should be continuity. ere should be continuity.

To X-9001 pin 47 chassis ground chassis ground

Value There should be 120 ÎŠ . Should no be continuity Should no be continuity

Use a multimeter to measure the resistance of the CAN termination resistor, internal to the ECU A-9000: From X-9001 pin 46

To X-9001 pin 47

Value There should be 120 ÎŠ .

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3338 - CAN communication failure between vehicle controller and ECU controller - TSC1_VE message Context: The Engine Control Unit (ECU) A-9000 is capable of connecting to and communicating on three separate Controller Area Networks (CAN). Proper configuration and monitoring of the three twisted pair configured networks is also a function of the ECU A-9000. CAN Node A Bus is the main vehicle interface bus. The ECU A-9000 provides a CAN termination resistor for the CAN Node A Bus, internal to the ECU A-9000. The ECU A-9000 receives and responds to Torque/Speed Control (TSC) information at two different rates (active and passive) dependant upon change request status. If the ECU A-9000 is not sensing the TSC message at the active rate, this fault will occur. Cause: The ECU A-9000 is not properly sensing the TSC message. Possible failure modes: 1. Faulty vehicle system, related CAN fault. 2. Faulty supply voltage or ground, missing. 3. Faulty CAN circuit wiring, open circuit, short to ground, or short circuit. 4. Faulty ECU A-9000, termination resistor or software. Solution: 1. Verify fault is present and in active state. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step2. B. If the fault is no longer present or is in an inactive state, the fault may be intermittent and not currently active. Continue with step 6. 2. Check for related vehicle CAN faults. Use the EST to determine if vehicle CAN faults exist. A. If related vehicle CAN faults do exist, resolve the vehicle CAN faults, then check to see that DTC 91CB â&#x20AC;&#x201C; CAN communication failure between vehicle controller and ECU controller - TSC1_VE message is also resolved. B. If related vehicle CAN faults do not exist, continue with step 3. 3. Check the ECU A-9000 supply voltage. Disconnect the vehicle (VE) harness from the ECU A-9000 at connector X-9001. With the keyswitch in the on position, use a multimeter to check for voltage on the vehicle (VE) harness side: From X-9001 X-9001 X-9001 X-9001 X-9001

pin pin pin pin pin

1 25 26 49 73

To chassis chassis chassis chassis chassis

ground ground ground ground ground

Value There should be 12.0 V . There should be 12.0 V . There should be 12.0 V . There should be 12.0 V . There should be 12.0 V .

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With the keyswitch in the off position, use a multimeter to check for continuity on the vehicle (VE) harness side: From X-9001 X-9001 X-9001 X-9001 X-9001

pin pin pin pin pin

3 5 28 52 75

To chassis chassis chassis chassis chassis

ground ground ground ground ground

Value ere should be continuity. ere should be continuity. ere should be continuity. ere should be continuity. ere should be continuity.

To X-9001 pin 47 chassis ground chassis ground

Value There should be 120 ÎŠ . Should no be continuity Should no be continuity

Use a multimeter to measure the resistance of the CAN termination resistor, internal to the ECU A-9000: From X-9001 pin 46

To X-9001 pin 47

Value There should be 120 ÎŠ .

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3361 - There was an error during Write/Read EEPROM operation Context: The Engine Control Unit (ECU) A-9000 has the capability of reading and writing values to flash or Electrically Erasable Programmable Read Only Memory (EEPROM). The ECU A-9000 monitors the reading and writing capability of this function. If the ECU A-9000 determines that calibrated parameters for baud rate cannot be read from EEPROM during this monitoring, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, escalate an ASIST concern.

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3362 - ECU internal failure - Fuel calibration Context: The Electronic Control Unit (ECU) A-9000 monitors the conversion from fuel quantity to torque for consistency during A-9000 initialization. If a calibration error is detected during this test, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, escalate an ASIST concern.

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3368 - Torque limitation caused by performance limiter Context: This failure path is only for information. There was a performance limitation which was caused by too high NOx emissions for longer than 60 s. If there is a power reduction greater than 15% or an engine speed limitation is greater than 5% a fault is stored as confirmation that there was an active performance limitation. This failure is a confirmation of the temporary power limitation. This failure does not ask for any action except, to check if another failure concerning NOx emission is present in the failure memory. No actions are necessary due to this failure alone. If power reduction occurred due to an actual defect, the failure triggering the torque limitation should also be in the failure memory. Follow troubleshooting of the actual defect.

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3370 - Strong torque limitation from engine protection active Context: The engine is protected against too high air intake gas temperature (VGT protection), too high coolant temperature, too high oil temperature, and too high fuel temperature by reducing the torque. If one of the temperatures exceeds the dedicated limit established by parameters programmed within the Engine Control Unit (ECU) A-9000. If a power reduction is greater than 15.00% or an engine speed limitation is greater than 5.00% for more than 120.00 s, a failure is stored as confirmation that there was an active performance limitation. This is not caused by a failure of a component or system, but by an extreme working condition. This failure is a confirmation of a temporary power limitation. This failure does not ask for any action except, to check if other failures concerning the engine protection/engine speed are present in the failure memory. No actions are necessary due to this failure alone. If power reduction occurred due to actual defect, the failure triggering the torque limitation should also be in the failure memory. Follow troubleshooting of the actual defect. Cause: One or more of the following failure modes may be the reason for the occurrence of this fault. Possible failure modes: 1. Oil temperature 2. Coolant temperature 3. Fuel temperature 4. Intake air temperature

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3371 - Strong torque limitation from injection system active Context: This fault has set due to a performance limitation to protect the high pressure fuel pump from high temperatures. If there was a power reduction greater than 15.00% or an engine speed limitation greater than 5.00% for more than 120.00 s, a fault code was stored. This is not caused by a failure of a component or system. This fault code is for information only and does not require any further action. If other fault codes are present that could influence the high pressure fuel pump temperatures, those faults could pinpoint an actual failure. Follow the troubleshooting procedure for the other fault. Cause: One or more of the following failure modes may be the reason for the occurrence of this fault. Possible failure modes: 1. Dirty cooling package 2. Low Fuel Level 3. High pressure leak 4. Ambient conditions 5. Fuel tank location relative to heat source (overheated hydraulic tank, for example)

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3425 - Under boost failure Context: The Electronic Control Unit (ECU) A-9000 monitors boost pressure using the intake boost pressure sensor B-9001. If the A-9000 determines that boost pressure is lower than expected based on engine speed and ambient pressure. Cause: Boost pressure is lower than expected. Possible failure modes: 1. Operating in extreme environmental ambient pressures. 2. Boost leakage. 3. Restricted air filter. 4. Electronic Variable Geometric Turbocharger (EVGT) actuator sticking or blocked. (If equipped) 5. EVGT linkage disconnected or damaged. (If equipped) 6. Faulty turbocharger wastegate or linkage. (If equipped) 7. Faulty B-9001, wiring or internal failure. 8. Faulty A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 7. 2. Use the EST to check for the following related faults: DTC 1D64 â&#x20AC;&#x201C; Intake manifold pressure sensor voltage is higher than expected A. If the faults is active, troubleshoot it first and then return to this fault, DTC 1438 â&#x20AC;&#x201C; Under boost failure. B. Is the fault is not active, continue with step 3. 3. Visually inspect the Electronic Variable Geometric Turbocharger (EVGT) actuation (If equipped). Verify that the EVGT mechanism and linkage is properly attached and is not restricted or blocked in any way. Visually inspect the turbocharger wastegate (If equipped). Verify that the linkage is not damaged or disconnected. Verify that the machine is not being operated in extreme ambient pressure condition which may have triggered this fault to occur. Check for any boost leaks. Check the air filter and air induction system for any clogging or blockage. A. If any failures are found, repair as necessary. B. If no faults are found, continue with step 4. 4. Check the B-9001 wiring. Disconnect connector X-9002. Disconnect connector X-9003. The key must be in the OFF position for continuity and ON position for voltage. 48149953 12/06/2018

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Use a multimeter to perform the following wiring checks: From X-9002 X-9002 X-9002 X-9002 X-9002 X-9002

pin pin pin pin pin pin

86 86 86 86 86 86

To X-9003 pin 4 X-9002 pin 7 X-9002 pin 90 All other pins Chassis GND Chassis GND

Value ere should be continuity. ere should be no continuity. ere should be no continuity. ere should be no continuity. ere should be no continuity. There should be no voltage..

A. If the specified values are measured, continue with step 5. B. If the specified values are not measured, Locate and repair the failed conductor. 5. Replace the B-9001. Use the EST to verify that the status of this fault, DTC 1438 â&#x20AC;&#x201C; Under boost failure. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, continue with step 6. 6. Replace turbocharger wastegate (if equipped) or replace EVGT (if equipped). Use the EST to verify that the status of this fault, DTC 1438 â&#x20AC;&#x201C; Under boost failure. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 7. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3443 - Torque limitation due to excessive coolant temperature Context: This failure path is only for information. There was an active performance limitation due to high coolant temperature with a duration longer than 50.0 ms. This failure does not require any other action except to check if other failures concerning the cooling system are present in the failure memory. If a failure is present, follow the troubleshooting procedure for that fault. Cause: One or more of the following failure modes may be the reason for the occurrence of this fault. Possible failure modes: 1.

Radiator plugged

Coolant leak

Water pump or coolant flow issue

Fan drive issue

Coolant Level Low

Air in coolant

Thermostat stuck closed

Leakage in cylinder head gasket

Extreme environmental conditions

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3444 - Torque limitation due to excessive exhaust gas temperature Context: This failure path is only for information. There was an active performance limitation due to high exhaust gas temperature which was not caused by the failure of a component or system, but an extreme working condition with a duration longer than 3.00 s. This failure confirms there was a temporary torque limitation present. This failure does not require any other action except to check if another failure influencing exhaust system temperature is present in the failure memory. If another failure is present, follow the troubleshooting procedure for that fault. Cause: One or more of the following failure modes may be the reason for the occurrence of this fault. Possible failure modes: 1. Excessive hydrocarbons (oil and fuel) 2. Plugging of DOC (Diesel Oxidation Catalyst) 3. Boost leak 4. High altitude operation 5. Stuck exhaust flap 6. Clogged air fltr 7. Extreme environmental conditions

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3445 - Torque limitation due to excessive fuel temperature Context: This failure path is only for information. There was an active performance limitation due to high fuel temperature with a duration longer than 50.0 ms. This failure confirms there was a temporary torque limitation present. This failure does not require any action except to check if another failure that influences fuel temperature is present in the failure memory. No actions are necessary due to this failure alone. If another failure is present, follow the troubleshooting procedure for that fault. Cause: One or more of the following failure modes may be the reason for the occurrence of this fault. Possible failure modes: 1. Low fuel 2. Fuel cooler, if equipped 3. Internal high pressure fuel leak 4. Fuel filter heat, if equipped, stuck on 5. Fuel system air leak 6. Extreme environmental conditions

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3446 - Torque limitation due to excessive intake air temperature Context: This failure path is only for information, that there was an active performance limitation due to high air intake temperature with a duration longer than 50.0 ms. This failure does not ask for any action except, to check if other failures influencing air intake temperature are present in the failure memory. No actions are necessary due to this failure alone. If power reduction occurred due to actual defect, the failure triggering the torque limitation should also be in the failure memory. Follow troubleshooting of the actual defect. Cause: One or more of the following failure modes may be the reason for the occurrence of this fault. Possible failure modes: 1.

Radiator plugged

Coolant leak

Fan drive issue

Air filter issue

Aspirator, if equipped, issue

Exhaust leak before turbo, if equipped

Air intake leak

Coolant Level Low

Air in coolant

10. EGR, if equipped, stuck 11. Thermostat stuck closed 12. Plugged charged air cooler 13. Extreme environmental conditions

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3447 - Torque limitation due to excessive oil temperature Context: This failure path is only for information, that there was an active performance limitation due to high oil temperature, which was not caused by a failure, but an extreme working condition, with a duration longer than 50.0 ms. This failure is thought to have a confirmation in case of a temporary power lack. This failure does not ask for any action except, to check if other failures which could influence oil temperature are present in the failure memory. No actions are necessary due to this failure alone. If power reduction occurred due to actual defect, the failure triggering the torque limitation should also be in the failure memory. Follow troubleshooting of the actual defect. Cause: One or more of the following failure modes may be the reason for the occurrence of this fault. Possible failure modes: 1. Oil cooler issue 2. Coolant Temperature high 3. Oil Level Low 4. Oil dilution (with fuel, coolant or hydraulic oil) 5. Extreme environmental conditions

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3448 - Torque limitation due to turbocharger protection after start Context: This failure path is only for information, that there was an active performance limitation due to turbocharger protection after start, which was not caused by a failure, but an extreme working condition, with a duration longer than 50.0 ms. This failure is thought to have a confirmation in case of a temporary power lack. This failure does not ask for any action except, to check if other failures which could influence turbocharger protection are present in the failure memory. No actions are necessary due to this failure alone. If power reduction occurred due to actual defect, the failure triggering the torque limitation should also be in the failure memory. Follow troubleshooting of the actual defect. Turbocharger protection after start is a functionality which should prevent stress to the turbo until lubrication is optimal after engine start. Cause: One or more of the following failure modes may be the reason for the occurrence of this fault. Possible failure modes: 1. Hot engine soak 2. Boost too high 3. Turbine over speed 4. High altitude operation 5. Excessive fueling 6. Injector issue 7. Waste gate stuck, if equipped

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3449 - ECU internal failure - Calculated engine speed Context: The Electronic Control Unit (ECU) A-9000 monitors engine speed using two software monitoring levels. Level one monitoring monitors engine control and components. Level two monitors for defective processes in level one monitoring. If the A-9000 determines that there is a difference greater than 320.00 RPM between the two monitoring levels, a calibration error is assumed and this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, escalate an ASIST concern.

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3458 - Crankcase pressure too high Context: The Electronic Control Unit (ECU) A-9000 monitors crankcase pressure by the crankcase pressure sensor B-9009. If the A-9000 determines that crankcase pressure is too high, this fault will occur. Cause: Crankcase pressure is too high. Possible failure modes: 1. Faulty B-9009, wiring or internal failure. 2. Faulty engine oil level, too high. 3. Faulty blow by filter, clogged. 4. Faulty Positive Crankcase Ventilation (PCV) valve. 5. Faulty piston rings. 6. Faulty A-9000, software. Solution: 1. The following faults may have caused this fault to occur. Use the Electronic Service Tool (EST) to verify the status of these faults and diagnose first if necessary. DTC 13A3 â&#x20AC;&#x201C; Crankcase pressure sensor voltage is higher than expected

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3459 - Oil temperature too high Context: The Electronic Control Unit (ECU) A-9000 monitors oil temperature by the oil temperature sensor B-9000. The value is processed by the analog to digital converter, internal to the A-9000, into a physical oil temperature value. If the A-9000 determines that the oil temperature value is too high, this fault will occur. Cause: The A-9000 has detected an oil temperature value greater than 174.96 Â°C. Possible failure modes: 1. Faulty B-9000, implausible value. 2. Faulty A-9000, software. Solution: 1. Replace the B-9000. Use the Electronic Service Tool (EST) to verify the status of DTC 1BD3 â&#x20AC;&#x201C; Oil temperature too high. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary.

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3460 - Oil temperature too low Context: The Electronic Control Unit (ECU) A-9000 monitors oil temperature by the oil temperature sensor B-9000. The value is processed by the analog to digital converter, internal to the A-9000, into a physical oil temperature value. If the A-9000 determines that the oil temperature value is too low, this fault will occur. Cause: The A-9000 has detected an oil temperature value less than -35.04 Â°C. Possible failure modes: 1. Extreme ambient operating temperatures. 2. Faulty B-9000, implausible value. 3. Faulty A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 4. 2. Check the B-9000 temperature signal circuit for a short to ground condition. Disconnect connector X-9004. Disconnect connector X-9002 from the A-9000. The key must be at the OFF position. Use a multimeter to perform the following continuity check: From X-9002 pin 13 X-9002 pin 13 X-9002 pin 13

To Chassis GND X-9002 pin 6 All other pins

Value ere should be no continuity. ere should be no continuity. ere should be no continuity.

A. If there is continuity, there is a short to ground in the B-9000 temperature signal circuit, wire EN-009. Locate and repair shorted conductor. B. If there no continuity, continue with step 3. 3. Replace the B-9000. Use the Electronic Service Tool (EST) to verify the status of DTC 2CD3 â&#x20AC;&#x201C; Oil temperature too low. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 4. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

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B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3461 - ECU internal failure - Timeout in the shut off path test error Context: The Engine Control Unit (ECU) A-9000 performs shut off paths which deactivate all power stages relevant to fuel injection if certain internal ECU A-9000 errors are detected. In order to test this function, every path is shortly activated during ECU A-9000 initialization. Since the shut off is active, no fuel injection should occur during this test. If a time-out error in the power stage feedback is detected during this test, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, escalate an ASIST concern.

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3462 - ECU internal failure - Overvoltage monitoring error Context: The Engine Control Unit (ECU) A-9000 performs shut off paths which deactivate all power stages relevant to fuel injection if certain internal ECU A-9000 errors are detected. In order to test this function, every path is shortly activated during ECU A-9000 initialization. Since the shut off is active, no fuel injection should occur during this test. If a voltage higher than expected condition is detected during this test, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, escalate an ASIST concern.

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3475 - CAN timeout error from coolant water pump actuator Context: The Electric water pump A-9105 controller is required to report information at regular intervals to the Engine Control Unit (ECU) A-9000 via Controller Area Network (CAN). If this information is not communicated within the allotted time frame, this ECU A-9000 timeout fault will occur. Cause: The ECU A-9000 has reported, via the engine sensor CAN bus, that an Electric water pump A-9105 controller timeout has occurred. Possible failure modes: 1. Faulty supply voltage, out of required range. 2. Faulty CAN wiring, open or short circuit. 3. Faulty Electric water pump A-9105 controller, hardware or firmware. 4. Fault ECU A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 6. 2. Check for Electric water pump A-9105 controller supply voltage. Disconnect the VE harness from the Electric water pump A-9105 actuator controller at connector X-9126. Use a multimeter to check for voltage on the EN harness side: From X-9126 pin 4 X-9126 pin 3

To X-9126 pin 2 X-9126 pin 2

Value There should be 12.0 V . There should be 12.0 V .

A. If the voltage is present, continue with step 3. B. If the voltage is not present, continue with step 4. 3. Determine the condition of the Electric water pump A-9105 controller CAN circuit. Disconnect the VE harness from the Electric water pump A-9105 actuator controller at connector X-9126. Use a multimeter to measure the resistance of the CAN connection on the VE harness side: From X-9126 pin 1

To X-9126 pin 6

Value There should be 60 ÎŠ .

A. If the measured resistance is correct, continue with step 5. B. If the measured resistance is not correct, continue with step 4. 4. Check for other engine Selective Catalytic Reduction (SCR) CAN faults. Use EST to determine if other SCR CAN faults exist. A. If other faults do exist, see Fuse and controller power relay - Testing Auxiliary relay (55.640), for supply power and ground, or see the appropriate vehicle service manual, for CAN, to locate and repair the faulted condition. 48149953 12/06/2018

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B. If no other faults exist, the VE harness wiring is damaged between the power, ground, or network harness splice and the Electric water pump A-9105 controller connector X-9126 pin 3, X-9126 pin 4 and/or X-9126 pin 2, wire VEâ&#x20AC;&#x201C;216, VE-220 and/or VE-190A, for supply power and ground or X-9126 pin 1 and/or X-9126 pin 6, wire VE-210E and/or VE-194 for CAN signal. Locate and repair the damage to the SCR CAN circuit wiring. 5. As there is no method for field testing or re-flashing the Electric water pump A-9105 controller, replace the Electric water pump A-9105 unit. Then check to see if the fault is resolved. A. If this fault is resolved, then return the machine to service. B. If this fault is not resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 6. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3501 - ECU internal failure - Software resets in DSM 0 Context: The Engine Control Unit (ECU) A-9000 monitors for a possible error to the ECU A-9000 internal software. If the ECU A-9000 detects a software failure, a software reset will be performed and this fault will occur. During a software reset, all instrument panel lights could flash (power on test) and the instruments could shortly read zero. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, escalate an ASIST concern.

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3502 - ECU internal failure - Software resets in DSM 1 Context: The Electronic Control Unit (ECU) A-9000 monitors for a possible error to the A-9000 internal software. If the A-9000 detects a software failure, a software reset will be performed and this fault will occur. During a software reset, all instrument panel lights could flash (power on test) and the instruments could shortly read zero. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 7. 2. Check battery voltage. Use a multimeter to perform the following voltage check: From Battery (+) terminal

To Battery (â&#x20AC;&#x201C;) terminal

Value There should approximately 12 V

A. If there is not approximately 12 V, Charge the battery, then, perform a load test on the battery. If the battery passes the load test, continue to Step 3. If the battery fails the load test, continue to Step 5. B. If there is approximately 12 V, continue with step 3. 3. Check the voltage supply to the A-9000. Disconnect connector X-9001. The ignition switch must be in the ON position for voltage and OFF position for continuity. Use a multimeter to perform the following wiring checks: From X-9001 X-9001 X-9001 X-9001 X-9001 X-9001 X-9001 X-9001 X-9001 X-9001

pin pin pin pin pin pin pin pin pin pin

73 49 25 1 26 3 28 75 5 52

To Chassis Chassis Chassis Chassis Chassis Chassis Chassis Chassis Chassis Chassis

GND GND GND GND GND GND GND GND GND GND

Value There should approximately 12 V There should approximately 12 V There should approximately 12 V There should approximately 12 V There should approximately 12 V ere should be continuity. ere should be continuity. ere should be continuity. ere should be continuity. ere should be continuity.

A. If the specified values are measured, continue with step 4. B. If the specified values are not measured, there is a failure in the A-9000 supply wiring. Locate and repair the failed conductor. 4. Check the charging system for proper operation. A. If the charging system is not functioning properly, repair the charging system as necessary. B. If the charging system is functioning properly, continue with step 5. 5. Replace the battery.

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Use the Electronic Service Tool (EST) to verify the status of this fault, DTC 2461 â&#x20AC;&#x201C; Battery voltage is lower than expected. A. If the fault has been resolved, perform a parasitic draw test to measure excessive current draw from the battery. If an excessive draw is found, locate and repair as necessary and then return the machine to service.. B. If the fault has been not resolved, continue with step 6. 6. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, escalate an ASIST concern. 7. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3508 - Torque limitation active Context: This failure path is only for information, that there was an active performance limitation. One or more torque reductions are present. No actions are necessary due to this failure alone. If power reduction occurred due to actual defect, the failure triggering the torque limitation should also be in the failure memory. Follow troubleshooting of the actual defect.

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3517 - Ambient temperature sensor voltage is higher than expected Context: The Electronic Control Unit (ECU) A-9000 monitors the intake air temperature sensor B-9105 for a short to high source or open circuit condition. If the A-9000 determines that a short to high source or open circuit condition is present in the B-9105 temperature signal circuit, this fault will occur. Cause: The A-9000 has detected a voltage greater than 4.95 V for longer than 500 ms in the B-9105 temperature signal circuit. Possible failure modes: 1. Faulty B-9105 temperature signal wire, shorted to a high source or open circuit. 2. Faulty, B-9105, internal failure.. 3. Faulty A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 6. 2. Check the B-9105 temperature signal circuit for an open circuit condition. Disconnect connector X-9105. Disconnect connector X-9001 from the A-9000. The key must be at the OFF position. Use a multimeter to perform the following continuity check: From X-9001 pin 40

To X-9105 pin 4

Value ere should be continuity.

A. If there is continuity, leave X-9105 and X-9001 disconnected and continue to Step 3. B. If there is no continuity, there is an open circuit condition in the B-9105 temperature signal circuit, wire VE-103. Locate and repair broken conductor. 3. Check the B-9105 temperature signal circuit for a short to high source condition. The key must be at the OFF position. Use a multimeter to perform the following continuity check: From X-9001 pin 40 X-9001 pin 40

To X-9001 pin 90 All other pins

Value ere should be no continuity. ere should be no continuity.

A. If there is continuity, there is short to high source condition in the B-9105 temperature signal circuit, wire VE-103. Locate and repair shorted conductor. B. If there no continuity, leave the connectors disconnected and continue with Step 4. 4. Check the B-9105 temperature signal circuit for a short to key power condition.

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The must be in the ON position. Use a multimeter to perform the following voltage check: From X-9001 pin 40

To Chassis GND

Value There should be no voltage..

A. If there is voltage, there is a short to key power in the B-9105 temperature signal circuit, wire VE-103. Locate and repair shorted conductor. B. If there is no voltage present, continue with step 5. 5. Replace the B-9105. Use the EST to verify if DTC 19C4 â&#x20AC;&#x201C; Ambient temperature sensor voltage is higher than expected has been resolved. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, check the A-9000 for the appropriate software and re-flash, if necessary. 6. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3518 - Ambient temperature sensor voltage is lower than expected Context: The Electronic Control Unit (ECU) A-9000 monitors the intake air temperature sensor B-9105 signal circuit. If the A-9000 determines that the voltage in the B-9105 temperature signal circuit is lower than expected or if the machine is being operating in extremely low ambient conditions, this fault will occur. If this fault occurs, the ambient temperature value will be frozen by the A-9000 at the last valid value or to a fixed replacement value of 38.96Â° if the failure is validated. Before diagnosing this fault as an electrical failure, verify that this fault is active in normal operating ambient temperatures. Cause: The A-9000 has detected a voltage less than 200 mV for longer than 500 ms in the B-9105 temperature signal circuit. Possible failure modes: 1. Extremely low ambient operating temperatures. 2. Faulty B-9105 temperature signal wire, shorted to ground. 3. Faulty, B-9105, internal failure.. 4. Faulty A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 4. 2. Check the B-9105 temperature signal circuit for a short to ground condition. Disconnect connector X-9105. Disconnect connector X-9001 from the A-9000. The key must be at the OFF position. Use a multimeter to perform the following continuity check: From X-9001 pin 40 X-9001 pin 40

To Chassis GND All other pins

Value ere should be no continuity. ere should be no continuity.

A. If there is continuity, there is short to ground condition in the B-9105 temperature signal circuit, wire VE-103. Locate and repair shorted conductor. B. If there no continuity, continue with step 3. 3. Replace the B-9105. Use the EST to verify if DTC 2AC4 â&#x20AC;&#x201C; Ambient temperature sensor voltage is lower than expected has been resolved. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, check the A-9000 for the appropriate software and re-flash, if necessary. 4. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display.

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3525 - Downstream NOx sensor internal failure (Open Circuit Error) NOTE: Because this fault causes inducement, it is necessary to perform the SCR Fault Repair Verification Test once the fault has been resolved. NOTE: Because this fault causes inducement, it is necessary to perform the Engine Restart Counter Reset / Unlock Inducement configuration with the Electronic Service Tool (EST) before you return the machine to service. Context: The SCR downstream NOx sensor A-9102 has internal monitoring for open wire or short circuit and sends an error status in case of a detected failure. This failure is the result of an open circuit error in the sensor NOx and/or Oxygen level circuit. Cause: The SCR downstream NOx sensor A-9102 has reported, via CAN, to the ECU A-9000 that an open circuit condition exists in the NOx and/or Oxygen level circuit. Possible failure modes: 1. Faulty SCR downstream NOx sensor A-9102, hardware or firmware. 2. Fault ECU A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 3. 2. As there is no method for field testing or re-flashing the sensor controller, replace the SCR downstream NOx sensor A-9102. Then use the EST, see Nitrogen Oxide (NOx) sensor - Configure - Reset ECU data (Downstream sensor) (55.988), if necessary, to perform the Replacement of the Nox Downstream Sensor - Reset ECU Data configuration. Then use the EST, see Selective Catalytic Reduction (SCR) exhaust treatment - Configure - Engine restart counter reset (10.500), if necessary, to perform the Engine Restart Counter Reset / Unlock Inducement configuration. Then perform the SCR fault verification test. See Selective Catalytic Reduction (SCR) exhaust treatment Service instruction - SCR fault repair verification test (10.500), if necessary. Then check to see if the fault is resolved. A. If this fault is resolved, then return the machine to service. B. If this fault is not resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 3. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3526 - Downstream NOx sensor internal failure (Short Circuit Error) NOTE: Because this fault causes inducement, it is necessary to perform the SCR Fault Repair Verification Test once the fault has been resolved. NOTE: Because this fault causes inducement, it is necessary to perform the Engine Restart Counter Reset / Unlock Inducement configuration with the Electronic Service Tool (EST) before you return the machine to service. Context: The SCR downstream NOx sensor A-9102 has internal monitoring for open wire or short circuit and sends an error status in case of a detected failure. This failure is the result of a short circuit error in the sensor NOx and/or Oxygen level circuit. Cause: The SCR downstream NOx sensor A-9102 has reported, via CAN, to the ECU A-9000 that a short circuit condition exists in the NOx and/or Oxygen level circuit. Possible failure modes: 1. Faulty SCR downstream NOx sensor A-9102, hardware or firmware. 2. Fault ECU A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 3. 2. As there is no method for field testing or re-flashing the sensor controller, replace the SCR downstream NOx sensor A-9102. Then use the EST, refer to Nitrogen Oxide (NOx) sensor - Configure - Reset ECU data (Downstream sensor) (55.988), if necessary, to perform the Replacement of Nox Downstream Sensor - Reset ECU Data configuration. Then use the EST, see Selective Catalytic Reduction (SCR) exhaust treatment - Configure - Engine restart counter reset (10.500), if necessary, to perform the Engine Restart Counter Reset / Unlock Inducement configuration. Then perform the SCR fault verification test. See Selective Catalytic Reduction (SCR) exhaust treatment Service instruction - SCR fault repair verification test (10.500), if necessary. Then check to see if the fault is resolved. A. If this fault is resolved, then return the machine to service. B. If this fault is not resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 3. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3528 - Downstream NOx sensor values are not plausible Context: The SCR downstream NOx sensor A-9102 delivers information about its error status and the results of self diagnosis procedure, via CAN, to the Engine Control Unit (ECU) A-9000. If the SCR downstream NOx sensor A-9102 sends the message Lambda or NOx signal not plausible, this fault will occur. Cause: The SCR downstream NOx sensor A-9102 has reported, via CAN, to the ECU A-9000 that the Lambda or NOx signal is not plausible. Possible failure modes: 1. Faulty SCR downstream NOx sensor A-9102, hardware or firmware. Solution: 1. Check for related fault. Use the Electronic Service Tool (EST) to check for fault DTC 2DDA – SCR catalyst efficiency lower than first NOx production threshold levelboom. A. If neither fault DTC 2DDA – SCR catalyst efficiency lower than first NOx production threshold level is present, the SCR downstream NOx sensor A-9102 is poisoned. Replace the SCR downstream NOx sensor A-9102. Then use EST, see Nitrogen Oxide (NOx) sensor - Configure - Reset ECU data (Downstream sensor) (55.988), if necessary, to perform the Replacement of Nox Downstream Sensor - Reset ECU Data configuration. B. If neither fault DTC 2DDA – SCR catalyst efficiency lower than first NOx production threshold level is not present, ignore fault DTC 319E – Downstream NOx sensor values are not plausibleboom.

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3529 - Downstream NOx sensor internal failure (Heater Open Circuit Error) NOTE: Because this fault causes inducement, it is necessary to perform the SCR Fault Repair Verification Test once the fault has been resolved. NOTE: Because this fault causes inducement, it is necessary to perform the Engine Restart Counter Reset / Unlock Inducement configuration with the Electronic Service Tool (EST) before you return the machine to service. Context: The SCR downstream NOx sensor A-9102 has internal monitoring for open wire or short circuit and sends an error status in case of a detected failure. This failure is the result of an open circuit error in the sensor heater circuit. Cause: The SCR downstream NOx sensor A-9102 has reported, via CAN, to the Engine Control Unit (ECU) A-9000 that an open circuit condition exists in the heater control circuit. Possible failure modes: 1. Faulty SCR downstream NOx sensor A-9102, hardware or firmware. 2. Fault ECU A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 3. 2. As there is no method for field testing or re-flashing the sensor controller, replace the SCR downstream NOx sensor A-9102. Then use the EST, see Nitrogen Oxide (NOx) sensor - Configure - Reset ECU data (Downstream sensor) (55.988), if necessary, to perform the Replacement of the Nox Downstream Sensor - Reset ECU Data configuration. Then use the EST, see Selective Catalytic Reduction (SCR) exhaust treatment - Configure - Engine restart counter reset (10.500), if necessary, to perform the Engine Restart Counter Reset / Unlock Inducement configuration. Then perform the SCR fault verification test. See Selective Catalytic Reduction (SCR) exhaust treatment Service instruction - SCR fault repair verification test (10.500), if necessary. Then check to see if the fault is resolved. A. If this fault is resolved, then return the machine to service. B. If this fault is not resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 3. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation. 48149953 12/06/2018

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3530 - Downstream NOx sensor internal failure (Heater Short Circuit Error) NOTE: Because this fault causes inducement, it is necessary to perform the SCR Fault Repair Verification Test once the fault has been resolved. NOTE: Because this fault causes inducement, it is necessary to perform the Engine Restart Counter Reset / Unlock Inducement configuration with the Electronic Service Tool (EST) before you return the machine to service. Context: The SCR downstream NOx sensor A-9102 has internal monitoring for open wire or short circuit and sends an error status in case of a detected failure. This failure is the result of a short circuit error in the sensor heater circuit. Cause: The SCR downstream NOx sensor A-9102 has reported, via CAN, to the Engine Control Unit (ECU) A-9000 that a short circuit condition exists in the heater control circuit. Possible failure modes: 1. Faulty SCR downstream NOx sensor A-9102, hardware or firmware. 2. Fault ECU A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 3. 2. As there is no method for field testing or re-flashing the sensor controller, replace the SCR downstream NOx sensor A-9102. Then use the EST, refer to Nitrogen Oxide (NOx) sensor - Configure - Reset ECU data (Downstream sensor) (55.988), if necessary, to perform the Replacement of Nox Downstream Sensor - Reset ECU Data configuration. Then use the EST, see Selective Catalytic Reduction (SCR) exhaust treatment - Configure - Engine restart counter reset (10.500), if necessary, to perform the Engine Restart Counter Reset / Unlock Inducement configuration. Then perform the SCR fault verification test. See Selective Catalytic Reduction (SCR) exhaust treatment Service instruction - SCR fault repair verification test (10.500), if necessary. Then check to see if the fault is resolved. A. If this fault is resolved, then return the machine to service. B. If this fault is not resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 3. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3531 - Downstream NOx sensor internal failure (Heater Performance Plausibility Error) Context: The SCR downstream NOx sensor A-9102 has internal monitoring and delivers information about its error status and the results of self diagnosis procedure, via CAN, to the Engine Control Unit (ECU) A-9000. One of the monitored conditions is whether or not the SCR downstream NOx sensor A-9102 reached the appropriate operating temperature within the allotted time. Once the dew point has been reached, the sensor has 120.0 s to reach heat up. If the sensor heat up is not completed in time, this fault will occur. Cause: The SCR downstream NOx sensor A-9102 has reported, via CAN, to the ECU A-9000 that the sensor failed to reach heater working temperature in the allotted time. Possible failure modes: 1. Faulty SCR downstream NOx sensor A-9102, hardware or firmware. 2. Fault ECU A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2boom. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 4boom. 2. Check for other relevant faults. Use the EST to check for the presence of fault DTC 478E – Downstream NOx sensor supply voltage is out of range . A. If neither fault DTC 478E – Downstream NOx sensor supply voltage is out of range is present, resolve fault DTC 478E – Downstream NOx sensor supply voltage is out of rangeboom. Then check to see that fault DTC A36E – Downstream NOx sensor internal failure (Heater Performance Plausibility Error) is also resolved. B. If neither fault DTC 478E – Downstream NOx sensor supply voltage is out of range is not present, continue with step 3boom. 3. As there is no method for field testing or re-flashing the sensor controller, replace the SCR downstream NOx sensor A-9102. Then use EST, see Nitrogen Oxide (NOx) sensor - Configure - Reset ECU data (Downstream sensor) (55.988) if necessary, to perform the Replacement of the Nox Downstream Sensor - Reset ECU Data configuration. Run the machine and use the EST capability to view parameters to verify that the sensor has reached dew point. Then check to see if the fault is resolved. A. If this fault is resolved, then return the machine to service. B. If this fault is not resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 4. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display.

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3533 - CAN timeout error from downstream NOx sensor NOTE: Because this fault causes inducement, it is necessary to perform the Engine Restart Counter Reset / Unlock Inducement configuration with the Electronic Service Tool (EST) before you return the machine to service. Context: The Selective Catalytic Reduction (SCR) downstream NOx sensor A-9102 is required to report information at regular intervals to the Engine Control Unit (ECU) A-9000 via CAN. If this information is not communicated within the allotted time frame, this ECU A-9000 timeout fault will occur. Cause: The ECU A-9000 has reported, via the engine sensor CAN bus, that a SCR downstream NOx sensor A-9102 timeout of the SCR downstream NOx sensor A-9102 message has occurred. Possible failure modes: 1. Faulty supply voltage, out of required range. 2. Faulty CAN wiring, open or short circuit. 3. Faulty SCR downstream NOx sensor A-9102, hardware or firmware. 4. Fault ECU A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 6. 2. Check for the presence of supply voltage fault. Use EST to determine the presence of fault DTC 478E – Downstream NOx sensor supply voltage is out of range A. If neither fault DTC 478E – Downstream NOx sensor supply voltage is out of range is present, resolve the DTC 478E – Downstream NOx sensor supply voltage is out of range fault. Then determine if fault DTC 9D6E – CAN timeout error from downstream NOx sensor is also resolved. B. If neither fault DTC 478E – Downstream NOx sensor supply voltage is out of range is not present, continue with step 3. 3. Determine the condition of the SCR downstream NOx sensor A-9102 CAN circuit. Disconnect the vehicle (VE) harness from the SCR downstream NOx sensor A-9102 at connector X-9134. Use a multimeter to measure the resistance of the CAN circuit on the ATS vehicle (VE) harness side: From X-9134 pin 3

To X-9134 pin 4

Value There should be 60 Ω

A. If the measured resistance is correct, continue with step 4. B. If the measured resistance is not correct, continue with step 5. 4. As there is no method for field testing or re-flashing the sensor controller, replace the SCR downstream NOx sensor A-9102. Then use EST to perform the Replacement of NOx Downstream Sensor – Reset ECU Data configuration. Then check to see if the fault is resolved. 48149953 12/06/2018

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A. If this fault is resolved, use EST to perform the Engine Restart Counter Reset/Unlock Inducement configuration. Then return the machine to service. B. If this fault is not resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 5. Check for other engine SCR CAN faults. Use EST to determine if other SCR CAN faults exist. A. If other faults do exist, use the appropriate vehicle service manual and electrical schematics to locate and repair the faulted condition. B. If no other faults exist, the vehicle (VE) harness wiring is damaged between the network harness splice and the SCR downstream NOx sensor A-9102 connector X-9134 pin 3 and/or X-9134 pin 4, wire VE-198 and/or VE-201J. Locate and repair the damage to the CAN circuit wiring. 6. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3549 - Intake air humidity sensor voltage is higher than expected for too long Context: The Electronic Control Unit (ECU) A-9000 monitors the efficiency of the intake air humidity sensor B-9105. The B-9105 is sensitive to water droplets, which can cause a short to high source condition. Normally, the sensor will dry after a few minutes of engine operation. If the A-9000 detects that this fault is still present 8.00 min after engine start, it is assumed that this is a short to high source electrical failure that is not related to water droplets and this fault will occur. Cause: The A-9000 has detected a voltage greater than 3.6 V for a period greater than 500 ms after 8.00 min of engine start. Possible failure modes: 1. Faulty B-9105, wet condition for a period greater than 8.00 min. 2. Faulty, B-9105, internal failure.. 3. Faulty B-9105 humidity signal wire, shorted to power. 4. Faulty A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 4. 2. Check the B-9105 signal circuit for a short to high source condition. Disconnect connector X-9105. Disconnect connector X-9001 from the A-9000. The key must be at the OFF position. Use a multimeter to perform the following continuity check: From X-9001 pin 15 X-9001 pin 15

To X-9001 pin 90 All other pins

Value ere should be no continuity. ere should be no continuity.

A. If there is continuity, there is short to high source condition in the B-9105 signal circuit, wire VE-104. Locate and repair shorted conductor. B. If there no continuity, leave the connectors disconnected and continue with Step 3. 3. Check the signal circuit B-9105 for a short to key power condition. The must be in the ON position. Use a multimeter to perform the following voltage check: X-9001 pin 15

Chassis GND

There should be no voltage..

A. If there is voltage, there is a short to key power condition in the B-9105 signal circuit, wire VE-104. Locate and repair shorted conductor. B. If there is no voltage present, continue with step 4.

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4. Replace the B-9105. Use the EST to verify that the fault has been resolved. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, check the A-9000 for the appropriate software and re-flash, if necessary. 5. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3557 - Intake air humidity sensor voltage is higher than expected Context: The Electronic Control Unit (ECU) A-9000 monitors the voltage of the intake air humidity sensor B-9105 signal circuit. The B-9105 is sensitive to water droplets, which can cause a voltage higher than expected condition. Normally, the sensor will dry after a few minutes of engine operation. Two stage monitoring is conducted to verify if water droplets or an actual electrical failure is the cause of a voltage higher than expected reading by the A-9000. If this fault occurs, the A-9000 has determined that water droplets into the B-9105 is the cause. Cause: The A-9000 has detected a voltage greater than 3.6 V for a period greater than 500 ms after engine start caused by water droplets into the B-9105. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2boom. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 3boom. 2. Check for the following related faults: DTC 1C54 – Intake air humidity sensor voltage is higher than expected for too long A. If the faults is active, troubleshoot it first and then return to this fault, DTC FB54 – Intake air humidity sensor voltage is higher than expectedboom. B. If the fault is not active, the B-9105 is experiencing a temporary short circuit condition due to water droplets into the sensor. This fault should resolve itself after a approximately 8.00 – 10.00 min of engine operation. If the fault remains active after approximately 8.00 – 10.00 min and DTC 1C54 – Intake air humidity sensor voltage is higher than expected for too long does not set, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 3. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3581 - Torque limitation is active NOTE: Since this fault is part of the inducement strategy, it may be necessary to perform the Engine Restart Counter Reset / Unlock Inducement configuration with the Electronic Service Tool (EST) before you return the machine to service, unless this was accomplished as part of the resolution of the fault causing this fault. See Selective Catalytic Reduction (SCR) exhaust treatment - Configure - Engine restart counter reset (10.500), if necessary. Context: This fault is only for informational purposes and requires no action other than the resolution of the active fault causing this fault to occur. Any one of many Selective Catalytic Reduction (SCR) not displayed faults that remains active for an Engine Control Module (ECU) A-9000 predetermined length of time will trigger this fault.

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3616 - Torque limitation due to turbo charger protection Context: The Engine Control Unit (ECU) has detected an active power reduction due to turbo charger protection. This error is for informational purposes and is initiated by a power reduction due to turbo charger protection being active causing a torque limitation greater than 25% of the desired torque for longer than 60 seconds and is reset once the torque limitation due to turbo charger protection is less than 25% of the desired torque over 10 seconds. Though no action is necessary due to this error, if the power reduction occurred due to an actual defect, the error triggering the torque limitation should also be in fault memory. Follow the troubleshooting procedure for that error.

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3623 - Downstream NOx sensor lambda signal deviation - NOx sensor possible removal detected NOTE: Because this fault causes inducement, it is necessary to perform the SCR Fault Repair Verification Test once the fault has been resolved. NOTE: Because this fault causes inducement, it is necessary to perform the Engine Restart Counter Reset / Unlock Inducement configuration with the Electronic Service Tool (EST) before you return the machine to service. Context: The SCR downstream NOx sensor A-9102 has internal monitoring for operating conditions and reports status along with sensed data. If the sensor lambda data value is outside the values established by the minimum/maximum curves specified in the Engine Control Unit (ECU) A-9000, dependent on the lambda value itself, this fault will occur. Cause: The ECU A-9000 has determined that the SCR downstream NOx sensor A-9102 is not measuring correct lambda values. Possible failure modes: 1. Faulty SCR downstream NOx sensor A-9102, hardware or firmware. 2. Fault ECU A-9000, software. Solution: 1. Determine proper installation of the SCR downstream NOx sensor A-9102. Remove and re-install, if necessary, the SCR downstream NOx sensor A-9102 to assure that it is properly aligned and securely installed. Then perform the SCR fault repair verification test. Then check to see if the fault is resolved. A. If this fault is resolved, then return the machine to service. B. If this fault is not resolved, continue with step 2. 2. As there is no method for field testing or re-flashing the sensor controller, replace the SCR downstream NOx sensor A-9102. Then check to see if the fault is resolved. A. If this fault is resolved, then return the machine to service. B. If this fault is not resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary.

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3624 - Crankcase pressure sensor voltage is higher than expected Context: The Electronic Control Unit (ECU) A-9000 monitors the crankcase pressure sensor B-9009 signal circuit. If the A-9000 determines that the voltage in the pressure signal circuit is higher than expected, this fault will occur. Cause: The A-9000 has detected a value greater than 4.80 V for a period greater than 150 ms in the B-9009 pressure signal circuit. Possible failure modes: 1. Faulty, B-9009, internal failure.. 2. Faulty B-9009 pressure signal circuit, shorted to a high source or open circuit condition. 3. Faulty A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 6. 2. Check the B-9009 pressure signal circuit for an open circuit condition. Disconnect connector X-9023. Disconnect connector X-9002 from the A-9000 The key must be at the OFF position. Use a multimeter to perform the following continuity check: From X-9002 pin 61

To X-9023 pin 3

Value ere should be continuity.

A. If there is continuity, leave the connectors disconnected and continue with Step 3. B. If there is no continuity, there is an open circuit condition in the B-9009 pressure signal circuit, wire EN-045. Locate and repair broken conductor. 3. Check the B-9009 signal circuit for a short to high source condition. The key must be at the OFF position. Use a multimeter to perform the following continuity check: From X-9002 pin 61 X-9002 pin 61

To X-9001 pin 32 All other pins

Value ere should be no continuity. ere should be no continuity.

A. If there is continuity, there is a short to high source condition in the B-9009 signal circuit, wire EN-045. Locate and repair shorted conductor. B. If there no continuity, leave the connectors disconnected and continue with Step 4. 4. Check the signal circuit B-9009 for a short to key power condition. The must be in the ON position. 48149953 12/06/2018

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Use a multimeter to perform the following voltage check: From X-9002 pin 61

To Chassis GND

Value There should be no voltage..

A. If there is voltage, there is a short to key power condition in the B-9009 signal circuit, wire EN-045. Locate and repair shorted conductor. B. If there is no voltage present, continue with step 5. 5. Replace the B-9009. Use the EST to verify if DTC 13A3 â&#x20AC;&#x201C; Crankcase pressure sensor voltage is higher than expected has been resolved. A. If it has been resolved, then return the machine to service. B. If it has not been resolved, check the A-9000 for the appropriate software and re-flash, if necessary. 6. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3625 - Crankcase pressure sensor voltage is lower than expected Context: The Electronic Control Unit (ECU) A-9000 monitors the crankcase pressure sensor B-9009 pressure signal circuit. If the A-9000 determines that the voltage in the pressure signal circuit is lower than expected, this fault will occur. Cause: The A-9000 has detected a voltage less than 200 mV for a period greater than 150 ms in the B-9009 pressure signal circuit. Possible failure modes: 1. Faulty, B-9009, internal failure.. 2. Faulty B-9009 pressure signal circuit, short to ground condition. 3. Faulty A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 4. 2. Check the B-9009 pressure signal circuit for a short to ground condition. Disconnect connector X-9023. Disconnect connector X-9002 from the A-9000. The key must be at the OFF position. Use a multimeter to perform the following continuity check: From X-9002 pin 61 X-9002 pin 61 X-9002 pin 61

To Chassis GND X-9002 pin 42 All other pins

Value ere should be no continuity. ere should be no continuity. ere should be no continuity.

A. If there is continuity, there is a short to ground in the B-9009 pressure signal circuit, wire ENâ&#x20AC;&#x201C;045. Locate and repair shorted conductor. B. If there no continuity, continue with step 3. 3. Replace the B-9009. Use the EST to verify if DTC 24A3 â&#x20AC;&#x201C; Crankcase pressure sensor voltage is lower than expected has been resolved. A. If it has been resolved, then return the machine to service. B. If it has not been resolved, check the A-9000 for the appropriate software and re-flash, if necessary. 4. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. 48149953 12/06/2018

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B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3626 - Crankcase pressure has exceeded tolerance limit Context: The Electronic Control Unit (ECU) A-9000 monitors crankcase pressure during after using the crankcase pressure sensor B-9009. If the A-9000 determines that crankcase pressure is greater than 12.04 cm H₂₂O (4.74 in H₂₂O) during after run, this fault will occur. Cause: The A-9000 has determined that crankcase pressure has exceeded 12.04 cm H₂₂O (4.74 in H₂₂O) during after run. Possible failure modes: 1. Excessive crankcase pressure. 2. Faulty PCV valve, positive crankcase ventilation. 3. Faulty blow by filter, clogged. 4. Faulty B-9009, wiring or internal failure. 5. Faulty piston rings. 6. Faulty A-9000, software.

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3628 - Crankcase pressure too low Context: The Electronic Control Unit (ECU) A-9000 monitors crankcase pressure by the crankcase pressure sensor B-9009. If the A-9000 determines that crankcase pressure is lower than –0.05 bar, this fault will occur. Cause: The A-9000 has determined that crankcase pressure is too low. Possible failure modes: 1. Faulty B-9009, wiring. 2. Faulty, B-9009, internal failure.. 3. Faulty A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 4. 2. Check the status of the following related faults: DTC 24A3 – Crankcase pressure sensor voltage is lower than expected DTC 3DA3 – Crankcase pressure sensor value is not plausible DTC 13A3 – Crankcase pressure sensor voltage is higher than expected A. If any of the related faults are active, diagnose them first and then return to this fault, DTC 22A3 – Crankcase pressure too low. B. If none of the related faults are active, continue with step 3. 3. Replace the B-9009. Use the EST to verify the status of DTC 22A3 – Crankcase pressure too low. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 4. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3638 - Torque limitation caused by engine brake Context: This failure path is only for information. There was an active performance limitation after engine brake release, which was not caused by a failure, but an extreme working condition, with a duration longer than 60.00 s. This failure is a confirmation of a temporary reduction in power. If a power reduction of greater than 15.00% or an engine speed limitation of greater than 5.00% after engine brake release, this fault is set. This failure does not require any action except to check if other failures concerning the engine brake are present in the failure memory. If another failure is present, follow the troubleshooting procedure for that fault. No actions are necessary due to this failure alone. Cause: The following failure mode may be the reason for the occurrence of this fault. Possible failure modes: 1. Extended usage of engine brake

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3647 - Over boost failure Context: The Electronic Control Unit (ECU) A-9000 monitors boost pressure using the intake boost pressure sensor B-9001. If the A-9000 determines that boost pressure is higher than expected based on engine speed and ambient pressure. Cause: Boost pressure is higher than expected. Possible failure modes: 1. Higher than normal environmental ambient pressure. 2. Electronic Variable Geometric Turbocharger (EVGT) actuator sticking or blocked. (If equipped) 3. EVGT linkage disconnected or damaged. (If equipped) 4. Faulty turbocharger wastegate or linkage. (If equipped) 5. Faulty B-9001, wiring or internal failure. 6. Faulty A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 7. 2. Use the EST to check for the following related faults: DTC 1D64 â&#x20AC;&#x201C; Intake manifold pressure sensor voltage is higher than expected A. If the faults is active, troubleshoot it first and then return to this fault, DTC 1338 â&#x20AC;&#x201C; Over boost failure. B. Is the fault is not active, continue with step 3. 3. Visually inspect the Electronic Variable Geometric Turbocharger (EVGT) actuation (If equipped). Verify that the EVGT mechanism and linkage is properly attached and is not restricted or blocked in any way. Visually inspect the turbocharger wastegate (If equipped). Verify that the linkage is not damaged or disconnected. Verify that the machine is not being operated in extreme ambient pressure condition which may have triggered this fault to occur. A. If any failures are found, repair as necessary. B. If no faults are found, continue with step 4. 4. Check the B-9001 wiring. Disconnect connector X-9002. Disconnect connector X-9003. The key must be in the OFF position for continuity and ON position for voltage. Use a multimeter to perform the following wiring checks: From X-9002 pin 86 X-9002 pin 86

To X-9003 pin 4 X-9002 pin 7 48149953 12/06/2018

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Value ere should be continuity. ere should be no continuity.

Electrical systems - FAULT CODES

From X-9002 X-9002 X-9002 X-9002

pin pin pin pin

86 86 86 86

To X-9002 pin 90 All other pins Chassis GND Chassis GND

Value ere should be no continuity. ere should be no continuity. ere should be no continuity. There should be no voltage..

A. If the specified values are measured, continue with step 5. B. If the specified values are not measured, Locate and repair the failed conductor. 5. Replace the B-9001. Use the EST to verify that the status of this fault, DTC 1338 â&#x20AC;&#x201C; Over boost failure. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, continue with step 6. 6. Replace turbocharger wastegate (if equipped) or replace EVGT (if equipped). Use the EST to verify that the status of this fault, DTC 1338 â&#x20AC;&#x201C; Over boost failure. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 7. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3652 - CAN A Bus off passive failure Context: The Engine Control Unit (ECU) A-9000 is capable of connecting to and communicating on three separate Controller Area Networks (CAN). Proper configuration and monitoring of the three twisted pair configured networks is also a function of the ECU A-9000. CAN Node A Bus is the main vehicle interface bus. The ECU A-9000 provides a CAN termination resistor for the CAN Node A Bus, internal to the ECU A-9000. If the ECU A-9000 senses that CAN Node A Bus is not functioning properly, this fault will occur. Cause: ECU A-9000 has sensed a “Bus Off” state to be present at the CAN Node A. Possible failure modes: 1. Faulty supply voltage or ground, missing. 2. Faulty CAN circuit wiring, open circuit, short to ground, or short circuit. 3. Faulty ECU A-9000, termination resistor or software. Solution: 1. Verify fault is present and in active state. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step2boom. B. If the fault is no longer present or is in an inactive state, the fault may be intermittent and not currently active. Continue with step 6boom. 2. Check for other vehicle CAN faults. Use the EST to determine if vehicle CAN faults exist. A. If other vehicle CAN faults do exist, resolve the vehicle CAN faults, then check to see that DTC 911B – CAN A Bus off passive failure is also resolved. B. If other vehicle CAN faults do not exist, continue with step 3boom. 3. Check the ECU A-9000 supply voltage. Disconnect the vehicle (VE) harness from the ECU A-9000 at connector X-9001. With the keyswitch in the on position, use a multimeter to check for voltage on the vehicle (VE) harness side: From X-9001 X-9001 X-9001 X-9001 X-9001

pin pin pin pin pin

1 25 26 49 73

To chassis chassis chassis chassis chassis

ground ground ground ground ground

Value There should be 12.0 V . There should be 12.0 V . There should be 12.0 V . There should be 12.0 V . There should be 12.0 V .

A. If the voltage is present on all of the checks, leave connector X-9001 disconnected and continue with Step 4boom. B. If the voltage is not present for one or more of the checks, refer to the appropriate vehicle service manual and electrical schematics to locate and restore supply power to the ECU A-9000. 4. Check the ECU A-9000 grounding. With the keyswitch in the off position, use a multimeter to check for continuity on the vehicle (VE) harness side:

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From X-9001 X-9001 X-9001 X-9001 X-9001

pin pin pin pin pin

3 5 28 52 75

To chassis chassis chassis chassis chassis

ground ground ground ground ground

Value ere should be continuity. ere should be continuity. ere should be continuity. ere should be continuity. ere should be continuity.

A. If there is continuity on all of the checks, leave connector X-9001 disconnected and continue with Step 5boom. B. If there is no continuity for one or more of the checks, refer to the appropriate vehicle service manual and electrical schematics to locate and restore the grounding circuit to the ECU A-9000. 5. Determine the condition of the ECU A-9000 CAN circuit. With the ignition switch in the OFF position, use a multimeter to measure the resistance of the CAN connection on the vehicle (VE) harness side: From X-9001 pin 46 X-9001 pin 46 X-9001 pin 47

To X-9001 pin 47 chassis ground chassis ground

Value There should be 120 ÎŠ . Should no be continuity Should no be continuity

Use a multimeter to measure the resistance of the CAN termination resistor, internal to the ECU A-9000: From X-9001 pin 46

To X-9001 pin 47

Value There should be 120 ÎŠ .

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3680 - Engine speed limitation via fuel injection cut off is active Context: This fault is for informational purposes only and requires no action. Other active faults resulted in this fault. The Electronic Control Unit (ECU) A-9000 performs fuel injection cut off to limit engine speed to a controllable range. This procedure is triggered if engine speed has exceeded 1200 RPM and if certain A-9000 internal failures which concern the reliability of the accelerator pedal signal, fuel injection parameters or engine speed are detected. If this fault occurs, this fuel injection cut off procedure is active.

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3686 - DOC upstream temperature sensor signal drift at cold start Context: The Electronic Control Unit (ECU) A-9000 monitors the SCR upstream temperature sensor B-9106 signal. If the A-9000 determines that ambient pressure is at least 0.8 bar (11.6 psi) and the last driving cycle was for longer than 5.00 s with a temperature of at least 70.0 °C (157.9 °F) at least once, this fault will occur. Cause: The A-9000 determines that the B-9106 temperature signal has drifted at cold start. Possible failure modes: 1. Sudden change in ambient temperature. 2. Faulty B-9106, wiring or internal failure. 3. Faulty A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 5. 2. Check the following related faults: DTC 1899 – Upstream oxidation catalyst temperature sensor voltage is higher than expected DTC 2999 – Upstream oxidation catalyst temperature sensor voltage is lower than expected DTC 352C – Upstream oxidation catalyst temperature sensor comparison to a calculated temperature value failure A. If any of the related faults are active, diagnose them first and then return to this fault, DTC 3D1C – DOC upstream temperature sensor signal drift at cold start. B. If none of the related faults are active, continue with step 3. 3. Use the EST to compare the B-9106 temperature value to the B-9104 and B-9107 temperature values. Monitor for possible signal drift due to a rapid change in ambient temperature. The sensors should have similar characteristics. Monitoring must be done after a cold soak condition to avoid any residual heat. A. If no faults are found, continue with step 4. B. If any failures are found, verify that a rapid change in ambient temperature has not occurred that has caused this fault to occur. 4. Replace the B-9106. Use the EST to verify that the status of this fault, DTC 3D1C – DOC upstream temperature sensor signal drift at cold start. Perform an engine cold start to verify that this fault has been resolved. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary.

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5. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3688 - Water in fuel sensor or sensor circuit failure NOTE: This fault code is for the Water in Fuel switch with black connector housing. Context: The water in fuel switch S-9102 provides a diagnostic self-test signal (less than 3.9 V for 2.5 s +/- 20%) at key-ON. If the Engine Control Unit (ECU) A-9000 does not sense the diagnostic self-test signal, this fault will occur and there will be no monitoring of water content in the fuel supply. Cause: The ECU A-9000 has not received an acceptable water in fuel switch S-9102 self-test signal. Possible failure modes: 1. Faulty water in fuel switch S-9102 circuit wiring, damaged. 2. Faulty water in fuel switch S-9102, internal failure. 3. Fault ECU A-9000, software. Solution: 1. Verify this error code is still present and in an active state. Use the Easy Engine software provided on the Electronic Service Tool (EST) to check the fault status. A. If the fault is still present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, Continue with step 6. 2. Use the EST to check the status of the related fault DTC 4415 – Water in fuel detected or water in fuel circuit failure A. If neither fault DTC 4415 – Water in fuel detected or water in fuel circuit failure is active, resolve fault DTC 4415 – Water in fuel detected or water in fuel circuit failure, then determine if fault DTC 4F15 – Water in fuel sensor or sensor circuit failure is also resolved. B. If neither fault DTC 4415 – Water in fuel detected or water in fuel circuit failure is not active,continue with step 3. 3. Check the water in fuel switch S-9102 for the initial self-test voltage pulse. Carefully back probe the water in fuel switch S-9102 at connector X-9125 pin 1. With the help of an assistant, use a multimeter to perform the following test at Key-ON: From

Value There should be less than 3.9 V for 2.5 s +/- 20%. NOTE: The signal line should switch to battery voltage after the self-test period. X-9125 pin 1

Ground

A. If the self-test is successful, continue with step 4. B. If the self-test is not successful, the water in fuel switch S-9102 has failed internally. Substitute the switch. 4. Check for open, short and grounded circuit conditions in the water in fuel switch S-9102 circuit. Disconnect the water in fuel switch S-9102 at connector X-9125. Disconnect the vehicle (VE) harness from the ECU A-9000 at connector X-9001. With the key switch in the OFF position, use a multimeter to perform the following tests, on the vehicle (VE) harness:

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From X-9125 pin 1 X-9125 pin 2 X-9125 pin 3

To X-9001 pin 13 X-9001 pin 43 X-9118 pin 4

Value ere should be continuity. ere should be continuity. ere should be continuity.

Then use the multimeter to perform the following tests, on the vehicle (VE) harness: From X-9125 pin 1 X-9125 pin 1 X-9125 pin 2

To X-9125 pin 2 X-9125 pin 3 X-9125 pin 3

Value Should no be continuity Should no be continuity Should no be continuity

Then use the multimeter to perform the following tests, on the vehicle (VE) harness: From X-9125 pin 1 X-9125 pin 2 X-9125 pin 3

To Ground Ground Ground

Value Should no be continuity Should no be continuity Should no be continuity

A. If the results are not as expected for any of the wiring tests listed above, there is an open, short or grounded circuit condition in the wiring. Use the appropriate vehicle service manual and schematics to diagnose and repair the wiring. B. If the results are as expected in all of the wiring tests listed above, the wiring is ok. Leave connector X-9125 disconnected and continue with Step 5. 5. Check for key switch voltage supply to water in fuel switch S-9102. If it has not been reconnected, reconnect the vehicle (VE) harness to the ECU A-9000 at connector X-9001. With the key switch in an ON position, use a multimeter to perform the following test, on the vehicle (VE) harness side: From X-9125 pin 3

To Ground

Value There should be key switch voltage.

A. If there is key switch voltage present, check the ECU A-9000 for the appropriate software and re-flash, if necessary. B. If key switch voltage is not present, use the appropriate vehicle service manual and schematics to diagnose and repair the wiring. 6. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3699 - ECU EEPROM memory failure - EEPData1 block Context: The Electronic Control Unit (ECU) A-9000 monitors the EEPROM block internal to the A-9000. If the A-9000 determines that the correction values used for fuel rail pressure regulation are corrupted or are not accessible, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, escalate an ASIST concern.

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3700 - Intake air humidity sensor value is not plausible Context: The Electronic Control Unit (ECU) A-9000 monitors the intake air humidity sensor B-9105 signal circuit for a signal sticking condition. If the change in the B-9105 relative humidity signal value is less than 1.00% per 1.00 s, this fault will occur. Cause: The A-9000 has determined that the B-9105 humidity signal value is not plausible. Possible failure modes: 1. Faulty B-9105, humidity signal circuit. 2. Faulty, B-9105, internal failure.. 3. Faulty A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 4. 2. Check the status of the following related faults: DTC FB54 – Intake air humidity sensor voltage is higher than expected DTC 1C54 – Intake air humidity sensor voltage is higher than expected for too long DTC 2D54 – Intake air humidity sensor voltage is lower than expected A. If any of the related faults are active, diagnose them first and then return to this fault, DTC 3754 – Intake air humidity sensor value is not plausible. B. If none of the related faults are active, continue with step 3. 3. Replace the B-9105. Use the EST to verify the status of DTC 3754 – Intake air humidity sensor value is not plausible. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 4. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3703 - The minimum rail pressure value necessary to allow fuel injection has not been reached Context: The Electronic Control Unit (ECU) A-9000 monitors the fuel pressure sensor B-9004 for the necessary minimum pressure to allow fuel injection. If the A-9000 determines that fuel pressure is below 180.0 bar (2610.0 psi), fuel injection will not be allowed and this fault will occur. Cause: The minimum rail pressure value necessary to allow fuel injection has not been reached. Possible failure modes: 1. Faulty B-9004, wiring or internal failure. 2. Faulty fuel injection system, low pressure side. (clogged fuel filter, leakage or blockage) 3. Faulty gear pump pressure, too low. 4. Faulty fuel metering unit Y-9000, wiring or internal failure. 5. Faulty high pressure pump. 6. Faulty Pressure relief valve (PRV), stuck open.

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3738 - ECU internal failure - ROM error Context: The Engine Control Unit (ECU) A-9000 performs a Read-Only Memory (ROM) check during after run. If ROM memory blocks are detected during this check, power stages will be shut off and this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, escalate an ASIST concern.

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3739 - ECU internal failure - Loss of synchronization to MM from CPU Context: The Engine Control Unit (ECU) A-9000 performs shut off paths which deactivate all power stages relevant to injection if certain internal ECU A-9000 errors are detected. In order to test the correct functioning of the shut off procedure, every path is shortly activated during ECU A-9000 initialization to activate the fuel injection power stage. Since the ECU A-9000 has activated the shut off, no fuel injection should occur during this test. If the wrong response from the processor to the power stage supply is detected during the shut off path test, this fault occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, escalate an ASIST concern.

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3740 - ECU internal failure - ECU shutdown test failure Context: The Elngine Control Unit (ECU) A-9000 tests the correct functioning of the fuel injection path shut off procedure. During this test, each injection path is shortly activated during ECU A-9000 initialization. If at least one error is detected during this test occurs, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, escalate an ASIST concern.

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3741 - ECU internal failure - Wrong set response time Context: The Elngine Control Unit (ECU) A-9000 tests the correct functioning of the fuel injection path shut off procedure. During this test, each injection path is shortly activated during ECU A-9000 initialization. If a time-out error occurs during this test, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, escalate an ASIST concern.

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3742 - ECU internal failure - SPI errors during MoCSOP execution Context: The Elngine Control Unit (ECU) A-9000 tests the correct functioning of the fuel injection path shut off procedure. During this test, each injection path is shortly activated during ECU A-9000 initialization. If a Serial Peripheral Interface (SPI) communication error is detected during this test, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, escalate an ASIST concern.

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3743 - ECU internal failure - Undervoltage monitoring error Context: The Engine Control Unit (ECU) A-9000 performs shut off paths which deactivate all power stages relevant to fuel injection if certain internal ECU A-9000 errors are detected. In order to test this function, every path is shortly activated during ECU A-9000 initialization. Since the shut off is active, no fuel injection should occur during this test. If a voltage lower than expected condition is detected during this test, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, escalate an ASIST concern.

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3745 - ECU internal failure - WDA is not working correctly Context: The Engine Control Unit (ECU) A-9000 performs shut off paths which deactivate all power stages relevant to fuel injection if certain internal ECU A-9000 errors are detected. In order to test this function, every path is shortly activated during ECU A-9000 initialization. Since the shut off is active, no fuel injection should occur during this test. If an implausible response in the power stage feedback is detected during this test, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, escalate an ASIST concern.

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3746 - ECU internal failure - Alarm task period error Context: The Engine Control Unit (ECU) A-9000 performs shut off paths which deactivate all power stages relevant to fuel injection if certain internal ECU A-9000 errors are detected. In order to test this function, every path is shortly activated during ECU A-9000 initialization. Since the shut off is active, no fuel injection should occur during this test. If a time-out error during the shut off path test is detected and the alarm task cannot be set or reset, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, escalate an ASIST concern.

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3747 - ECU internal failure - Positive test failed Context: The Engine Control Unit (ECU) A-9000 performs shut off paths which deactivate all power stages relevant to injection if certain internal ECU A-9000 errors are detected. In order to test the correct functioning of the shut off procedure, every path is shortly activated during ECU A-9000 initialization to activate the fuel injection power stage. Since the ECU A-9000 has activated the shut off, no fuel injection should occur during this test. If an error is detected during this test, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, escalate an ASIST concern.

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3749 - ECU internal failure - Accelerator pedal position sensor Context: The Engine Control Unit (ECU) A-9000 performs an internal plausibility check of the accelerator pedal position signal and the low idle switch, for function monitoring. If the ECU A-9000 detects a implausible value between the accelerator pedal position sensor and the low idle switch, this fault will occur. Cause: The ECU A-9000 has detected an implausible value, internally, of the low idle switch and acceleration pedal position sensor B-9100. Possible failure modes: 1. Faulty A-9000, software. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, escalate an ASIST concern.

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3750 - ECU internal failure - Fuel injection energizing time not plausible Context: The Engine Control Unit (ECU) A-9000 monitors injector energizing time. If the ECU A-9000 determines that the energizing time for either the pilot injection, main injection or post injection is implausible, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, escalate an ASIST concern.

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3751 - ECU internal failure - Fuel injection energizing phase is not plausible Context: The Engine Control Unit (ECU) A-9000 monitors for injector energizing start time. If the ECU A-9000 determines that the energizing start time for either the pilot injection, main injection or post injection is implausible, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, escalate an ASIST concern.

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3753 - ECU internal failure - Injection quality correction Context: Engine performance is assisted by the addition of pilot injections, main injections and three post injections. The Engine Control Unit (ECU) A-9000 monitors the efficiency of these injections and provides injection quantity corrections, if necessary. If the ECU A-9000 determines that excessive corrections to injection quantity are being made, there is a calibration error and this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, escalate an ASIST concern.

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3754 - ECU internal failure - Rail pressure plausibility Context: The Engine Control Unit (ECU) A-9000 monitors fuel rail pressure for proper engine performance as well as safety concerns. Fuel rail pressure is monitored by the ECU A-9000 to check if the ECU A-9000 is functioning properly. If the ECU A-9000 detects an implausible rail pressure during monitoring, the ECU A-9000 is not functioning correctly and this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, escalate an ASIST concern.

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3755 - ECU internal failure - Torque request comparison Context: The Engine Control Unit (ECU) A-9000 determines engine torque based on the requests of many vehicle functions. The total requested engine torque is compared to the maximal engine torque allowed. If the total requested torque is greater than the maximal allowed torque, the ECU A-9000 has a calibration error and this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, escalate an ASIST concern.

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3756 - ECU internal failure - Post injection quality Context: Engine performance is assisted by the addition of pilot injections, main injections and three post injections. The Engine Control Unit (ECU) A-9000 monitors the start angle and efficiency of post Injection 2. If the ECU A-9000 determines that the post Injection 2 is not within a plausible value, a calibration error has occurred and this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, escalate an ASIST concern.

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3757 - ECU internal failure - Post injection shut off failure Context: Engine performance is assisted by the addition of pilot injections, main injections and three post injections. The Electronic Control Unit (ECU) A-9000 monitors the post Injection 2 shut off quantity in normal mode. If the A-9000 detects that the post Injection 2 shut off quantity has exceeded 5.00 mg in normal mode, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, escalate an ASIST concern.

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3758 - Post injection efficiency failure Context: Engine performance is assisted by the addition of pilot injections, main injections and post injections. The Electronic Control Unit (ECU) A-9000 monitors the post injection 3 efficiency. If injection is not commanded at an engine speed greater than 1200 RPM and an engine speed greater than 1320 RPM is then detected at least two times, this fault will occur. Cause: The A-9000 has detected an unwanted increase in engine speed. This failure may have been caused by unwanted leakage of fuel or engine oil into the engine or by unwanted post injections. Possible failure modes: 1. Faulty fuel injectors, leakage. 2. Engine oil leakage into cylinders, faulty piston rings. 3. Faulty A-9000, software.

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3759 - ECU internal failure - Torque request due to fuel pressure exceeds maximum torque limit Context: The Engine Control Unit (ECU) A-9000 determines engine torque based on the requests of many vehicle functions. The total requested engine torque is compared to the maximal engine torque allowed. Fuel pressure is dependent on requested torque. Therefore, the torque is calculated separately and called â&#x20AC;&#x153;Main torque.â&#x20AC;? If that fails to happen, the ECU A-9000 has sensed that the main torque value requested exceeds the permitted maximum torque. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, escalate an ASIST concern.

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3760 - ECU internal failure - Torque request due to air control exceeds maximum torque limit Context: The Engine Control Unit (ECU) A-9000 determines engine torque based on the requests of many vehicle functions. The total requested engine torque is compared to the maximal engine torque allowed. Air control is dependent on requested torque. Therefore, the air control is calculated separately and called â&#x20AC;&#x153;Main torque.â&#x20AC;? If that fails to happen, the ECU A-9000 has sensed that the main torque value requested exceeds the permitted maximum torque. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, escalate an ASIST concern.

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3761 - ECU internal failure - Torque request exceeds maximum torque limit Context: The Engine Control Unit (ECU) A-9000 determines engine torque based on the requests of many vehicle functions. The total requested engine torque is compared to the maximal engine torque allowed. If the total requested torque is greater than the maximal allowed torque, the ECU A-9000 has a calibration error and this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, escalate an ASIST concern.

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3762 - ECU 5 volt supply voltage is higher than expected Context: The ECU A-9000 monitors for a voltage error of the internal 5 V supply. If the voltage supply exceeds the internal maximal limit, this fault will occur. Possible failure modes: 1. Faulty A-9000, supply wiring. 2. Faulty A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 4. 2. Check the A-9000 supply wiring. Disconnect connector X-9001. The must be in the ON position. Use a multimeter to perform the following voltage check: From X-9001 X-9001 X-9001 X-9001 X-9001

pin pin pin pin pin

73 49 25 1 26

To Chassis Chassis Chassis Chassis Chassis

GND GND GND GND GND

Value There should approximately 12 V. There should approximately 12 V. There should approximately 12 V. There should approximately 12 V. There should approximately 12 V.

A. If there is not approximately 12 V, check the charging system for proper operation and repair as necessary. B. If there is approximately 12 V, continue with step 3. 3. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, escalate an ASIST concern. 4. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3763 - ECU 5 volt supply voltage is lower than expected Context: The ECU A-9000 monitors for a voltage error of the internal 5 V supply. If the voltage supply is below the internal maximal limit, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, escalate an ASIST concern.

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3764 - ECU after run power interruption Context: The Electronic Control Unit (ECU) A-9000 monitors the ignition switch. When the ECU A-9000 determines that the ignition switch has been turned OFF, it will go into after run. The after run disconnection relay K-9106 controls the voltage to the main relay which allows the ECU A-9000 to store failures into memory (and other relevant machine operating parameters) before being turned OFF. If the ECU A-9000 determines that the after run cycle was interrupted three consecutive times, this fault will occur. Cause: The ECU A-9000 has detected an interruption in the after run process. Possible failure modes: 1. Premature use of the battery disconnect switch. (if equipped) 2. Faulty battery voltage. 3. Faulty K-9106, internal failure or loose connection. 4. Faulty K-9102, internal failure or loose connection. 5. Faulty fuse F-9105. 6. Faulty K-9106, wiring. 7. Faulty A-9000, software. Solution: 1.

Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 11.

Check battery voltage. Use a multimeter to perform the following voltage check: From Battery post (+)

To Battery post (–)

Value There should approximately 12 V.

A. If there is approximately 12 V, continue with step 3. B. If there is not approximately 12 V, there is a battery or charging system fault. Repair as necessary. 3.

Check for the following related faults: DTC 5971 – After run relay low side driver circuit open or short to ground failure DTC 5171 – After run relay high side driver circuit open failure DTC 6771 – After run relay low side driver circuit short to battery failure DTC 8671 – After run relay low side ECU driver circuit over temperature failure DTC 8271 – After run relay high side ECU driver circuit over temperature failure DTC 6471 – After run relay high side driver circuit short to ground failure A. If any of the related faults are active, diagnose them first and then return to this fault, DTC F561 – ECU after run power interruption.

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B. If none of the related faults are active, continue with step 4. 4.

Check the K-9106 for an internal failure. Remove the K-9106. Use a multimeter to perform the following resistance test: From X-9123 pin 1

To X-9123 pin 2

Value The resistance should be between 70 – 130 Ω .

A. If the resistance is between 70 – 130 Ω, leave the K-9106 disconnected and continue to Step 5. B. If the resistance is not within the specified value, the K-9106 has failed internally. Replace the K-9106. 5.

Check the K-9106 wiring. The must be in the ON position. Use a multimeter to perform the following voltage check from the K-9106 relay socket: From X-9123 pin 3

To Chassis ground.

Value There should approximately 12 V.

A. If there is not approximately 12 V, there is a fault in the wiring from the battery to the K-9106. Locate and repair the failed conductor. B. If there is approximately 12 V, continue with step 6. 6.

Check Fuse F-9105. Remove the F-9105. Use a multimeter to determine the condition of the fuse. A. If there is no continuity the F-9105 has failed. Replace the F-9105. B. If there is continuity, continue with step 7.

Check the main relay K-9102 for an internal failure. Remove the K-9102. Use a multimeter to check the coil resistance. There should be 70 – 130 Ω A. If the resistance is between 70 – 130 Ω, leave the K-9102 disconnected and continue to Step 8. B. If the resistance is not within the specified value, the K-9102 has failed internally. Replace the K-9102.

Check the K-9106 to the main relay K-9102 wiring. The key must be at the OFF position. Use a multimeter to perform the following continuity check from the K-9106 relay socket to the K-9102 relay socket: From X-9123 pin 4 X-9123 pin 4 X-9123 pin 4

To the K-9102 socket pin 2 Chassis GND Chassis GND

Value ere should be continuity. ere should be no continuity. There should be no voltage..

A. The specified value is not detected. There is a fault in the wiring between the relays.Locate and repair the failed conductor. B. If the specified value has been detected, continue with step 9. 48149953 12/06/2018

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Check the K-9102 wiring. The must be in the ON position. Use a multimeter to perform the following voltage check from the K-9102 relay socket: From the socket of K-9102 pin 1

To Chassis GND

Value There should approximately 12 V.

A. If there is not approximately 12 V, there is a fault in the wiring from the battery to the K-9102. Locate and repair the failed conductor. B. If there is approximately 12 V, continue with step 10. 10. Check the K-9102 wiring. The key must be at the OFF position. Use a multimeter to perform the following continuity check: From the socket of K-9102 pin 3

To Chassis GND

Value ere should be continuity.

A. If there is no continuity, there is a broken path to ground in the K-9102 wiring. Locate and repair broken conductor. B. If there is continuity, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 11. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3767 - ECU internal failure - 'WDA active' reported due to errors in query/response communication Context: The Engine Control Unit (ECU) A-9000 monitors the communication, internal to the ECU A-9000, between the power stages and the power stage voltage supplier. If an unexpected communication (a wire is active when it should not be) is detected during this monitoring, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, escalate an ASIST concern.

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3768 - ECU internal failure - 'ABE active' reported due to undervoltage detection Context: The Engine Control Unit (ECU) A-9000 monitors the communication, internal to the ECU A-9000, between the power stages and the power stage voltage supplier. This fault occurs if the ECU A-9000 detects a low voltage condition while the battery voltage is greater than 8.00 V and the shut off path test is not active. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, escalate an ASIST concern.

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3769 - ECU internal failure - 'ABE active' report due to overvoltage detection Context: The Engine Control Unit (ECU) A-9000 monitors the communication, internal to the ECU A-9000, between the power stages and the power stage voltage supplier. If the ECU A-9000 detects a high voltage condition while the shut off path test is not active, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, escalate an ASIST concern.

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3770 - ECU internal failure - 'WDA/ABE active' reported Context: The Engine Control Unit (ECU) A-9000 monitors the communication, internal to the ECU A-9000, between the power stages and the power stage voltage supplier. Monitoring is performed continuously as long as the battery voltage is greater than 8.00 V and the shut off path test is not active. If the WDA/ABE communication wire becomes active, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, escalate an ASIST concern.

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3799 - Fuel pressure relief valve is forced open, perform pressure shock Context: For more information on the fuel injection system, see Injection control - Dynamic description (55.010). To determine mechanical wear out or to send the system into limp home mode, the Electronic Control Unit (ECU) A-9000 can force the fuel pressure relief valve open. This action consists of two steps, waiting for the rail pressure to build up and then performing the pressure shock. If the A-9000 commands this operation, this fault will occur. Once a rail pressure sensor Y-9007 failure is detected or maximum rail pressure is exceeded, the system will go into a limp home mode. If this fault occurs, the A-9000 has determined that a pressure shock has occurred, other fuel related system faults can occur due to the increase in fuel pressure. Solution: 1. Other possible fuel system faults that may occur or may have caused this fault: DTC F245 – Fuel pressure relief valve is forced to open, perform pressure increase DTC F445 – Fuel pressure relief valve is open DTC 5255 – Fuel metering unit has an open load error DTC 4155 – Fuel metering unit intermittent electrical connection failure DTC 8355 – Fuel metering unit has an over-temperature error DTC 3C65 – High pressure pump fuel delivery quantity at low idle is too high DTC 3B65 – High pressure pump fuel delivery quantity in over run exceeds a maximum threshold DTC 2265 – Fuel rail pressure has exceeded maximum positive deviation limits DTC 1D85 – Maximum rail pressure exceeded DTC 1425 – Fuel rail pressure sensor voltage is higher than expected DTC 15E5 – Prefilter fuel pressure sensor voltage is higher than expected

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3805 - Maximum rail pressure exceeded NOTE: Because this fault causes inducement, it is necessary to perform the Engine Restart Counter Reset / Unlock Inducement configuration with the Electronic Service Tool (EST) before you return the machine to service. Context: The Electronic Control Unit (ECU) A-9000 monitors fuel rail pressure during limp home mode. If the A-9000 determines that fuel pressure has exceeded 2250.0 bar (32625.0 psi) during lime home mode, this fault will occur. Cause: Maximum fuel pressure has been exceeded. Possible failure modes: 1. Faulty fuel metering unit Y-9000, wiring or mechanical failure. 2. Faulty Pressure Relief Valve (PRV), clogged. 3. Faulty fuel injectors, electrical or mechanical failure. 4. Faulty fuel return lines. 5. Faulty gear pump pressure, too high. 6. Faulty A-9000, software. Solution: 1. Use the Electronic Service Tool to check for related faults. The following faults may have caused this fault, DTC 1D85 – Maximum rail pressure exceeded to occur and should diagnosed first if active: DTC 4155 – Fuel metering unit intermittent electrical connection failure DTC 5255 – Fuel metering unit has an open load error DTC 6655 – Fuel metering unit is shorted to battery voltage at the low side DTC 7555 – Fuel metering unit is shorted to ground at the high side DTC 8355 – Fuel metering unit has an over-temperature error

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3808 - High pressure pump fuel delivery quantity at low idle is too high Context: The Electronic Control Unit (ECU) A-9000 controls fuel delivery by the fuel metering unit Y-9000. If the A-9000 determines that proper fuel pressure can not be reached at engine idle speed, leakage in the system is assumed and this fault will occur. Cause: The A-9000 has determined that commanded fuel rail pressure is lower than expected at engine idle speed. Possible failure modes: 1. Faulty fuel injectors, internal leakage or stuck open. 2. Faulty pressure relief valve, leaking. 3. Faulty fuel metering unit Y-9000. 4. Faulty high pressure pump. 5. Faulty fuel filter, clogged. 6. Faulty low pressure fuel lines, leaking. (air entrance) 7. Faulty low pressure gear pump. 8. Faulty electric lift pump. (if applicable)

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3811 - ECU internal failure - Sensor 5 volt supply 1 NOTE: Because this fault causes inducement, it is necessary to perform the Engine Restart Counter Reset / Unlock Inducement configuration with the Electronic Service Tool (EST) before you return the machine to service. Context: The Engine Control Unit (ECU) A-9000 provides three independent 5.0 V voltage supplies for sensors. These voltages are monitored by hardware within the A-9000 to make sure they are within a given range. This given range is defined by the A-9000 hardware and cannot be calibrated. If a sensor supply 1 reference voltage is out of range, this fault will occur.

Cause: The A-9000 sensor supply 1 reference voltage is out of range. Possible failure modes: 1. Faulty SCR pressure sensor B-9100 or sensor supply wire. 2. Faulty air filter clogging pressure sensor B-9102 or sensor supply wire. 3. Faulty oil pressure and temperature sensor B-9000 or sensor supply wire. 4. Faulty intake manifold pressure and temperature sensor B-9001 or sensor supply wire. 5. Faulty crankcase pressure sensor B-9009 or sensor supply wire. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 4. 2. Disconnect each connector one at a time, use EST to monitor the status of DTC E22D – ECU internal failure Sensor 5 volt supply 1. - SCR pressure sensor B-9100 connector X-9108 - Air filter clogging pressure sensor B-9102 connector X-9102 – Oil pressure and temperature sensor B-9000 connector X-9004 - Intake manifold pressure and temperature sensor B-9001 connector X-9003 - Crankcase pressure sensor B-9009 connector X-9023 A. If either DTC E22D – ECU internal failure - Sensor 5 volt supply 1 is eliminated after a connector disconnection, the relevant component has failed. Replace the relevant component. B. If either DTC E22D – ECU internal failure - Sensor 5 volt supply 1 has not been eliminated after connector disconnection, leave all connectors disconnected and continue to Step 3. 3. Check the all of the supply 1 circuits for a short circuit condition. The must be in the ON position. Use a multimeter to perform the following voltage check: From X-9108 pin 2 X-9102 pin 1

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Value There should be between 4.5 – 5.5 V. There should be between 4.5 – 5.5 V.

Electrical systems - FAULT CODES

From X-9004 pin 3 X-9003 pin 3 X-9023 pin 1

To Chassis GND Chassis GND Chassis GND

Value There should be between 4.5 – 5.5 V. There should be between 4.5 – 5.5 V. There should be between 4.5 – 5.5 V.

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3814 - ECU temperature sensor error detected Context: The Electronic Control Unit (ECU) A-9000 performs a signal check of the signal of each digital temperature sensor internal to the A-9000. If an error message sent from the sensor is detected, this fault will occur. Temperature value will be frozen at the last valid value for a preliminary failure and a fixed value of 39.96 Â°C (103.93 Â°F) if the failure is validated. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, escalate an ASIST concern.

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3838 - Upstream oxidation catalyst temperature sensor voltage is lower than expected NOTE: Because this fault causes inducement, it is necessary to perform the Engine Restart Counter Reset / Unlock Inducement configuration with the Electronic Service Tool (EST) before you return the machine to service. Context: The Electronic Control Unit (ECU) A-9000 monitors the downstream SCR catalyst temperature sensor B-9106 circuit voltage. If the A-9000 detects a voltage less than 407.00 mV in the B-9106 signal circuit, this fault will occur. The temperature value is frozen at the last valid value or at 574.0 °C (1065.2 °F) for a validated failure. Cause: The A-9000 has detected a voltage less than 407.00 mV in the B-9104 signal circuit. Possible failure modes: 1. Faulty B-9106, wiring. 2. Faulty, B-9106, internal failure.. 3. Faulty A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 4. 2. Check the B-9106 signal circuit for a short to ground condition. Disconnect connector X-9001. Disconnect connector X-9106. The key must be at the OFF position. Use a multimeter to perform the following continuity check: From X-9001 pin 16 X-9001 pin 9

To X-9001 pin 10 Chassis GND

Value ere should be no continuity. ere should be no continuity.

A. If there is continuity, there is a short to ground condition in the B-9106 signal circuit, wire VE-106. Locate and repair shorted conductor. B. If there no continuity, continue with step 3. 3. Replace the B-9106. Use the EST to verify that the status of this fault, DTC 2999 – Upstream oxidation catalyst temperature sensor voltage is lower than expected. A. If the fault has been resolved, use EST, if necessary, to perform the Engine Restart Counter Reset/Unlock Inducement configuration then return the machine to service. B. If the fault has been not resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 4. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. 48149953 12/06/2018

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3870 - CAN communication failure between vehicle controller and ECU - BC2ECU1 message Context: The Engine Control Unit (ECU) A-9000 is capable of connecting to and communicating on three separate Controller Area Networks (CAN). Proper configuration and monitoring of the three twisted pair configured networks is also a function of the ECU A-9000. CAN Node A Bus is the main vehicle interface bus. The ECU A-9000 provides a CAN termination resistor for the CAN Node A Bus, internal to the ECU A-9000. The ECU A-9000 receives and responds to proprietary Body Computer (BC) information. If the ECU A-9000 senses a message timeout, this fault will occur. Cause: ECU A-9000 has sensed a BC message timeout. Possible failure modes: 1. Faulty vehicle system, related CAN fault. 2. Faulty supply voltage or ground, missing. 3. Faulty CAN circuit wiring, open circuit, short to ground, or short circuit. 4. Faulty ECU A-9000, termination resistor or software. Solution: 1. Verify fault is present and in active state. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step2boom. B. If the fault is no longer present or is in an inactive state, the fault may be intermittent and not currently active. Continue with step 6boom. 2. Check for related vehicle CAN faults. Use the EST to determine if related vehicle CAN faults exist. A. If related vehicle CAN faults do exist, resolve the vehicle CAN faults, then check to see that DTC 936B â&#x20AC;&#x201C; CAN communication failure between vehicle controller and ECU - BC2ECU1 message is also resolved. B. If related vehicle CAN faults do not exist, continue with step 3boom. 3. Check the ECU A-9000 supply voltage. Disconnect the vehicle (VE) harness from the ECU A-9000 at connector X-9001. With the keyswitch in the on position, use a multimeter to check for voltage on the vehicle (VE) harness side: From X-9001 X-9001 X-9001 X-9001 X-9001

pin pin pin pin pin

1 25 26 49 73

To chassis chassis chassis chassis chassis

ground ground ground ground ground

Value There should be 12.0 V . There should be 12.0 V . There should be 12.0 V . There should be 12.0 V . There should be 12.0 V .

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From X-9001 X-9001 X-9001 X-9001 X-9001

pin pin pin pin pin

3 5 28 52 75

To chassis chassis chassis chassis chassis

ground ground ground ground ground

Value ere should be continuity. ere should be continuity. ere should be continuity. ere should be continuity. ere should be continuity.

To X-9001 pin 47 chassis ground chassis ground

Value There should be 120 ÎŠ . Should no be continuity Should no be continuity

Use a multimeter to measure the resistance of the CAN termination resistor, internal to the ECU A-9000: From X-9001 pin 46

To X-9001 pin 47

Value There should be 120 ÎŠ .

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3877 - Supply UB1 short to battery failure Context: The Electronic Control Unit (ECU) A-9000, monitors the supply UB1 circuit. If the A-9000 detects that the UB1 supply circuit has a short to battery power condition, this fault will occur. Cause: The A-9000 has detected a short to battery power in the supply UB1 circuit. Possible failure modes: 1. Faulty supply UB1 circuit, short to battery power condition. 2. Faulty A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 4. 2. Check the supply UB1 circuit for a short to battery power condition. Disconnect connector X-9001 from the A-9000. The key must be at the OFF position. Use a multimeter to perform the following continuity check: From X-9001 pin 50

To All pins in connector X-9001

Value ere should be no continuity.

A. If there is continuity at any pin, there is a short to battery power condition in the supply UB1 circuit. Locate and repair shorted conductor. B. If there no continuity, leave connector disconnected and continue with step 3. 3. Check the supply UB1 circuit for a short to key battery power condition. The must be in the ON position. Use a multimeter to perform the following voltage test: From X-9001 pin 50

To Chassis GND

Value There should be no voltage..

A. If there is voltage, there is a short to key battery power in the supply UB1 circuit. Locate and repair shorted conductor. B. If there is no voltage present, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 4. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

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B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3878 - Supply UB2 short to battery failure Context: The Electronic Control Unit (ECU) A-9000, monitors the supply UB2 circuit. If the A-9000 detects that the UB2 supply circuit has a short to battery power condition, this fault will occur. Cause: The A-9000 has detected a short to battery power in the supply UB2 circuit. Possible failure modes: 1. Faulty supply UB2 circuit, short to battery power condition. 2. Faulty A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 4. 2. Check the supply UB2 circuit for a short to battery power condition. Disconnect connector X-9001 from the A-9000. The key must be at the OFF position. Use a multimeter to perform the following continuity check: From X-9001 pin 74

To All pins in connector X-9001

Value ere should be no continuity.

A. If there is continuity, there is a short circuit condition in the supply UB2 circuit. Locate and repair shorted conductor. B. If there no continuity, leave connector disconnected and continue with step 3. 3. Check the supply UB2 circuit for a short to key battery power condition. The must be in the ON position. Use a multimeter to perform the following voltage test: From X-9001 pin 74

To Chassis GND

Value There should be no voltage..

A. If there is voltage, there is a short to key battery power in the supply UB2 circuit. Locate and repair shorted conductor. B. If there is no voltage present, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 4. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

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B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3879 - Supply UB3 short to battery failure Context: The Electronic Control Unit (ECU) A-9000, monitors the supply UB3 circuit. If the A-9000 detects that the UB3 supply circuit has a short to battery power condition, this fault will occur. Cause: The A-9000 has detected a short to battery power in the supply UB3 circuit. Possible failure modes: 1. Faulty supply UB3 circuit, short to battery power condition. 2. Faulty A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 4. 2. Check the supply UB3 circuit for a short to battery power condition. Disconnect connector X-9001 from the A-9000. The key must be at the OFF position. Use a multimeter to perform the following continuity check: From X-9001 pin 27

To All pins in connector X-9001

Value ere should be no continuity.

A. If there is continuity, there is a short circuit condition in the supply UB3 circuit. Locate and repair shorted conductor. B. If there no continuity, leave connector disconnected and continue with step 3. 3. Check the supply UB3 circuit for a short to key battery power condition. The must be in the ON position. Use a multimeter to perform the following voltage test: From X-9001 pin 27

To Chassis GND

Value There should be no voltage..

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B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3881 - Supply UB1 short to ground failure NOTE: Because this fault causes inducement, it is necessary to perform the Engine Restart Counter Reset / Unlock Inducement configuration with the Electronic Service Tool (EST) before you return the machine to service. Context: The Electronic Control Unit (ECU) A-9000, monitors the supply UB1 circuit. If the A-9000 detects that the UB1 supply circuit has a short to ground condition, this fault will occur. Cause: The A-9000 has detected a short to ground in the supply UB1 circuit. Possible failure modes: 1. Faulty supply UB1 circuit, short to ground condition. 2. Faulty A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 4. 2. Check the supply UB1 circuit for a short to ground condition. Disconnect connector X-9001 from the A-9000. The key must be at the OFF position. Use a multimeter to perform the following continuity check: From X-9001 pin 50

To All pins in connector X-9001

Value ere should be no continuity.

A. If there is continuity, there is a short circuit condition in the supply UB1 circuit. Locate and repair shorted conductor. B. If there no continuity, leave connector disconnected and continue with step 3. 3. Check the supply UB1 circuit for a short to ground condition. The key must be at the OFF position. Use a multimeter to perform the following continuity test: From X-9001 pin 50

To Chassis GND

Value ere should be no continuity.

A. If there is continuity, there is a short to ground in the supply UB1 circuit. Locate and repair shorted conductor. B. If there no continuity, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 4. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. 48149953 12/06/2018

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B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3882 - Supply UB2 short to ground failure Context: The Electronic Control Unit (ECU) A-9000, monitors the supply UB2 circuit. If the A-9000 detects that the UB2 supply circuit has a short to ground condition, this fault will occur. Cause: The A-9000 has detected a short to ground in the supply UB2 circuit. Possible failure modes: 1. Faulty supply UB2 circuit, short to ground condition. 2. Faulty A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 4. 2. Check the supply UB2 circuit for a short to ground condition. Disconnect connector X-9001 from the A-9000. The key must be at the OFF position. Use a multimeter to perform the following continuity check: From X-9001 pin 74

To All pins in connector X-9001

Value ere should be no continuity.

A. If there is continuity, there is a short circuit condition in the supply UB2 circuit. Locate and repair shorted conductor. B. If there no continuity, leave connector disconnected and continue with step 3. 3. Check the supply UB2 circuit for a short to ground condition. The key must be at the OFF position. Use a multimeter to perform the following continuity test: From X-9001 pin 74

To Chassis GND

Value ere should be no continuity.

A. If there is continuity, there is a short to ground in the supply UB2 circuit. Locate and repair shorted conductor. B. If there no continuity, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 4. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation. 48149953 12/06/2018

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3883 - Supply UB3 short to ground failure NOTE: Because this fault causes inducement, it is necessary to perform the SCR Fault Repair Verification Test once the fault has been resolved. NOTE: Because this fault causes inducement, it is necessary to perform the Engine Restart Counter Reset / Unlock Inducement configuration with the Electronic Service Tool (EST) before you return the machine to service. Context: The Engine Control Unit (ECU) A-9000, monitors the supply UB3 circuit. If the ECU A-9000 detects that the UB3 supply circuit has a short to ground condition, this fault will occur. Cause: The ECU A-9000 has detected a short to ground in the supply UB3 circuit. Possible failure modes: 1. Faulty supply UB3 circuit, short to ground condition. 2. Fault ECU A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 4. 2. Check the supply UB3 circuit for a short to ground condition. Disconnect the ECU A-9000 connector X-9001. The key must be at the OFF position. Use a multimeter to perform the following continuity check: From X-9001 pin 27

To All pins in connector X-9001

Value ere should be no continuity.

A. If there is continuity, there is a short circuit condition in the supply UB3 circuit. Locate and repair shorted conductor. B. If there no continuity, leave connector disconnected and continue with step 3. 3. Check the supply UB3 circuit for a short to ground condition. The key must be at the OFF position. Use a multimeter to perform the following continuity test: From X-9001 pin 27

To Chassis GND

Value ere should be no continuity.

A. If there is continuity, there is a short to ground in the supply UB3 circuit. Locate and repair shorted conductor. B. If there no continuity, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 4. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display.

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3903 - Fuel temperature is too high Context: The Electronic Control Unit (ECU) A-9000 monitors the fuel temperature sensor B-9002. If the A-9000 detects a fuel temperature higher than 90 °C (194 °F), this fault will occur. Cause: The A-9000 has detected a fuel temperature greater than 90 °C (194 °F). Possible failure modes: 1. Faulty fuel cooling, clogged. (if equipped) 2. High ambient temperature. 3. Faulty, B-9002, internal failure.. 4. Faulty B-9002, wiring. 5. Faulty, A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 6. 2. Verify the status of the following possible related faults: DTC 1C15 – Fuel temperature sensor voltage is higher than expected A. If the faults is active, troubleshoot it first and then return to this fault, DTC 1A15 – Fuel temperature is too high. B. Is the fault is not active, continue with step 3. 3. Check the B-9002 signal circuit for a short circuit condition. Disconnect connector X-9005. Disconnect connector X-9002. The key must be at the OFF position. Use a multimeter to perform the following continuity check: From X-9002 pin 12

To All pins in connector X-9002

Value ere should be no continuity.

A. If there is continuity, there is a short circuit condition in the B-9002 signal circuit, wire EN-012. Locate and repair shorted conductor. B. If there no continuity, leave the connectors disconnected and continue with Step 4. 4. Check the B-9002 for a short to key power condition. The must be in the ON position. Use a multimeter to perform the following voltage check: From X-9002 pin 12

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Value There should be no voltage..

Electrical systems - FAULT CODES

A. If there is voltage, there is a short to key power condition in the B-9002 signal circuit, wire EN-012. Locate and repair shorted conductor. B. If there is no voltage present, continue with step 5. 5. Replace the B-9002. Use the EST to verify the status of DTC 1A15 â&#x20AC;&#x201C; Fuel temperature is too high. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 6. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3905 - Intake air heater ECU driver has an over temperature error Context: The Engine Control Unit (ECU) A-9000 monitors the intake air heater relay K-9101 control circuit for an over temperature condition. If an over temperature condition is detected, this fault will occur. Cause: The ECU A-9000 has detected an over temperature condition in the K-9101 control circuit. Possible failure modes: 1. Faulty K-9101, coil. 2. Faulty K-9101 control circuit, short to high source condition. 3. Fault ECU A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 6. 2. Check the status of the following possible related faults: DTC 6A14 – Intake air heater actuator is shorted to battery voltage A. If the faults is active, diagnose them first and then return to this fault, DTC 8814 – Intake air heater ECU driver has an over-temperature error. B. Is the fault is not active, continue with step 3. 3. Check the K-9101 coil for an internal failure. Remove the K-9101. Use a multimeter to perform the following resistance test: From X-9116 pin 1

To X-9116 pin 2

Value The coil resistance should be between 70 – 130 Ω.

A. If the value is not within the specified value, the K-9101 has failed internally. Replace the K-9101. B. If the value is within the specified range, leave the K-9101 disconnected and continue to Step 4. 4. Check the K-9101 signal circuit for a short to high source condition. Disconnect connector X-9001. The key must be at the OFF position. Use a multimeter to perform the following continuity check: From X-9001 pin 83 X-9001 pin 83

To X-9001 pin 74 All other pins

Value ere should be no continuity. ere should be no continuity.

A. If there is continuity, there is a short circuit condition in the K-9101 signal circuit, wire VE-202. B. If there no continuity, leave X-9001 disconnected and continue to Step 5. 48149953 12/06/2018

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5. Check the K-9101 for a short to key power condition. The must be in the ON position. Use a multimeter to perform the following voltage check: From X-9001 pin 83

To Chassis GND

Value There should be no voltage..

A. If there is voltage, there is a short to key power condition in the K-9101 signal circuit, wire VE-202. B. If there is no voltage present, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 6. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3911 - Fuel metering unit is shorted to battery voltage at the high side Context: The Electronic Control Unit (ECU) A-9000 monitors the fuel metering unit Y-9000 high side driver circuit for a short to battery power condition. If the A-9000 detects a short to battery power, this fault will occur. Cause: The A-9000 has detected a short to battery power in the Y-9000 high side driver circuit. Possible failure modes: 1. Faulty Y-9000, internal failure. 2. Faulty Y-9000 wiring, short to battery power condition. 3. Faulty A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 5. 2. Check the Y-9000 for an internal short. Disconnect the Y-9000 connector X-9007. Use a multimeter to perform the following resistance check: From X-9007 pin 1

To X-9007 pin 2

Value The value should be between 2.8 – 3.2 Ω (2.8 – 3.2 Ω).

A. If the value is in the specified range, leave the connector X-9007 disconnected and continue with step 3. B. If the value is not in the specified range, the Y-9000 has failed internally. Replace the Y-9000 to replace the Rail Pressure Metering Unit – Reset ECU Data. 3. Check the Y-9000 high side driver circuit for a short to battery power condition. Disconnect connector X-9002. The key must be at the OFF position. Use a multimeter to perform the following continuity check: From X-9002 pin 58

To All pins in connector X-9002

Value ere should be no continuity.

A. If there is continuity, there is a short circuit condition in the Y-9000 high side driver circuit, wire EN-015. Locate and repair shorted conductor. B. If there no continuity, leave both connectors disconnected and continue to Step 4. 4. Check the Y-9000 high side driver circuit for a short to key power condition. The must be in the ON position. Use a multimeter to perform the following voltage check: 48149953 12/06/2018

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From X-9002 pin 58

To Chassis GND

Value There should be no voltage.

A. If there is voltage, there is a short to key power condition in the Y-9000 high side driver circuit, wire EN-015. Locate and repair shorted conductor. B. If there is no voltage present, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 5. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3912 - Fuel metering unit is shorted to ground at the high side Context: If the Engine Control Unit (ECU) A-9000 detects a short circuit to ground in the Y-9000 high side, this fault will occur. Cause: The A-9000 has detected a short to ground in the Y-9000 circuit, high side. Possible failure modes: 1. Y-9000internal short to ground condition. 2. Short to ground condition in the Y-9000 circuit, high side. 3. Faulty A-9000, software. Solution: 1. Verify the fault code is active. Connect the Electronic Service Tool (EST) to the diagnostic port. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 4. 2. Check the Y-9000 for an internal short to ground condition. Disconnect the Y-9000 connector X-9007. The key must be at the OFF position. Use a multimeter to perform the following resistance check: From X-9007 pin 1

To X-9007 pin 2

Value There should be between 2.8 – 3.2 Ω (2.8 – 3.2 Ω).

A. If the value is in the specified range, leave X-9007 disconnected and continue to Step 3. B. If the value is not in the specified range, the Y-9000 has failed internally. Replace the Y-9000 to replace the Rail Pressure Metering Unit – Reset ECU Data. 3. Check for a short to ground condition in the (EN) harness at the A-9000 connector X-9002 . Disconnect the A-9000 connector X-9002. The key must be at the OFF position. Use a multimeter to perform the following continuity check: From X-9002 pin 58 X-9002 pin 58

To Chassis GND All pins in connector X-9002

Value ere should be no continuity. ere should be no continuity.

A. If there is continuity, there is a short to ground condition in the engine (EN) harness, wire EN-015. See the appropriate service manual to locate and repair the shorted conductor. B. If there no continuity, check the A-9000 for the appropriate software and re-flash, if necessary. 4. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display.

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A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3916 - Fuel pressure relief valve has reached maximum allowed open time NOTE: Because this fault causes inducement, it is necessary to perform the Engine Restart Counter Reset / Unlock Inducement configuration with the Electronic Service Tool (EST) before you return the machine to service. Context: The Pressure Relief Valve (PRV), integrated to the fuel rail, will open in the event of excessive fuel rail pressure. The Engine Control Unit (ECU) A-9000 senses, counts and records the number and duration of PRV openings. If the ECU A-9000 determines that the PRV has been open for a duration greater than 5.00 h, this fault will occur. Cause: The ECU A-9000 has recorded a PRV opening for greater than 5.00 h. Possible failure modes: 1. Faulty fuel injection system, causing PRV to open for an extended period of time. 2. Faulty low pressure fuel lines, clogged fuel filter, faulty charge gear pump, faulty lift pump (if equipped). 3. Faulty fuel metering unit Y-9000, internal failure or wiring. 4. Faulty PRV, mechanical failure. 5. Faulty rail pressure sensor B-9004, implausible value. 6. Fault ECU A-9000, software. Solution: 1. Use the Electronic Service Tool (EST) to check if any of the listed faults are active: DTC 5255 – Fuel metering unit has an open load error DTC 8355 – Fuel metering unit has an over-temperature error DTC 7755 – Fuel metering unit is shorted to ground at the low side DTC 6655 – Fuel metering unit is shorted to battery voltage at the low side DTC 7555 – Fuel metering unit is shorted to ground at the high side DTC 1865 – Fuel rail pressure has exceeded maximum limit DTC 1425 – Fuel rail pressure sensor voltage is higher than expected DTC 2525 – Fuel rail pressure sensor voltage is lower than expected DTC E6DD – ECU internal failure - Rail pressure plausibility DTC 1225 – Rail pressure sensor value is above maximum offset DTC 2325 – Rail pressure sensor value is below minimum offset A. If any of the related faults are active, diagnose them first and then return to this fault, DTC 1745 – Fuel pressure relief valve has reached maximum allowed open time. B. If none of the related faults are active, continue with step 2. 2. Check for leakage, clogging or damage that would allow air to enter the low pressure side of the fuel system. Visually and tactually inspect the low pressure side of the fuel system for leaks, clogs or air entry damage. Inspect gear pump for appropriate pressure. A. If leakage, clogging, air entry, damage or low gear pump pressure is found, repair of replace fittings, filters, lines, etc., as needed. B. If no leakage, clogging, air entry, damage or low gear pump pressure is found, continue with step 3. 3. Replace the fuel metering unit Y-9000. Use the EST to verify the status of DTC 1745 – Fuel pressure relief valve has reached maximum allowed open time. A. If the fault has been resolved, perform the Engine Restart Counter Reset/Unlock Inducement configuration then return the machine to service. 48149953 12/06/2018

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B. If the fault has been not resolved, continue with step 4. 4. Replace the PRV. Use the EST to verify the status of DTC 1745 â&#x20AC;&#x201C; Fuel pressure relief valve has reached maximum allowed open time. A. If the fault has been resolved, B. If the fault has been not resolved, continue with step 5. 5. Replace the rail pressure sensor B-9004. Use the EST to verify the status of DTC 1745 â&#x20AC;&#x201C; Fuel pressure relief valve has reached maximum allowed open time. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, Check the ECU A-9000 for the appropriate software and re-flash, if necessary.

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3936 - ECU internal: Error sensor supplies voltage tracker Context: The Electronic Control Unit (ECU) A-9000 monitors the external voltage tracker for the A-9000 internal 5 V supply. If the A-9000 determines that the voltage is too high or too low, this fault will occur. Solution: 1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, escalate an ASIST concern.

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3961 - CAN communication failure - External torque/speed checksum and counter Context: The Engine Control Unit (ECU) A-9000 is capable of connecting to and communicating on three separate Controller Area Networks (CAN). Proper configuration and monitoring of the three twisted pair configured networks is also a function of the ECU A-9000. CAN Node A Bus is the main vehicle interface bus. The ECU A-9000 provides a CAN termination resistor for the CAN Node A Bus, internal to the ECU A-9000. The ECU A-9000 provides checksum and counter functionality to assure torque/speed message integrity and completeness. If the ECU A-9000 senses an error in the rolling counter and checksum of the torque/speed message, this fault will occur. Cause: ECU A-9000 has sensed an error in the rolling counter and checksum of the torque/speed message. Possible failure modes: 1. Faulty vehicle system, related CAN fault. 2. Faulty supply voltage or ground, missing. 3. Faulty CAN circuit wiring, open circuit, short to ground, or short circuit. 4. Faulty ECU A-9000, termination resistor or software. Solution: 1. Verify fault is present and in active state. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step2boom. B. If the fault is no longer present or is in an inactive state, the fault may be intermittent and not currently active. Continue with step 6boom. 2. Check for related vehicle CAN faults. Use the EST to determine if related vehicle CAN faults exist. A. If related vehicle CAN faults do exist, resolve the vehicle CAN faults, then check to see that DTC ED2D â&#x20AC;&#x201C; CAN communication failure - External torque/speed checksum and counter is also resolved. B. If related vehicle CAN faults do not exist, continue with step 3boom. 3. Check the ECU A-9000 supply voltage. Disconnect the vehicle (VE) harness from the ECU A-9000 at connector X-9001. With the keyswitch in the on position, use a multimeter to check for voltage on the vehicle (VE) harness side: From X-9001 X-9001 X-9001 X-9001 X-9001

pin pin pin pin pin

1 25 26 49 73

To chassis chassis chassis chassis chassis

ground ground ground ground ground

Value There should be 12.0 V . There should be 12.0 V . There should be 12.0 V . There should be 12.0 V . There should be 12.0 V .

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With the keyswitch in the off position, use a multimeter to check for continuity on the vehicle (VE) harness side: From X-9001 X-9001 X-9001 X-9001 X-9001

pin pin pin pin pin

3 5 28 52 75

To chassis chassis chassis chassis chassis

ground ground ground ground ground

Value ere should be continuity. ere should be continuity. ere should be continuity. ere should be continuity. ere should be continuity.

To X-9001 pin 47 chassis ground chassis ground

Value There should be 120 ÎŠ . Should no be continuity Should no be continuity

Use a multimeter to measure the resistance of the CAN termination resistor, internal to the ECU A-9000: From X-9001 pin 46

To X-9001 pin 47

Value There should be 120 ÎŠ .

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3962 - Crankcase pressure too high for too long Context: The Electronic Control Unit (ECU) A-9000 monitors crankcase pressure using the crankcase pressure sensor B-9009. If the A-9000 determines that crankcase pressure is too high for too long, this fault will occur. Cause: The difference in crankcase pressure to expected crankcase pressure has exceeded 16.06 cm H₂₂O (6.32 in H₂₂O). Possible failure modes: 1. Faulty B-9009 wiring or internal failure. 2. Fuel in oil dilution. 3. Faulty fuel injectors, leaking. 4. Faulty piston rings. 5. Excessive turbocharger boost pressure. 6. Faulty A-9000, software. Solution: 1. Use the Electronic Service Tool (EST) to check for the following related faults. If any of the faults are active, diagnose them first and then return to this fault, DTC 49C3 – Crankcase pressure too high for too longboom. DTC 13A3 – Crankcase pressure sensor voltage is higher than expected DTC 4AC3 – Crankcase pressure too high and oil pressure too low - Fuel in oil suspected DTC 3DA3 – Crankcase pressure sensor value is not plausible DTC 1338 – Over boost failure DTC 1B48 – Overboost failure in engine brake mode

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3963 - Crankcase pressure too high and oil pressure too low - Fuel in oil suspected Context: The Electronic Control Unit (ECU) A-9000 monitors crankcase pressure using the crankcase pressure sensor B-9009 and the engine oil pressure using the oil pressure sensor B-9000. If the A-9000 determines that oil pressure is lower than expected and a high crankcase pressure fault was detected in the previous driving cycle, this fault will occur. Cause: Oil pressure is lower than expected and crankcase pressure has exceeded 1019.74 cm H₂₂O (401.47 in H₂₂O) for at least 20.00 s. Possible failure modes: 1. Faulty engine oil, fuel contamination or level low. 2. Faulty blow by filter, clogged. 3. Faulty A-9000, software.

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3968 - After run relay high side driver circuit open failure Context: The Electronic Control Unit (ECU) A-9000 monitors the ignition switch. When the ECU A-9000 determines that the ignition switch has been turned OFF, it will go into after run. The after run disconnection relay K-9106 controls the voltage to the main relay which allows the ECU to store failures into memory (and other relevant machine operating parameters) before being turned OFF. Cause: The ECU A-9000 has detected an open circuit condition in the K-9106 circuit, high side. Possible failure modes: 1. Faulty K-9106,coil. 2. Open circuit condition in the K-9106 circuit, high side. 3. Faulty A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 4. 2. Check the K-9106 for an internal failure. Remove the K-9106. Use a multimeter to perform the following resistance test: From X-9123 pin 1

To X-9123 pin 2

Value The resistance should be between 70 – 130 Ω .

A. If the resistance is between 70 – 130 Ω, go to Step 3. B. If the resistance is not within the specified value, the K-9106 has failed internally. Replace the K-9106. 3. Check for an open circuit condition in the K-9106 circuit, high side. Disconnect the K-9106 connector X-9123. Disconnect the A-9000 connector X-9001. Use a multimeter to perform the following continuity check: From X-9123 pin 1

To X-9001 pin 22

Value ere should be continuity.

A. If there is no continuity, there is an open circuit condition in the vehicle (VE) harness, wire VE-177. Use the appropriate service manual to locate and repair the damaged conductor. B. If there is continuity, check the A-9000 for the appropriate software and re-flash, if necessary. 4. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display.

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3969 - After run relay high side ECU driver circuit over temperature failure Context: The Electronic Control Unit (ECU) A-9000 monitors the ignition switch. When the ECU A-9000 determines that the ignition switch has been turned OFF, it will go into after run. The after run disconnection relay K-9106 controls the operation of the main relay which allows the ECU A-9000 to store failures into memory (and other relevant machine operating parameters) before being turned OFF. Cause: The ECU A-9000 has detected an over temperature condition in the after run disconnection relay K-9106 circuit, high side. Possible failure modes: 1. Faulty ECU A-9000, voltage supply. 2. Faulty after run disconnection relay K-9106, internal short. 3. Faulty after run disconnection relay K-9106 high side circuit, short to ground. 4. Fault ECU A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 5. 2. Check the battery supply to the ECU A-9000. Disconnect the ECU A-9000 connector X-9001 The must be in the ON position. Use a multimeter to perform the following voltage test: From X-9001 X-9001 X-9001 X-9001 X-9001

pin pin pin pin pin

1 25 26 49 73

To chassis chassis chassis chassis chassis

ground ground ground ground ground

Value There should approximately 12.0 V There should approximately 12.0 V There should approximately 12.0 V There should approximately 12.0 V There should approximately 12.0 V

A. If there is approximately 12.0 V, leave the connector X-9001 disconnected and continue with step 3. B. If there is greater than approximately 12.0 V, there is a fault in the battery charging system. See the appropriate service manual to troubleshoot the battery charging system failure. 3. Check the after run disconnection relay K-9106 coil for an internal failure. Remove the after run disconnection relay K-9106. Use a multimeter to perform the following resistance test: From X-9123 pin 1

To X-9123 pin 2

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Value There should be between 70 â&#x20AC;&#x201C; 130 ÎŠ.

Electrical systems - FAULT CODES

A. If the value is within the specified range, continue with step 3. B. If the value is not within the specified range, the after run disconnection relay K-9106 has failed internally. Replace the after run disconnection relay K-9106. 4. Check the after run disconnection relay K-9106 high side circuit for a short to ground condition. Disconnect connector X-9123. The key must be at the OFF position. Use a multimeter to perform the following continuity check: From X-9001 pin 22 X-9001 pin 22 X-9001 pin 22

To Chassis GND X-9001 pin 24 All other pins

Value ere should be no continuity. ere should be no continuity. ere should be no continuity.

A. If there is continuity, there is a short to ground condition in the after run disconnection relay K-9106 high side circuit, wire VE-177. Locate and repair shorted conductor. B. If there no continuity, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 5. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3970 - After run relay high side driver circuit short to battery failure Context: The Engine Control Unit (ECU) A-9000 monitors the ignition switch. When the ECU A-9000 determines that the ignition switch has been turned OFF, it will go into after run. The after run disconnection relay K-9106 controls the voltage to the main relay which allows the ECU A-9000 to store failures into memory (and other relevant machine operating parameters) before being turned OFF. Cause: The ECU A-9000 has detected a short to high source condition in the after run disconnection relay K-9106, high side driver circuit. Possible failure modes: 1. Open circuit condition in the after run disconnection relay K-9106 high side circuit. 2. Short to high source condition in the after run disconnection relay K-9106 high side circuit. 3. Fault ECU A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 4. 2. Measure the after run disconnection relay K-9106 high side circuit for an open condition. Disconnect the ECU A-9000 connector X-9001. Disconnect the after run disconnection relay K-9106 connector X-9123. Use a multimeter to perform the following test: From X-9123 pin 1

To X-9001 pin 22

Value ere should be continuity.

A. If there is continuity, leave X-9123 and X-9001 disconnected and continue to Step 3. B. If there is no continuity, there is an open circuit condition between X-9123 pin 1 and X-9001 pin 22. Use the appropriate service manual to locate and repair the damaged conductor. 3. Measure the voltage on the high side signal wire. Use a multimeter to perform the following voltage test: From X-9001 pin 22

To Chassis GND

Value There should be no voltage..

A. If there is voltage, there is a short to high source condition in the vehicle (VE) harness wire VE-177. See the appropriate service manual to locate and repair the shorted conductor. B. If there is no voltage present, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 4. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display.

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3977 - Prefilter fuel pressure sensor voltage is higher than expected Context: The Electronic Control Unit (ECU) A-9000 monitors the prefilter fuel pressure sensor B-9006 signal circuit for a voltage higher than expected condition. If A-9000 detects a voltage greater than 4.92 V in the B-9006 signal circuit, this fault will occur. Cause: The A-9000 has detected a voltage greater than 4.92 V in the B-9006 signal circuit. Possible failure modes: 1. Faulty, B-9006, internal failure.. 2. Faulty B-9006 wiring, short to high source or open circuit condition. 3. Faulty A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 6. 2. Check the B-9006 signal circuit for an open circuit condition. Disconnect connector X-9002. Disconnect connector X-9019. The key must be at the OFF position. Use a multimeter to perform the following continuity check: From X-9002 pin 62

To X-9019 pin 4

Value ere should be continuity.

A. If there is no continuity, there is an open circuit condition in the B-9006 signal circuit, wire EN-036. Locate and repair broken conductor. B. If there is continuity, leave both connectors disconnected and continue to Step 3. 3. Check the B-9006 signal circuit for a short circuit condition. The key must be at the OFF position. Use a multimeter to perform the following continuity check: From X-9002 pin 62

To All pins in connector X-9002

Value ere should be no continuity.

A. If there is continuity, there is a short circuit condition in the B-9006 signal circuit, wire EN-036. Locate and repair shorted conductor. B. If there no continuity, continue with step 4. 4. Check the signal circuit B-9006 for a short to key power condition. The must be in the ON position. Use a multimeter to perform the following continuity check: 48149953 12/06/2018

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From X-9002 pin 62

To Chassis GND

Value There should be no voltage..

A. If there is voltage, there is a short to key power condition in the B-9006 signal circuit, wire EN-036. Locate and repair shorted conductor. B. If there is no voltage present, continue with step 5. 5. Replace the B-9006. Use the EST to verify that the status of this fault, DTC 15E5 â&#x20AC;&#x201C; Prefilter fuel pressure sensor voltage is higher than expected. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 6. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3978 - Prefilter fuel pressure sensor voltage is lower than expected Context: The Electronic Control Unit (ECU) A-9000 monitors the fuel prefilter pressure sensor B-9006 signal circuit for a voltage lower than expected condition. If the A-9000 detects a voltage less than 203.00 mV, this fault will occur. Cause: The A-9000 has detected a voltage less than 203.00 mV in the B-9006 signal circuit. Possible failure modes: 1. Faulty, B-9006, internal failure.. 2. Faulty B-9006 wiring, short to ground condition. 3. Faulty A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 4. 2. Check the B-9006 signal circuit for a short to ground condition. Disconnect connector X-9002. Disconnect connector X-9019. The key must be at the OFF position. Use a multimeter to perform the following continuity check: From X-9002 pin 62 X-9002 pin 62

To X-9002 pin 19 Chassis GND

Value ere should be no continuity. ere should be no continuity.

A. If there is continuity, there is a short to ground condition in the B-9006 signal circuit. Locate and repair shorted conductor. B. If there no continuity, continue with step 3. 3. Replace the B-9006. Use the EST to verify that the status of this fault, DTC 16E5 â&#x20AC;&#x201C; Prefilter fuel pressure sensor voltage is lower than expected. A. If the fault has been resolved, then return the machine to service. B. If the fault has been not resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 4. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

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B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3985 - Exhaust gas pressure sensor voltage is higher than expected Context: The Electronic Control Unit (ECU) A-9000 monitors the exhaust gas absolute pressure sensor B-9005 signal circuit. If the ECU A-9000 determines that the B-9005 voltage is greater than 4.8 V for a period greater than 500 ms. Cause: The ECU A-9000 has determined that the B-9005 voltage is greater than 4.8 V for a period greater than 500 ms. Possible failure modes: 1. Faulty B-9005 signal circuit, short to high source condition. 2. Faulty, B-9005, internal failure.. 3. Fault ECU A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 6. 2. Check the B-9005 pressure signal circuit for an open circuit condition. Disconnect connector X-9018. Disconnect connector X-9002 from the A-9000 The key must be at the OFF position. Use a multimeter to perform the following continuity check: From X-9002 pin 16

To X-9018 pin 3

Value ere should be continuity.

A. If there is continuity, leave both connectors disconnected and continue to Step 3. B. If there is no continuity, there is an open circuit condition in the B-9005 pressure signal circuit, wire EN-035. Locate and repair broken conductor. 3. Check the B-9005 signal circuit for a short to high source condition. The key must be at the OFF position. Use a multimeter to perform the following continuity check: From X-9002 pin 16 X-9002 pin 16

To X-9002 pin 33 All other pins

Value ere should be no continuity. ere should be no continuity.

A. If there is continuity, there is a short to high source condition in the B-9005 pressure signal circuit, wire EN-035. Locate and repair shorted conductor. B. If there no continuity, leave both connectors disconnected and continue to Step 4. 4. Check the signal circuit B-9005 for a short to key power condition. The must be in the ON position. Use a multimeter to perform the following voltage check: 48149953 12/06/2018

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From X-9002 pin 16

To Chassis GND

Value There should be no voltage..

A. If there is voltage, there is a short to key power condition in the B-9005 pressure signal circuit, wire EN-035. Locate and repair shorted conductor. B. If there is no voltage present, continue with step 5. 5. Replace the B-9005. Use the EST to verify if DTC 1758 â&#x20AC;&#x201C; Exhaust gas pressure sensor voltage is higher than expected has been resolved. A. If it has been resolved, then return the machine to service. B. If it has not been resolved, check the A-9000 for the appropriate software and re-flash, if necessary. 6. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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3986 - Exhaust gas pressure sensor voltage is lower than expected Context: The Electronic Control Unit (ECU) A-9000 monitors the exhaust gas absolute pressure sensor B-9005 signal circuit for a voltage lower than expected condition. If the ECU A-9000 determines that the B-9005 voltage is less than 200 mV for a period greater than 500 ms. Cause: The ECU A-9000 has determined that the B-9005 voltage is less than 200 mV for a period greater than 500 ms. Possible failure modes: 1. Faulty B-9005 signal circuit, short to ground condition. 2. Faulty, B-9005, internal failure.. 3. Fault ECU A-9000, software. Solution: 1. Verify that fault is present and active. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 4. 2. Check the B-9005 signal circuit for a short to ground condition. The key must be at the OFF position. Use a multimeter to perform the following continuity check: From X-9002 pin 16 X-9002 pin 16 X-9002 pin 16

To X-9002 pin 19 All other pins Chassis GND

Value ere should be no continuity. ere should be no continuity. ere should be no continuity.

A. If there is continuity, there is a short to ground in the B-9005 pressure signal circuit, wire EN-035. Locate and repair shorted conductor. B. If there no continuity, continue with step 3. 3. Replace the B-9005. Use the EST to verify if DTC 2858 â&#x20AC;&#x201C; Exhaust gas pressure sensor voltage is lower than expected has been resolved. A. If it has been resolved, then return the machine to service. B. If it has not been resolved, check the A-9000 for the appropriate software and re-flash, if necessary. 4. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals or broken wires. Verify the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the displa y indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, erase the error code and continue operation.

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Index Electrical systems - 55 FAULT CODES - DTC 3001 - Diagnostic fault check of synchronization for double potentiometer and Low idle switch . . .

3002 - Signal Range Check High for Acceleration Pedal Position Device Driver Sensor 1 . . . . . . . .

3005 - Air filter clog or circuit failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3007 - Engine coolant temperature sensor is higher than expected . . . . . . . . . . . . . . . . . . . . . . . . . . .

3008 - Engine coolant temperature sensor voltage is lower than expected . . . . . . . . . . . . . . . . . . . . .

3014 - Air filter clog or circuit failure present for a long time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3015 - Fuel temperature sensor voltage is higher than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3016 - Fuel temperature sensor voltage is lower than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3019 - Intake manifold pressure sensor voltage is higher than expected . . . . . . . . . . . . . . . . . . . . . . .

3024 - ECU internal failure - Ambient pressure sensor voltage is higher than expected . . . . . . . . . .

3025 - ECU internal failure - Ambient pressure sensor voltage is lower than expected . . . . . . . . . . .

3028 - Oil pressure is too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3029 - Oil pressure sensor voltage is higher than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3030 - Oil pressure sensor voltage is lower than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3034 - Oil temperature sensor voltage is higher than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3035 - Oil temperature sensor voltage is lower than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3037 - Intake manifold pressure sensor voltage is lower than expected . . . . . . . . . . . . . . . . . . . . . . . .

3051 - Battery Voltage To Engine Controller - Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3052 - Battery Voltage To Engine Controller - Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3063 - Short circuit in injector 1 (in firing order) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3067 - Short circuit in injector 4 (in firing order) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3071 - Short circuit in injector 2 (in firing order) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3075 - Short circuit in injector 6 (in firing order) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3079 - Short circuit in injector 3 (in firing order) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3083 - Short circuit in injector 5 (in firing order) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3088 - Crankshaft speed sensor values are not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3089 - Crankshaft speed sensor pattern is not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3090 - Camshaft speed sensor values are not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3091 - Camshaft speed sensor pattern is not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3093 - Compared camshaft and crankshaft speed sensor values are not plausible . . . . . . . . . . . . . .

3096 - CAN A Bus off failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3102 - Fuel rail pressure sensor voltage is lower than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3104 - Fuel pressure relief valve is open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3105 - Fuel pressure relief valve is forced to open, perform pressure increase . . . . . . . . . . . . . . . . .

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3106 - Fuel pressure relief valve reached maximum allowed opening count . . . . . . . . . . . . . . . . . . . .

3110 - Rail pressure sensor value is above maximum offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3111 - Rail pressure sensor value is below minimum offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3112 - Fuel rail pressure sensor voltage is higher than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3141 - Fuel pump pressure has exceeded desired pressure limits . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3146 - Water in fuel detected or water in fuel circuit failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3154 - Intake air heater actuator is shorted to battery voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3155 - Intake air heater actuator is shorted to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3156 - Grid Heater Relay - No Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3157 - Engine controller configuration timeout anti-tamper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3160 - Fan clutch solenoid short circuit to battery failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3161 - Fan actuator - short circuit to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3162 - Fan actuator - open load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3163 - Fan clutch solenoid ECU driver over temperature failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3164 - Fan speed above maximum threshold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3165 - Fan speed below minimum threshold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3166 - Fuel filter heater actuator is shorted to battery voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3167 - Fuel Filter Heater Relay - Short Circuit To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3168 - Fuel filter heater relay - open load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3169 - Fuel filter heater relay - signal not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3172 - Engine coolant temperature has exceeded the pre-warning threshold . . . . . . . . . . . . . . . . . . .

100

3173 - Engine coolant temperature has exceeded the warning threshold . . . . . . . . . . . . . . . . . . . . . .

102

3175 - Fan speed could not be measured for a period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

104

3176 - High pressure pump fuel delivery quantity in over run exceeds a maximum threshold . . . . .

106

3177 - Engine over speed condition detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

107

3179 - CAN communication failure between vehicle controller and ECU - BC2ECU2 message . . .

109

3180 - CAN communication error between vehicle controller to ECU . . . . . . . . . . . . . . . . . . . . . . . . . .

111

3182 - CAN timeout error from cruise control vehicle speed (CCVS) . . . . . . . . . . . . . . . . . . . . . . . . . .

113

3183 - CAN communication failure between vehicle controller and ECU controller - TSC1_VR message (Engine brake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 3184 - CAN communication failure between vehicle controller and ECU controller - TSC1_VR message (Engine brake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 3185 - CAN timeout error from transmission - Transmission fluids (TF) message . . . . . . . . . . . . . . .

119

3196 - Open load error of injector in cylinder 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

121

3204 - Open load error of injector in cylinder 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

124

3210 - Injection bank 1 short circuit failure (all injectors of the same bank can be affected) . . . . . . .

127

3218 - Injection bank 2 short circuit failure (all injectors of the same bank can be affected) . . . . . . .

128

3230 - ECU internal failure - Injector CY33x component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

129

3238 - ECU internal failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

130

3245 - ECU internal failure - Query/response communication errors . . . . . . . . . . . . . . . . . . . . . . . . . .

131

3252 - ECU internal failure - SPI communication error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

132

3253 - ECU internal failure - Voltage ratio in ADC monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

133

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3255 - ECU internal failure - ADC test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

134

3263 - CAN C Bus off failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

135

3265 - Fuel injection requested during overrun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

137

3283 - ECU internal failure - Sensor 5 volt supply 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

138

3285 - ECU internal failure - Sensor 5 volt supply 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

140

3293 - Fuel pressure has exceeded maximum positive deviation limits . . . . . . . . . . . . . . . . . . . . . . . .

142

3301 - Fuel rail pressure has exceeded maximum negative deviation limits . . . . . . . . . . . . . . . . . . . .

143

3305 - Fuel rail pressure has dropped below the minimum limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

144

3309 - Fuel rail pressure has exceeded maximum limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

145

3334 - CAN communication failure between vehicle controller and ECU controller - TSC1_PE message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 3338 - CAN communication failure between vehicle controller and ECU controller - TSC1_VE message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 3361 - There was an error during Write/Read EEPROM operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .

151

3362 - ECU internal failure - Fuel calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

152

3368 - Torque limitation caused by performance limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

153

3370 - Strong torque limitation from engine protection active . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

154

3371 - Strong torque limitation from injection system active . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

155

3425 - Under boost failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

156

3443 - Torque limitation due to excessive coolant temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

158

3444 - Torque limitation due to excessive exhaust gas temperature . . . . . . . . . . . . . . . . . . . . . . . . . . .

159

3445 - Torque limitation due to excessive fuel temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

160

3446 - Torque limitation due to excessive intake air temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

161

3447 - Torque limitation due to excessive oil temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

162

3448 - Torque limitation due to turbocharger protection after start . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

163

3449 - ECU internal failure - Calculated engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

164

3458 - Crankcase pressure too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

165

3459 - Oil temperature too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

166

3460 - Oil temperature too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

167

3461 - ECU internal failure - Timeout in the shut off path test error . . . . . . . . . . . . . . . . . . . . . . . . . . . .

169

3462 - ECU internal failure - Overvoltage monitoring error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

170

3475 - CAN timeout error from coolant water pump actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

171

3501 - ECU internal failure - Software resets in DSM 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

173

3502 - ECU internal failure - Software resets in DSM 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

174

3508 - Torque limitation active . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

176

3517 - Ambient temperature sensor voltage is higher than expected . . . . . . . . . . . . . . . . . . . . . . . . . .

177

3518 - Ambient temperature sensor voltage is lower than expected . . . . . . . . . . . . . . . . . . . . . . . . . . .

179

3525 - Downstream NOx sensor internal failure (Open Circuit Error) . . . . . . . . . . . . . . . . . . . . . . . . . .

181

3526 - Downstream NOx sensor internal failure (Short Circuit Error) . . . . . . . . . . . . . . . . . . . . . . . . . .

182

3528 - Downstream NOx sensor values are not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

183

3529 - Downstream NOx sensor internal failure (Heater Open Circuit Error) . . . . . . . . . . . . . . . . . . .

184

3530 - Downstream NOx sensor internal failure (Heater Short Circuit Error) . . . . . . . . . . . . . . . . . . . .

185

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3531 - Downstream NOx sensor internal failure (Heater Performance Plausibility Error) . . . . . . . . .

186

3533 - CAN timeout error from downstream NOx sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

188

3549 - Intake air humidity sensor voltage is higher than expected for too long . . . . . . . . . . . . . . . . . .

190

3557 - Intake air humidity sensor voltage is higher than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . .

192

3581 - Torque limitation is active . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

193

3616 - Torque limitation due to turbo charger protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

194

3623 - Downstream NOx sensor lambda signal deviation - NOx sensor possible removal detected

195

3624 - Crankcase pressure sensor voltage is higher than expected . . . . . . . . . . . . . . . . . . . . . . . . . . .

196

3625 - Crankcase pressure sensor voltage is lower than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . .

198

3626 - Crankcase pressure has exceeded tolerance limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

200

3628 - Crankcase pressure too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

201

3638 - Torque limitation caused by engine brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

202

3647 - Over boost failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

203

3652 - CAN A Bus off passive failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

205

3680 - Engine speed limitation via fuel injection cut off is active . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

207

3686 - DOC upstream temperature sensor signal drift at cold start . . . . . . . . . . . . . . . . . . . . . . . . . . . .

208

3688 - Water in fuel sensor or sensor circuit failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

210

3699 - ECU EEPROM memory failure - EEPData1 block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

212

3700 - Intake air humidity sensor value is not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

213

3703 - The minimum rail pressure value necessary to allow fuel injection has not been reached . .

214

3738 - ECU internal failure - ROM error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

215

3739 - ECU internal failure - Loss of synchronization to MM from CPU . . . . . . . . . . . . . . . . . . . . . . . .

216

3740 - ECU internal failure - ECU shutdown test failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

217

3741 - ECU internal failure - Wrong set response time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

218

3742 - ECU internal failure - SPI errors during MoCSOP execution . . . . . . . . . . . . . . . . . . . . . . . . . . .

219

3743 - ECU internal failure - Undervoltage monitoring error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

220

3745 - ECU internal failure - WDA is not working correctly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

221

3746 - ECU internal failure - Alarm task period error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

222

3747 - ECU internal failure - Positive test failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

223

3749 - ECU internal failure - Accelerator pedal position sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

224

3750 - ECU internal failure - Fuel injection energizing time not plausible . . . . . . . . . . . . . . . . . . . . . . .

225

3751 - ECU internal failure - Fuel injection energizing phase is not plausible . . . . . . . . . . . . . . . . . . .

226

3753 - ECU internal failure - Injection quality correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

227

3754 - ECU internal failure - Rail pressure plausibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

228

3755 - ECU internal failure - Torque request comparison . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

229

3756 - ECU internal failure - Post injection quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

230

3757 - ECU internal failure - Post injection shut off failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

231

3758 - Post injection efficiency failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

232

3759 - ECU internal failure - Torque request due to fuel pressure exceeds maximum torque limit .

233

3760 - ECU internal failure - Torque request due to air control exceeds maximum torque limit . . . .

234

3761 - ECU internal failure - Torque request exceeds maximum torque limit . . . . . . . . . . . . . . . . . . .

235

3762 - ECU 5 volt supply voltage is higher than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

236

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3763 - ECU 5 volt supply voltage is lower than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

237

3764 - ECU after run power interruption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

238

3767 - ECU internal failure - 'WDA active' reported due to errors in query/response communication

241

3768 - ECU internal failure - 'ABE active' reported due to undervoltage detection . . . . . . . . . . . . . . .

242

3769 - ECU internal failure - 'ABE active' report due to overvoltage detection . . . . . . . . . . . . . . . . . .

243

3770 - ECU internal failure - 'WDA/ABE active' reported . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

244

3799 - Fuel pressure relief valve is forced open, perform pressure shock . . . . . . . . . . . . . . . . . . . . . .

245

3805 - Maximum rail pressure exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

246

3808 - High pressure pump fuel delivery quantity at low idle is too high . . . . . . . . . . . . . . . . . . . . . . . .

247

3811 - ECU internal failure - Sensor 5 volt supply 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

248

3814 - ECU temperature sensor error detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

250

3838 - Upstream oxidation catalyst temperature sensor voltage is lower than expected . . . . . . . . . .

251

3870 - CAN communication failure between vehicle controller and ECU - BC2ECU1 message . . .

253

3877 - Supply UB1 short to battery failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

255

3878 - Supply UB2 short to battery failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

257

3879 - Supply UB3 short to battery failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

259

3881 - Supply UB1 short to ground failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

261

3882 - Supply UB2 short to ground failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

263

3883 - Supply UB3 short to ground failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

264

3903 - Fuel temperature is too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

266

3905 - Intake air heater ECU driver has an over temperature error . . . . . . . . . . . . . . . . . . . . . . . . . . . .

268

3911 - Fuel metering unit is shorted to battery voltage at the high side . . . . . . . . . . . . . . . . . . . . . . . .

270

3912 - Fuel metering unit is shorted to ground at the high side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

272

3916 - Fuel pressure relief valve has reached maximum allowed open time . . . . . . . . . . . . . . . . . . . .

274

3936 - ECU internal: Error sensor supplies voltage tracker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

276

3961 - CAN communication failure - External torque/speed checksum and counter . . . . . . . . . . . . .

277

3962 - Crankcase pressure too high for too long . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

279

3963 - Crankcase pressure too high and oil pressure too low - Fuel in oil suspected . . . . . . . . . . . .

280

3968 - After run relay high side driver circuit open failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

281

3969 - After run relay high side ECU driver circuit over temperature failure . . . . . . . . . . . . . . . . . . . .

283

3970 - After run relay high side driver circuit short to battery failure . . . . . . . . . . . . . . . . . . . . . . . . . . .

285

3977 - Prefilter fuel pressure sensor voltage is higher than expected . . . . . . . . . . . . . . . . . . . . . . . . . .

287

3978 - Prefilter fuel pressure sensor voltage is lower than expected . . . . . . . . . . . . . . . . . . . . . . . . . .

289

3985 - Exhaust gas pressure sensor voltage is higher than expected . . . . . . . . . . . . . . . . . . . . . . . . .

291

3986 - Exhaust gas pressure sensor voltage is lower than expected . . . . . . . . . . . . . . . . . . . . . . . . . .

293

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CNH Industrial Latin America LTDA, Av. Jerome Case, 1801, Aparecidinha - Socoraba (SP) - Brasil, CEP:18087-220

SERVICE - Technical Publications & Tools

48149953 12/06/2018 EN

SERVICE MANUAL Chemical applicators SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Chemical applicators - 63

[63.100] Liquid fertilizer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63.1

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SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Chemical applicators - 63 Liquid fertilizer system - 100

TECHNICAL DATA Liquid fertilizer system Torque - PWM product pump control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Pump Product pump hydraulic motor - General specification Product Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Liquid fertilizer system Overview - PWM product pump control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Pump Overview - Product pump circuit troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SERVICE Liquid fertilizer system Flow test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Test - PWM product pump control valve relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Remove - PWM product pump control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Install - PWM product pump control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Pump Remove - Product pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Install - Product pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Manifold Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

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Chemical applicators - Liquid fertilizer system

Liquid fertilizer system - Torque - PWM product pump control valve Description Pulse Width Modulation (PWM) cartridge Product control valve relief valve Product control valve check valve

Torque values 68 – 75 N·m (50 – 55 lb ft) 45 – 47 N·m (33 – 35 lb ft) 45 – 47 N·m (33 – 35 lb ft)

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Chemical applicators - Liquid fertilizer system

Product pump hydraulic motor - General specification Product Pump

PIIL18SP00014AA

Pump Specifications Type of pump Inlet port Outlet port Flow Intermediate pressure Assembly approximate weight Engine type Volumetric displacement Flow Inlet pressure Output Pressure Oil Temp.

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Chemical applicators - Liquid fertilizer system

Liquid fertilizer system - Overview - PWM product pump control valve The oil flow from the gear pump is ported to the â&#x20AC;&#x153;Pâ&#x20AC;? port of the PWM product pump control valve (1). The PWM product control valve is a PWM (Pulse Width Modulated) controlled valve. It is located at the lower front part of the product tank.

RAIL13SP01400AA

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Chemical applicators - Liquid fertilizer system

Pump - Overview - Product pump circuit troubleshooting Symptom

Possible cause

Controller shows no product pressure Rate controller faulty at the booms

Controller shows product spraying low or erratic output

Corrective action Place rate controller to MAN, if product pressure ok, proceed to the rate controller troubleshooting, in the Rate Controller Manual Open shutoff valves Fill hydraulic tank to proper level Fill product tank Test product pump control valve

Manual shutoff valves not open Hydraulic oil level low Product tank low Product pump control valve faulty Product pump control (Pulse Width Modulated - PWM) valve driver Pump ON sensor faulty Product pump/motor faulty Gear pump faulty

Test pump ON sensor Replace product pump Replace the gear pump

Manual shutoff valves not fully open

Open shutoff valves

Throttling valve closed (only if using a rate controller) Hydraulic oil level low Product tank level low Product pump control valve faulty Product pump control (PWM) valve driver faulty Product pump/motor faulty Gear pump faulty Hydraulic suction strainer clogged

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Test PWM valve driver

Open throttling valve Fill hydraulic tank to proper level Fill product tank Test product pump control valve Test PWM valve driver Replace product pump Replace the gear pump Clean or replace suction strainer

Chemical applicators - Liquid fertilizer system

Liquid fertilizer system - Flow 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

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Chemical applicators - Liquid fertilizer system

1. Disconnect the supply hose (1) of the PWM valve (2). 2. Connect a length of hydraulic hose on the open port of the hose (1). 3. Connect the other end of the length of hose to the inlet port on the flowmeter. NOTE: The flowmeter should be positioned on the side of the machine. Therefore, the lengths of hose must be long enough to do this. 4. Disconnect the return hose (3). 5. Connect a length of hydraulic hose to the open port of the hose (3). 6. Connect the other end of the extension to the outlet port on the flowmeter. NOTE: The flowmeter load valve must be completely open. NOTICE: Install the flowmeter so that the flow arrow points to the hydraulic reservoir, since this is the direction of flow. Reverse flow on the flowmeter can cause damage to the unit. 7. Install plugs into the open ports of the valve (2). 8. With the parking brake applied, start the machine engine. Operate at idle speed. 9. Allow the hydraulic oil to reach an approximate temperature of 50 Â°C. Then accelerate to a speed of 2200 RPM. 10. Gradually increase the pressure through the flowmeter load valve, until the pressure reaches approximately 138.0 bar (2001.0 psi). NOTE: When you perform this test, there is no relief valve to protect the pump. Therefore, do not subject the circuit to a pressure greater than 172.0 bar (2494.0 psi) through the flowmeter load valve. 11. Observe and record the flow value marked by the flowmeter, which should be 64 â&#x20AC;&#x201C; 72 L/min. 12. Decrease the pressure through the charge valve. Then return the engine to idle speed. 13. A flow of less than 64 L/min means the pump is losing efficiency. If such a situation impedes the spraying performance, repair or replace the pump. 14. Disconnect the lengths of hydraulic hoses from the hoses (1) and (3). 15. Connect the hoses (1) and (3) on the correct ports of the valve (2).

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PIIL18SP00015AA

Chemical applicators - Liquid fertilizer system

Liquid fertilizer system - Test - PWM product pump control valve relief valve Equipment needed: 200 bar ( 3000 psi) pressure gauge. NOTICE: Do not run the product pump without liquid in the product tank. NOTE: Port identification is stamped in the valve body. The adjustable relief valve (2) is set at 172.3 bar (2498 psi) and a torque of 50.2 N·m (37 lb ft). The relief valve is responsible for the product pump circuit protection from over-pressure. The setting can be verified by installing a “T” and a 200 bar ( 3000 psi) gauge in the “P” port and closing or capping the “M1” port. As the duty cycle is increased the gauge should increase in pressure to 172 bar (2494 psi). NOTICE: Before opening any hydraulic connections, the area must be thoroughly cleaned of any possible contaminant. Use great care not to introduce contaminants into the hydraulic system. 1.

NOTE: Depressurize the hydraulic tank by slowly loosening the breather cap until pressure is bled from the hydraulic tank. Tighten breather.

RAIL13SP04670AA

RAIL13SP01401AA

2. Remove the line from the “M1” port (1) on the product pump control valve going to the hydraulic motor. Plug the line going to the hydraulic motor. Install a 200 bar ( 3000 psi) pressure gauge in the “M1” port (1) on the product pump control valve. 3. Engage park brake and start the engine. Allow the hydraulic oil to warm to 49 °C (120 °F). 4. On the pump station remote box, place the auto/manual switch to the manual position. 5. Turn the pump switch to the “ON” position and hold the increase/decrease switch towards the increase position. Increase the engine to 2200 RPM. 6. Record the reading on the gauge. If the reading is not 172 bar (2494 psi), the product pump control adjustable relief valve needs to be adjusted.

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7. Adjust relief valve pressure by loosening nut (1) on end of valve. Turn adjusting screw (2) in to increase pressure and out to decrease pressure. Tighten nut after proper pressure setting is reached. NOTE: f the relief valve pressure cannot be set to specifications, remove relief valve for repair or replacement. 8. Return the engine to low idle speed, turn the pump switch “OFF” and place the auto/manual switch in the auto position. 9. Remove the gauge in the “M1” port (1) and connect the hydraulic motor hose line to the “M1” port. RAIL13SP01401AA

RAIL13SP01403AA

10. NOTICE: Anytime the hydraulic system(s) is opened up for repairs, tests and/or anytime fluid is changed or added, it must be assumed that contaminates are being introduced to the system. Cleanliness cannot be overemphasized. Changing the oil filter and oil at the proper intervals is necessary to maintain a reliable hydraulic system. NOTICE: If a system component failed. The hydraulic system in-tank return filter must be replaced. See Oil return filter - Replace (35.300). 11. Install a new in-tank return filter on the auxiliary hydraulic circuit. NOTE: Even if the return filter is not being replaced follow the procedure below. 12. Start the engine and run in neutral at a minimum of 1500 RPM. 13. Allow the engine to run at 1500 RPM with the vehicle in neutral for a minimum of 20 min to filter and warm the hydraulic oil prior to any operation. 14. Run the machine for at least 1 h under light load to complete the hydraulic oil filtration. 15. Shut down the machine and check for leaks.

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Liquid fertilizer system - Remove - PWM product pump control valve Prior operation: The Pulse Width Modulating Valve is located behind and above the product pump. Prior operation: Pulse width modulation valve tests can be found in Liquid fertilizer system - Flow test - PWM product pump control valve (63.100). Prior operation: Power wash entire machine, especially around area to be worked on. 1.

Depressurize head pressure from the hydraulic tank. Slowly loosen breather until pressure has been bled from the hydraulic tank. Tighten breather.

RAIL13SP04670AA

RAIL13SP01534AA

Disconnect wire harness (1) and four hydraulic lines (2). Remove the mounting bolts (3) and remove the valve. NOTE: Mark the hydraulic lines for proper installation. NOTE: Clean all connections to be removed with an aerosol degreaser and brush before loosening. Repeat flush with aerosol degreaser with fitting backed out 2-3 turns. NOTICE: Immediately cap or plug any connection opened with clean, threaded caps and plugs.

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3. The command solenoid valve assembly (1) can be replaced. When installing a new assembly, tighten to a torque of 68 – 75 N·m (50 – 55 lb ft).

RAIL13SP01535BA

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Liquid fertilizer system - Install - PWM product pump control valve NOTE: f any of the fittings were removed the O-rings must be replaced. 1. Install valve and install bolts (1). Connect hydraulic lines (2) and wire harness (3).

RAIL13SP01534AA

RAIL13SP01357AA

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Pump - Remove - Product pump WARNING Chemical hazard! Wear protective clothing and a face shield when working with chemicals. Do not allow chemicals to contact skin or eyes. Always follow the chemical manufacturer's instructions. Failure to comply could result in death or serious injury. W0052A

NOTE: If replacing hardware, must use the hardware noted in this Machineâ&#x20AC;&#x2122;s Parts Manual. 1.

Slowly loosen the breather on the hydraulic tank to release the pressure on the hydraulic tank.

RAIL13SP04670AA

PIIL18SP00008AA

RAIL13SP01979AA

Close product tank sump valve (1). 3. Disconnect the product pump pressure switch connector from the harness.

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4. Remove the pump vent hose (1) located at the top front of the product pump. 5. Remove the hydraulic supply and return lines (2). NOTE: Clean all connections to be removed with an aerosol degreaser and brush before loosening. Repeat flush with aerosol degreaser with fitting backed out 2-3 turns NOTE: Mark location of the hydraulic lines and cap immediately after they are removed.

PIIL18SP00009AA

RAIL13SP01980AA

RAIL13SP01485AA

6. Loosen the two plumbing clamps (1). Support the product pump/motor assembly and remove the two retaining bolts (2). NOTE: When the tubing seals are broken, any product left in the pump may leak out.

7. Remove the four motor retaining bolts (1) and separate the motor (2) from the product pump (3).

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Pump - Disassemble Prior operation: Product pump - Remove (78.111) Whenever necessary, refer to the exploded view on Product pump - Exploded view (78.111). 1. Remove cap screws (1). 2. Remove the volute (2).

SOIL17SP00078AA

SOIL17SP00079AA

SOIL17SP00080AA

SOIL17SP00081AA

3. Remove the O-ring installed on the pump flange (1). 4. Remove the tight nut (2). 5. Remove the rotor (3).

6. Remove the Woodruff keyway installed on the end of the axle (1). 7. Remove the seal (2). 8. Remove the mechanical seal rotary assembly (3).

9. Remove cap screws (1). 10. Remove the pump flange (2). 11. Remove the mechanical seal stationary assembly, mounted on the flange (2).

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12. Remove the tight nut (1). 13. Remove the washer and the seal installed along with the nut (1). 14. Remove the adjustment bolt (2). 15. Remove cap screws (3). 16. Remove the rear plate (4) of the hydraulic motor.

SOIL17SP00082AA

SOIL17SP00084AA

SOIL17SP00085AA

SOIL17SP00086AA

17. Remove the O-ring (1). 18. Remove the needle bearing (2).

19. Remove the gerotor housing (1).

20. Remove the O-ring (1). 21. Remove the gerotor assembly (2).

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22. Remove the roller pin (1).

SOIL17SP00087AA

23. Position the hydraulic motor housing (1) so that the larger shaft extension (2) faces up. 24. Remove the rubber washer (3). 25. Remove the inner snap ring installed under the washer (3).

SOIL17SP00088AA

SOIL17SP00089AA

SOIL17SP00090AA

26. Turn the hydraulic motor housing (1). 27. Use a press to push the shaft (2) out of the housing (1).

28. Remove the following components from the shaft (1), in sequence: Lock ring (2). Thrust bearing (3). Spacer (4). O-rings (5). Lock ring (6). NOTE: The bearing (7), housing (8), and retainer (9) must be removed with the aid of a press.

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29. Remove the shaft (1) with a press, as shown.

SOIL17SP00091AA

Next operation: Product pump - Visual inspection (78.111)

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Pump - Visual inspection Prior operation: Product pump - Disassemble (78.111) 1. Volute (1): Check the inside for points with wear and oxidation, which could impair the performance of the pump. NOTE: Periodical rinsing ( flushing) of the spray system increases the service life of the pump components. 2. Rotor (2): Check for signs of wear or deformities. 3. O-ring (3): Replace. 4. Seal (4): Replace. 5. Mechanical seal (5): Check for excessive wear. If there is excessive wear, the component may be recovered or, as a last resort, replaced.

SOIL17SP00092AA

SOIL17SP00090AA

SOIL17SP00093AA

6. Pump flange (6): Check the inside for points with wear and oxidation, which could impair the performance of the pump. 7. Rubber washer (1): Replace if the part is dried out or has cracks. 8. Ball bearing (2): Must not emit noise when turned by hand. 9. Retainer housing (3): Replace in case of excessive wear. 10. Retainer (4): Replace. 11. O-rings (5): Replace. 12. Thrust bearing (6): Replace in case of excessive wear in any of the parts. 13. Shaft (7): Check for points with wear. 14. Roller pin (8): Replace in case of deformation. 15. Hydraulic motor housing (1): Check for excessive wear on the mounting surfaces. 16. O-rings (2): Replace. 17. Gerotor (3): Check for signs of damage caused by contaminated oil, wear, scratches, etc. 18. Gerotor housing (4): Check for excessive wear on the mounting surfaces. 19. Hydraulic motor rear plate (5): Check for heavy wear on the mounting surface. 20. O-ring (6): Replace. 21. O-ring (7): Replace. Next operation: Product pump - Assemble (78.111)

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Pump - Assemble Prior operation: Product pump - Visual inspection (78.111) Whenever necessary, refer to the exploded view on Product pump - Exploded view (78.111). 1. Install the following components on the shaft (1), in sequence: Lock ring. (2). Thrust bearing (3). NOTE: Check if the parts of the bearing are thoroughly clean. Spacer (4). Retainer and housing (5). NOTE: The seal lip must be toward the bearing (3).

SOIL17SP00090AA

SOIL17SP00094AA

SOIL17SP00090AA

2. Use a press to install the shaft (1) on the bearing (2).

3. Install two new O-rings (1). NOTE: Apply a thin layer of lubricant oil on the edge of the rings (1) after assembly.

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4. Use a press to install the shaft (1) on the engine housing (2).

SOIL17SP00095AA

SOIL17SP00090AA

SOIL17SP00095AA

SOIL17SP00096AA

5. Install the snap ring (1) to contain the bearing (2). 6. Install the lock ring (3) to contain the shaft (4).

7. Rotate the shaft (1) in both directions to make sure that the shaft turns freely. 8. Check the shaft end play (1). 9. Install the rubber washer (2).

10. Secure the roller pin (1) in the slot of the shaft (2). 11. Install the inner gear (3) of the gerotor. The inner slot should line up with the pin (1).

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12. Install the outer gear (1) of the gerotor. 13. Install a new O-ring (2).

SOIL17SP00086AA

SOIL17SP00097AA

14. Install the gerotor housing (1), which has two guide pins with different diameters. NOTE: Apply a film of lubricant oil on the housing (1) before assembly.

15. Mount the needle bearing (1) on the rear plate (2) of the hydraulic motor. 16. Install a new O-ring (3). 17. Apply a film of lubricant oil on the plate (2) and on the housing of the gerotor (4).

SOIL17SP00084AA

SOIL17SP00083AA

18. Install the rear plate (1) on the hydraulic motor with the bolts (2). NOTE: Tighten the bolts (2), in a criss-crossed pattern, to a torque of 20.3 NÂˇm (15.0 lb ft). 19. Thread the seal (3) on the adjustment screw (4), to leave four or five threads exposed. 20. Install the screw (4) on the plate (1). Tighten the screw until the screw touches the seal (3).

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21. Install a washer and the nut (1) on the adjustment screw (2).

SOIL17SP00082AA

SOIL17SP00081AA

SOIL17SP00098AA

SOIL17SP00099AA

22. Use the bolts (2) to assemble the pump flange (1) on the hydraulic motor.

23. Install the mechanical seal stationary assembly (1) on the pump flange (2). NOTE: Lubricate the component with oil before assembly.

24. Install the mechanical seal rotary assembly (1) on the pump flange (2).

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25. Install a new seal (1). 26. Install the Woodruff keyway on the end of the shaft (2).

SOIL17SP00080AA

SOIL17SP00079AA

SOIL17SP00078AA

27. Install the rotor (1). Secure with the nut (2). NOTE: Apply a drop of LOCTITE® 242® on the thread of the nut for assembly. 28. Install a new O-ring in the pump flange (3).

29. Install the volute (1) with the bolts (2).

Next operation: Product pump - Install (78.111)

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Pump - Install - Product pump 1. Install new seals on the product pumpâ&#x20AC;&#x2122;s inlet and outlet flanges. Position the pump mounting frame on the mounting bracket and install and tighten the two retaining bolts and nuts (1). Position and tighten the plumbing clamps (2).

RAIL13SP01980AA

RAIL13SP01484AA

RAIL13SP01979AA

RAIL13SP01977AA

2. Install the hydraulic supply and return lines (1) and the case drain line (2) to the motor.

3. Connect the pressure sensor to the wire harness. Install the pump vent hose (not shown) to the top of the pump.

4. Open the manual sparge valve (1) at the front lower side of the product tank. 5. Open the manual product valve (2) located below the product tank.

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NOTICE: Do not run the product pump without having liquid in the tank. 6. Partially fill product tank. See the Operatorâ&#x20AC;&#x2122;s Manual. 7. Install a new in-tank return filter on the auxiliary hydraulic circuit. 8. Allow the engine to run at 1500 RPM with the vehicle in neutral for a minimum of 20 min to filter and warm the hydraulic oil prior to any operation. 9. Run product pump for 5 min to move any air and debris to the hydraulic tank. 10. Run the machine for at least 1 h under light load to complete the hydraulic oil filtration. 11. Shut down the machine and check for leaks.

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Manifold - Remove Prior operation: If replacing hardware, must use the hardware noted in this Machineâ&#x20AC;&#x2122;s Parts Manual. Prior operation: The manifold valve is located on the inside of the right frame below the radiator. Prior operation: Manifold valve tests can be found in Hydraulic systems - Overview - Manifold (35.000). Prior operation: Power wash entire machine, especially around area to be worked on. 1.

Depressurize the hydraulic tank. Slowly loosen breather until pressure is bled off of the hydraulic tank. Tighten breather.

RAIL13SP04670AA

RAIL13SP01559AA

RAIL13SP01560AA

Disconnect hydraulic lines. NOTE: Mark hydraulic lines for proper installation. NOTE: Clean all connections to be removed with an aerosol degreaser and brush before loosening. Repeat flush with aerosol degreaser with fitting backed out 2-3 turns. NOTICE: Immediately cap or plug any connection opened with clean, threaded caps and plugs. 3. Remove the mounting bolts and remove valve.

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Manifold - Disassemble CAUTION Flying debris! Compressed air can propel dirt, rust, etc. into the air. Wear eye and face protection when using compressed air. Failure to comply could result in minor or moderate injury. C0049A

1. Mark the direction of the 90Â° fittings (1) in reference to the valve block. 2. Remove all four fittings from the valve block. 3. Remove all five plugs. 4. Thoroughly wash the valve block with solvent. Dry with compressed air.

RAIL13SP01561AA

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Manifold - Assemble 1. Replace all O-rings. 2. Install the five plugs. Torque the four 1255-8 plugs (1) to 47.5 N·m (35 lb ft) and one 1255-6 plug (2) to 25.4 N·m (225 lb in). 3. Install straight fitting into the IN port (3). Torque fitting to 101.7 N·m (75 lb ft). 4. Install the three 90° fittings (4), align the fitting with the marks put on the valve body during disassembly. NOTE: Do not torque the 90° fittings. This will be accomplished when the valve is installed. RAIL13SP01561AA

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Manifold - Install NOTE: If any of the fittings were removed the O-rings must be replaced. 1. Install valve and install mounting bolts.

RAIL13SP01560AA

RAIL13SP01559AA

RAIL13SP04670AA

2. Connect all four hydraulic lines. Torque the #8 Morb x #6 90° fittings (1) to 65.1 N·m (48 lb ft) and the #12 Morb x #12 90° fitting (2) to 122.1 – 149.1 N·m (90 – 110 lb ft). NOTE: Make sure the O-rings for the hydraulic lines are in place and not damaged.

4. Install a new in-tank return filter on the auxiliary hydraulic circuit. 5. Start the engine and run in neutral at a minimum of 1500 RPM. 6. Allow the engine to run at 1500 RPM with the vehicle in neutral for a minimum of 20 min to filter and warm the hydraulic oil prior to any operation. 7. Run the machine for at least 1 h under light load to complete the hydraulic oil filtration. 8. Shut down the machine and check for leaks.

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Index Chemical applicators - 63 Liquid fertilizer system - 100 Liquid fertilizer system - Flow test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Liquid fertilizer system - Install - PWM product pump control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Liquid fertilizer system - Overview - PWM product pump control valve . . . . . . . . . . . . . . . . . . . . . . . . .

Liquid fertilizer system - Remove - PWM product pump control valve . . . . . . . . . . . . . . . . . . . . . . . . .

Liquid fertilizer system - Test - PWM product pump control valve relief valve . . . . . . . . . . . . . . . . . . .

Liquid fertilizer system - Torque - PWM product pump control valve . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manifold - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manifold - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Product pump hydraulic motor - General specification Product Pump . . . . . . . . . . . . . . . . . . . . . . . . .

Pump - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump - Install - Product pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump - Overview - Product pump circuit troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump - Remove - Product pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump - Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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CNH Industrial Latin America LTDA, Av. Jerome Case, 1801, Aparecidinha - Socoraba (SP) - Brasil, CEP:18087-220

SERVICE - Technical Publications & Tools

48149953 12/06/2018 EN

SERVICE MANUAL Spraying SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Spraying - 78

[78.110] Chemical spraying. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.1

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Spraying - 78 Chemical spraying - 110

SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Spraying - 78 Chemical spraying - 110

FUNCTIONAL DATA Boom spray bar Overview - Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Boom spray bar Remove - Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Test - Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install - Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Boom shutoff valve Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Sparge valve Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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Spraying - Chemical spraying

Boom spray bar - Overview - Nozzle Each nozzle body is equipped with a 12 V nozzle valve, which pulses at 10 Hz. The valves are connected with the boom sections. The valves control flow by varying the duty cycle (on time/off time) of the pulses, when used with a rate controller the flow control is done automatically. Various diaphragm check options and screen mesh sizes are available for the Combo-rate nozzles. NOTE: Each valve should have a noticeable clicking and be operated without flow to the boom section. NOTE: Check nozzles and screens between nozzle bodies on a regular basis to keep them clean and flowing correctly NOTICE: Frequently wash the boom, valves, and nozzles with a low-pressure sprayer to remove dirt and fertilizers. Do not use a high-pressure sprayer on the boom as it may cause corrosion. The high-pressure sprayer can force fertilizers and other corrosive materials into the connectors and boxes, which causes corrosion and failures. NOTE: Be sure product pump is off and pressure is removed from the line before removing nozzle bodies.

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Spraying - Chemical spraying

Boom spray bar - Remove - Nozzle 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

1. Remove the screw (1) that holds the nozzle on the sprayer boom. Remove the nozzle.

PIIL18SP00010AA

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Boom spray bar - Test - Nozzle CAUTION Chemical hazard! Never add chemicals to the sprayer when performing nozzle flow checks. Failure to comply could result in minor or moderate injury. C0041A

NOTICE: Do not use a steel wire brush or glass beading to clean the injectors. The nozzle will be damaged causing performance problems. If the nozzle body drips chemical: 1.

Inspect the diaphragm and O-ring.

Replace any worn or damaged components.

The best way to determine if a spray tip is excessively worn is to compare the flow rate from the used tip to the flow rate of a new tip of the same size and type: 1.

Test the flow rate of each tip by using an accurate graduated collection container, a timing device and an accurate pressure gauge mounted at the nozzle tip.

Compare the flow rate of the old tip to a new one.

For more testing see Nozzle Body Inspection and Testing.

NOTE: Spray tips are considered excessively worn when their flow rate exceeds the flow of a new tip by 10% and should be replaced.

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Boom spray bar - Install - Nozzle 1. Position the nozzle holder (1). Install the screw (2) that holds the nozzle holder on the sprayer boom.

CAUTION Chemical hazard! Never add chemicals to the sprayer when performing nozzle flow checks. Failure to comply could result in minor or moderate injury. C0041A

PIIL18SP00010AA

2. Operate the machine. Check the nozzle operation for leaks.

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Spraying - Chemical spraying

Boom spray bar - Remove CAUTION Chemical hazard! Never add chemicals to the sprayer when performing nozzle flow checks. Failure to comply could result in minor or moderate injury. C0041A

NOTE: If replacing hardware must use the hardware noted in this machineâ&#x20AC;&#x2122;s parts manual. 1. Disconnect liquid line from spray bar. 2. Remove all nozzles from spray bar. See Boom spray bar - Remove - Nozzle (78.110). NOTE: It is not necessary to remove wire harnesses from nozzles.

RAIL13SP01998AA

RAIL13SP01940AA

3. Remove rubber clamps from spray bar and remove bar.

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Spraying - Chemical spraying

Boom spray bar - Install 1. Install spray bar. Install rubber clamps on the bar. 2. Install nozzles onto spray bar. See Boom spray bar Install - Nozzle (78.110). Secure wires to spray bar. NOTE: Nozzles need to be orientated the same direction as other nozzles on the machine.

RAIL13SP01940AA

RAIL13SP01998AA

3. Connect liquid line to the spray bar. 4.

CAUTION Chemical hazard! Never add chemicals to the sprayer when performing nozzle flow checks. Failure to comply could result in minor or moderate injury. C0041A

Operate the machine. Check the spray bar and nozzle operation and for leaks. See Operatorâ&#x20AC;&#x2122;s Manual.

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Spraying - Chemical spraying

Boom shutoff valve - Remove WARNING Chemical hazard! Wear protective clothing and a face shield when working with chemicals. Do not allow chemicals to contact skin or eyes. Always follow the chemical manufacturer's instructions. Failure to comply could result in death or serious injury. W0052A

1. Close the valve (1) which is used to close the line in case of maintenance.

PIIL17SP00125AA

PIIL18SP00012AA

2. Shut down the manual sparge shutoff valve (1) located under the machine near the front of the product tank

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Spraying - Chemical spraying

3. Disconnect the connector from the wiring harness of the boom selection valve (1).

PIIL18SP00011AA

RAIL13SP01993AA

4. Loosen the clamps of the hoses (1) on the boom selection valve to be removed. 5. Remove the boom selection valve (2) from the hoses.

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Spraying - Chemical spraying

Boom shutoff valve - Install 1. Install the boom selection valve assembly (2) on the hoses. 2. Tighten the hose clamps (1).

RAIL13SP01993AA

PIIL18SP00011AA

PIIL17SP00125AA

PIIL18SP00012AA

3. Connect the connector to the boom wiring harness (1).

4. Open the valve (1) which is used to close the line in case of maintenance.

5. Open the main tank valve (1) located under the machine directly below the product tank. 6.

CAUTION Chemical hazard! Never add chemicals to the sprayer when performing nozzle flow checks. Failure to comply could result in minor or moderate injury. C0041A

Operate the spray boom selection valve. See the Operatorâ&#x20AC;&#x2122;s Manual. Shut down the machine and check the connections for leaks.

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Spraying - Chemical spraying

Sparge valve - Remove NOTE: If replacing hardware, must use the hardware noted in this Machineâ&#x20AC;&#x2122;s Parts Manual. 1. Make sure that the flush/induction valve (1) is closed.

SOIL17SP00337AA

PIIL17SP00125AA

PIIL18SP00012AA

2. Close the valve (1) which is used to close the line in case of maintenance.

3. Shut down the manual sparge shutoff valve (1) located under the machine near the front of the product tank.

4. Disconnect the wiring harness of the agitation valve.

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Spraying - Chemical spraying

5. Remove the retaining bolts and nuts (1). Remove the hose clamps (2) and then remove the agitation valve assembly (3).

PIIL18SP00013AA

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Spraying - Chemical spraying

Sparge valve - Install 1. Install the agitation valve assembly (1) with retaining bolts and nuts (2). Install and tighten the hose clamps (3).

PIIL18SP00013AA

PIIL18SP00012AA

PIIL17SP00125AA

SOIL17SP00337AA

2. Install the wiring harness of the agitation valve. 3. Open the manual sparge shutoff valve (1) located under the machine near the front of the product tank.

4. Open the valve (1) which is used to close the line in case of maintenance.

5. Make sure that the flush/induction valve (1) is open. 6. Partially fill the product tank and check for leaks. Use the sparge switch to check the operation of the sparge valve. See the Operatorâ&#x20AC;&#x2122;s Manual.

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Index Spraying - 78 Chemical spraying - 110 Boom shutoff valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom shutoff valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom spray bar - Install - Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom spray bar - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom spray bar - Overview - Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom spray bar - Remove - Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom spray bar - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom spray bar - Test - Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sparge valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sparge valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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CNH Industrial Latin America LTDA, Av. Jerome Case, 1801, Aparecidinha - Socoraba (SP) - Brasil, CEP:18087-220

SERVICE - Technical Publications & Tools

48149953 12/06/2018 EN

SERVICE MANUAL Platform, cab, bodywork, and decals SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Platform, cab, bodywork, and decals - 90

[90.150] Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1 [90.151] Cab interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2 [90.105] Machine shields and guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.3

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Platform, cab, bodywork, and decals - 90 Cab - 150

SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Platform, cab, bodywork, and decals - 90 Cab - 150

TECHNICAL DATA Cab Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Cab Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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Platform, cab, bodywork, and decals - Cab

Cab - Special tools 380003306 Cab lift cradle (Use with 380003353)

380003306

380003353

380003353 Cab lift frame (Universal)

Cab - Torque Description

Torque values 190 – 244 N·m (140 – 180 lb ft)

Cab mounting bolts

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Platform, cab, bodywork, and decals - Cab

Cab - Remove Prior operation: Power wash machine, especially around area to be worked on. Prior operation: Park the machine on smooth, level, concrete surface. Prior operation: Block all wheels. 1. Shut down the engine and remove the key (1).

RAIL14SP01921FA

SOIL17SP00403AA

RAIL14SP00033AA

2. Disconnect the negative cable (1) of all batteries. 3. Recover refrigerant. See Air-Conditioner System Refrigerant Recovery in Section 9000.

4. Remove the front hood. Please see Front shield Remove - Front hood (90.105) . 5. Remove and cap the steering lines (1) and service brake lines (2). NOTE: Clean all connections to be removed with an aerosol degreaser and brush before loosening. Repeat flush with aerosol degreaser with fitting backed out 2 to 3 turns. Immediately cap or plug any connection opened with clean, threaded caps and plugs.

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Platform, cab, bodywork, and decals - Cab

6. Remove the right-hand (shown) and left-hand trim panels.

RAIL13SP01782AA

RAIL13SP01783AA

RAIL13SP01784AA

RAIL13SP01785AA

7. Remove the filter inlet hose (1) from the air outlet tube (2). Remove the air outlet tube from the cab.

8. Remove the cab connector from the bottom of the cab behind the air outlet tube that was removed. NOTE: If the connector cannot be loosened and removed at this point, wait until the cab is raised a small amount to provide greater access.

9. Remove the right-hand mirror and set to the side.

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Platform, cab, bodywork, and decals - Cab

10. At the rear of the cab, remove the two cab connectors.

RAIL13SP01786AA

RAIL13SP01787AA

11. At the right rear of the cab, remove the cab harness clamp.

12. At the rear of the cab, remove the cab power (1) and ground (2) cables.

RAIL13SP01788AA

RAIL13SP01789AA

13. From under the cab, remove the two A/C lines. Cap the lines and fittings.

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Platform, cab, bodywork, and decals - Cab

14. Remove the heater hose clamps from the cab.

RAIL13SP01790AA

RAIL13SP01791AA

RAIL13SP01792AA

RAIL13SP01793AA

15. Install an appropriate clamp on the heater lines to prevent antifreeze loss from the engine. Mark the lines. Loosen the hose clamps and remove the lines. Cap the fittings on the heater core.

16. Remove the cab filter outlet tube.

17. Remove the front fuel line clamp.

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Platform, cab, bodywork, and decals - Cab

18. Remove the rear fuel line clamp.

RAIL13SP01794AA

RAIL13SP01795AA

RAIL13SP01796AA

RAIL13SP01797AA

19. Remove the light harness clamp.

20. Remove the four cab filter mounting bracket retaining bolts and allow the bracket to hang to release the hoses behind it. 21. Remove any tie straps that may interfere with cab removal.

22. Install the rear cab lift cradles 380003306.

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Platform, cab, bodywork, and decals - Cab

23. Install the front cab lift cradles 380003306.

RAIL13SP01798AA

RAIL13SP01799AA

RAIL13SP01800AA

RAIL13SP01801AA

24. Install the cab lift tool 380003353 on the lift cradles.

25. Remove the left and right hand front cab mounting bolts.

26. Remove the left and right hand rear cab mounting bolts.

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Platform, cab, bodywork, and decals - Cab

27.

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

To remove the cab, connect a proper lifting device to the cab lifting bracket. Lift the cab until it is approximately 406.00 â&#x20AC;&#x201C; 508.00 mm (15.98 â&#x20AC;&#x201C; 20.00 in) above the machine front frame. While lifting, ensure all cables, hoses and loose items stay free from cab frame. Remove the cab over the front side of the machine frame. 28. Place 300.00 mm (11.81 in) blocks on the floor under the cab frame.

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Platform, cab, bodywork, and decals - Cab

Cab - Install 1. Attach the lifting bracket 380003306 (1) on the front and rear of the cab. Install the lift frame (2). NOTICE: Be careful not to damage cab when installing lifting bracket.

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

Connect a proper lifting device to the cab lifting bracket. Lift the cab until it is approximately 406.00 – 508.00 mm (15.98 – 20.00 in) above the machine front frame. Move the cab over the machine front frame.

RAIL13SP01799AA

RAIL13SP01784AA

RAIL13SP01801AA

NOTE: Use two front mounting bolts to position the cab as it is slowly lowered onto the frame cab supports. 2. When the cab is almost fully lowered, connect the cab connector on the right front of the cab.

3. Install the bolts, washers, isolators and nuts on the four cab mounts. Tighten the four cab mounting bolts and nuts to a torque of 190.00 – 778.00 N·m (140.14 – 573.82 lb ft).

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Platform, cab, bodywork, and decals - Cab

4. Install the cab filter mounting bracket using the four nuts while positioning the hoses behind it.

RAIL13SP01802AA

RAIL13SP01803AA

RAIL13SP01793AA

RAIL13SP01794AA

5. Install the cab filter out let tube onto the filter.

6. Install the front fuel line clamp.

7. Install the rear fuel line clamp.

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Platform, cab, bodywork, and decals - Cab

8. Install the light harness clamp.

RAIL13SP01804AA

RAIL13SP01791AA

9. Connect the heater lines and remove the clamps.

10. Install the heater hose clamps.

RAIL13SP01790AA

RAIL13SP01789AA

11. Install the A/C lines. NOTE: Lubricate refrigerant lines with clean air conditioner compressor oil and install new O-rings on the high pressure hoses.

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Platform, cab, bodywork, and decals - Cab

12. At the rear of the cab, install the cab power (1) and ground (2) cables.

RAIL13SP01788AA

RAIL13SP01787AA

RAIL13SP01786AA

RAIL13SP01785AA

13. At the right rear of the cab, install the cab harness clamp.

14. At the rear of the cab, install the two cab connectors.

15. Install the right-hand mirror.

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Platform, cab, bodywork, and decals - Cab

16. Install the air outlet tube (2) onto the cab. Install the filter inlet hose (1) onto the air outlet tube.

RAIL13SP01783AA

RAIL13SP01782AA

RAIL14SP00033AA

SOIL17SP00403AA

17. Install the left and right hand trim panels.

18. Install the steering lines and service brake lines. 19. Install the front hood and fuel tank. Please see Front shield - Install - Front hood (90.105) . 20. Install new tie straps where removed.

21. Connect the negative battery cables (1) on all batteries. 22. Recharge the air conditioning system. Please see Air conditioning - Charging (50.200) .

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Platform, cab, bodywork, and decals - Cab

23. Install a new in-tank return filter on the auxiliary hydraulic circuit. 24. Start the engine and run in neutral at a minimum of 1500 RPM. 25. See Operator Manual. Cycle the steering pump 5 times through complete stroke, to move any air and debris to the tank. 26. See Operator Manual. Cycle the parking brake five times. 27. Allow the engine to run at 1500 RPM with the vehicle in neutral for a minimum of 20 min to filter and warm the hydraulic oil prior to any operation. 28. Run the machine for at least one hour under light load to complete the hydraulic oil filtration. 29. Check all systems and controls for correct operation per Operatorâ&#x20AC;&#x2122;s Manual. Shut down machine and check for leaks.

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Index Platform, cab, bodywork, and decals - 90 Cab - 150 Cab - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cab - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cab - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cab - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Platform, cab, bodywork, and decals - 90 Cab interior - 151

SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Platform, cab, bodywork, and decals - 90 Cab interior - 151

SERVICE Console Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Platform, cab, bodywork, and decals - Cab interior

Console - Remove 1. Remove the mat from the floor.

SOIL17SP00020AA

SOIL17SP00021AA

SOIL17SP00022AA

SOIL17SP00023AA

2. Remove the cover (1) of the front windshield wiper motor.

3. Remove the cradle (1) of the cover of the front windshield wiper motor.

4. Remove the bolts (1) that secure the front console to the floor and to the frame of the cab.

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Platform, cab, bodywork, and decals - Cab interior

5. Move the front console to gain access to the electrical wiring harnesses on the right-hand side of the console. Then disconnect the plugs (1) and (2).

SOIL17SP00024AA

SOIL17SP00025AA

6. Remove the front console as shown.

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Platform, cab, bodywork, and decals - Cab interior

Console - Install 1. Position the front console as shown.

SOIL17SP00025AA

SOIL17SP00024AA

SOIL17SP00023AA

SOIL17SP00022AA

2. Move the front console to gain access. Then connect the plugs (1) and (2) of the wiring harnesses, on the right-hand side of the console.

3. Use the bolts (1) to secure the front console to the floor and to the cab frame.

4. Use the bolts (2) to install the cradle (1) of the cover of the front windshield wiper motor.

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Platform, cab, bodywork, and decals - Cab interior

5. Use the bolts (2) to install the cover (1) of the front windshield wiper motor.

SOIL17SP00021AA

SOIL17SP00020AA

6. Install the mat on the floor.

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Index Platform, cab, bodywork, and decals - 90 Cab interior - 151 Console - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Console - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Platform, cab, bodywork, and decals - 90 Machine shields and guards - 105

SP3500 Defensor - FPT NEF engine, Tier 3, 6 cylinder [PRCYS350VJPC02834-]

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Contents Platform, cab, bodywork, and decals - 90 Machine shields and guards - 105

SERVICE Engine hood Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Remove - Engine casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install - Engine casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Front shield Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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Platform, cab, bodywork, and decals - Machine shields and guards

Engine hood - Remove 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

1. Open the latch (1). 2. Tip the parts (2) and (3) of the engine hood.

SOIL16SP00073AA

SOIL17SP00019AA

SOIL17SP00018AA

3. Support the rear hood (1) with a block and tackle. Secure the lift strap on the handles (2). 4. Remove cap screws (3). 5. Remove the rear hood (1).

6. Support the front hood (1) with a block and tackle. Secure the lift strap on the perforated plate (2). 7. Remove cap screws (3). 8. Remove the front hood (1).

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Platform, cab, bodywork, and decals - Machine shields and guards

Engine hood - Install 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

1. Position the front hood (1) on the hinge (2). 2. Secure the front hood (1) with the bolts (3). 3. Loosen the hoist strap.

SOIL17SP00018AA

SOIL17SP00019AA

SOIL16SP00073AA

4. Position the rear hood (1) on the hinge (2). 5. Secure the rear hood (1) with the bolts (3). 6. Loosen the hoist strap.

7. Close the parts (1) and (2) of the engine hood. 8. Apply the latch (3). 9. Check the alignment of the parts (1) and (2) of the hood in relation to the engine casing (4). If necessary, open the hood and adjust the parts to achieve proper alignment.

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Platform, cab, bodywork, and decals - Machine shields and guards

Engine hood - Remove - Engine casing 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

1. Partially lower the sprayer booms, to obtain space to remove the engine casing. 2. Remove the side shields (1). 3. Remove the front shield (2).

SOIL16SP00058AA

SOIL17SP00004AA

SOIL17SP00005AA

4. Remove the bolts (1)that secure the casing (2) on the sides of the hydraulic reservoir.

5. Remove the bolts (1)that secure the casing (2) on the sides of the radiator group.

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Platform, cab, bodywork, and decals - Machine shields and guards

6. Attach lifting straps to the sides of the casing (1). 7. Lift and remove the casing (1) with a lifting device.

SOIL17SP00006AA

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Platform, cab, bodywork, and decals - Machine shields and guards

Engine hood - Install - Engine casing 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

1. Position the casing (1) over the engine assembly. 2. Remove hoisting straps.

SOIL17SP00007AA

SOIL17SP00005AA

SOIL17SP00004AA

3. Use the bolts (2) to attach the casing (1) on the sides of the radiators group.

4. Use the bolts (2) to attach the casing (1) on the sides of the hydraulic reservoir. 5. Check that the casing (1) is secured so that the casing is aligned. If the casing is not aligned, loosen the mounting bolts. Correct the alignment. Retighten the bolts.

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Platform, cab, bodywork, and decals - Machine shields and guards

6. Install the front shield (1). 7. Install the side shields (2)

SOIL16SP00058AA

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Platform, cab, bodywork, and decals - Machine shields and guards

Front shield - Remove 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

1. Support the hood (1) with a block and tackle. Secure the hoist straps (2) around the hood.

SOIL18SP00168AA

SOIL17SP00074AA

2. At the bottom of the machine remove the bolts (1) that secure the hood (2) to the support plates (3) on both sides.

3. With the aid of the lifting device, move the hood (1) a few centimeters over the support plates (2), until you can access the rear part of the headlights (3). 4. Disconnect the plugs of the headlight wiring harnesses (3). 5. Continue to move the hood (1) forward to remove the hood from the machine.

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Platform, cab, bodywork, and decals - Machine shields and guards

Front shield - Install 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

1. With the aid of the lifting device and the lift strap (1), move the hood (2) over the support plates (3) to a few centimeters before the final position. 2. Connect the plugs of the headlight electrical wiring harnesses (4) under the hood. 3. Move the hood (2) to the final position.

SOIL18SP00168AA

SOIL17SP00074AA

4. Attach the hood (1) onto both support plates (2). Use the bolts (3). 5. Test the function of the headlights.

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Index Platform, cab, bodywork, and decals - 90 Machine shields and guards - 105 Engine hood - Install - Engine casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine hood - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine hood - Remove - Engine casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine hood - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front shield - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front shield - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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CNH Industrial Latin America LTDA, Av. Jerome Case, 1801, Aparecidinha - Socoraba (SP) - Brasil, CEP:18087-220

SERVICE - Technical Publications & Tools

48149953 12/06/2018 EN

SPECIAL TOOL INDEX Genuine 84271105 [Hydraulic motor bearing puller] 84271106 [Hydraulic motor bearing installer] 84271107 [Gear Locking pin puller] 84400046 [Pliers] 380002422 [Cable Adapter] 380003052 [Retainer installer] 380003053 [Retainer installer] 380003054 [Hub retainer installer] 380003306 [Cab lift brackets Maxxum / Puma / T6 / T7] 380003312 [Planetary Bearing Nut Socket (LAR Only) ] 380003313 [Planetary Bearing Cone Installer (LAR Only) ] 380003314 [Planetary hub seal installer (LAR Only)] 380003353 [Cab Lift Frame] 380040220 [DPA-5 Adapter Kit Without The Case] 380050012 [Sanko/Sanden Compressor Service Tool Kit] 380050012 [Sanko/Sanden Compressor Service Tool Kit] 380050012 [Sanko/Sanden Compressor Service Tool Kit] 380050012 [Sanko/Sanden Compressor Service Tool Kit] 380050012 [Sanko/Sanden Compressor Service Tool Kit] 380003306 [Cab lift brackets Maxxum / Puma / T6 / T7] 380003353 [Cab Lift Frame] 380003306 [Cab lift brackets Maxxum / Puma / T6 / T7] 380003306 [Cab lift brackets Maxxum / Puma / T6 / T7] 380003353 [Cab Lift Frame] 380003306 [Cab lift brackets Maxxum / Puma / T6 / T7]

Reference

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tools tools tools tools tools

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Air-conditioning compressor - Disassemble - Electromagnetic clutch Air-conditioning compressor - Disassemble - Electromagnetic clutch Air-conditioning compressor - Disassemble - Electromagnetic clutch Air-conditioning compressor - Assemble - Electromagnetic clutch

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Air-conditioning compressor - Assemble - Electromagnetic clutch

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Cab - Special tools

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Cab - Special tools Cab - Remove

90.1 / 3 90.1 / 8

Cab - Remove

90.1 / 9

Cab - Remove Cab - Install

90.1 / 9 90.1 / 11

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CNH Industrial Latin America LTDA, Av. Jerome Case, 1801, Aparecidinha - Socoraba (SP) - Brasil, CEP:18087-220

SERVICE - Technical Publications & Tools

48149953 12/06/2018 EN